Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. SPECIFICATIONS
  • 1.1 Capacities
  • 1.2 Tires
  • 1.3 Engine Data
    • Deutz Prior to S/N 0300127698
    • Deutz S/N 0300127698 to Present
    • Caterpillar
  • 1.4 Specifications and Performance Data
    • Reach Specifications
    • Dimensional Data
    • Chassis
  • 1.5 Torque Requirements
  • 1.6 Hydraulic Oil
  • 1.7 Major Component Weights
  • 1.8 Pressure Settings
  • 1.9 Lubrication and Operator Maintenance
• 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
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Extending Axles
  • 3.3 Axle Limit Switch Adjustment Procedure
  • 3.4 Drive System
  • 3.5 Steering Control System
  • 3.6 Drive/Steering Speed Control
  • 3.7 Traction Control System
  • 3.8 Drive Orientation System
  • 3.9 Oscillating Axle System
  • 3.10 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.11 Drive Hub (Prior to S/N 100131)
    • Disassembly
    • Disassembly of Cover
    • Disassembly of the First Stage Planetary Assembly (7)
    • Disassembly of Second Stage Planet Gears (1)
    • Assembly of First Stage Planetary Assembly (7)
    • Assembly of End Cover Unit (8)
    • Final Assembly
    • Initial Start-up And After Repairs
    • Oil Change Interval-Gear Drive
  • 3.12 Drive Hub - Bonfiglioli (S/N 100128 to Present)
    • Product Identification
    • Hydraulic Motor Installation
    • Installation of the Wheel Drive on the Machine
    • Start Up and Running In
    • General Information
    • Connecting the Brake
    • Filling-up the Gearbox with Lubricating Oil
    • Gearbox Disengagement
    • Maintenance Information
    • Changing the Lubricating oil
    • Troubleshooting
    • Disassembly Information
    • Disassembly Procedure
    • Inspection of Parts
    • Assembly
    • Final Test and Reinstallation
  • 3.13 Drive Hub - Reggiana Riduttori (S/N 134389 to Present)
    • Symbol Nomenclature
    • Tools
    • Disassembly
    • Assembly
  • 3.14 Swing Drive
    • Roll and Leak Testing
    • Tightening and Torquing Bolts
    • Motor Control Valve Disassembly
    • Motor and Brake Disassembly
    • Main Disassembly
    • Hub-Shaft Disassembly
    • Carrier Disassembly
    • Hub-Shaft Sub-Assembly
    • Carrier Sub-Assembly
    • Main Assembly
    • Motor and Brake Assembly
    • Motor Control Valve Assembly
  • 3.15 Swing Brake
    • Pre-Installation Checks
    • Installation
    • Maintenance
    • Disassembly
    • Examination
    • Assembly
  • 3.16 Swing Motor
    • Disassembly and inspection
    • Assembly
    • One Piece Stator Construction
  • 3.17 Procedure For Setting Gear Backlash
  • 3.18 Swing Drive Lubrication
  • 3.19 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Removal
    • Swing Bearing Installation
    • Swing Bearing Torque Values
  • 3.20 Swing Speed Proportioning
  • 3.21 Chassis Tilt Indicator System
  • 3.22 Rotary Coupling
  • 3.23 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
  • 3.24 Auxiliary Power System
  • 3.25 Cold Weather Package
  • 3.26 Engine
    • Glow Plugs
    • Checking Oil Level
    • Changing Engine Oil
    • Changing the Oil Filter
    • Replacing the Fuel Filter
    • Cleaning the Fuel Strainer
  • 3.27 Deutz EMR 2 (S/N 87579 to Present)
  • 3.28 Bio Fuel in Deutz Engines
    • General
    • Bio Fuel
    • Biological Contamination In Fuels
  • 3.29 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 4. BOOM & PLATFORM
  • 4.1 Boom Systems
    • Broken Cable Indicator System
    • Platform Control Enable System
    • Transport Position Sensing System
    • Beyond Transport - Drive Speed Cutback System
    • Drive/Steer – Boom Function Interlock System (CE ONLY)
    • Jib Stow System
    • Envelope Tracking System
    • Moment Control System
    • Boom Control System (BCS) Functional Check (Push to Test) System
    • Controlled Arc System
    • Controlled Boom Angle System
    • Envelope Tracking
    • Slow Down System
    • Dual Capacity System
    • Electronic Platform Leveling
    • Boom Control Select
  • 4.2 Boom Removal, Disassembly/Assembly, & Cable Replacement
    • Removal
    • Disassembly
    • Assembly
  • 4.3 Boom Lubrication Application
  • 4.4 Boom Shimming Procedure
  • 4.5 Jib Rotator Orientation
  • 4.6 Jib Lift End of Stroke Dampening
  • 4.7 Load Sensing Pin Removal and Installation
  • 4.8 Powertrack Maintenance
    • One Piece Bracket Maintenance
    • Two Piece Bracket Maintenance
    • Snap Rings and Screws
  • 4.9 Hose Routing Procedure
  • 4.10 Wire Rope
    • Inspection
    • Three Month Inspection
    • Eight Year Inspection
    • Replacement Criteria
  • 4.11 Wire Rope Tensioning Adjustment
    • Boom Section Re-Positioning
    • Wire Rope Tensioning Procedure
  • 4.12 Broken Boom Cable Proximity Switch
    • Adjusting the Proximity Switch
  • 4.13 Electronic Platform Leveling
    • Description
    • Normal Operation
  • 4.14 Rotary Actuator
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Bleeding After Installation
• Section 5. HYDRAULICS
  • 5.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 5.2 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.3 Hydraulic Tank
  • 5.4 Pressure Setting Procedure
    • Set Up of the Function Pump
    • Adjustments made at the Main Valve Bank
    • Adjustments Made at the Frame Valve Bank
    • Adjustments Made at the Platform Valve Bank
  • 5.5 Drive Pumps
    • Troubleshooting Procedure
    • Charge Pressure Relief Valve Adjustment
    • Mechanical Centering of Pump
    • Hydraulic Centering of Control Modules
    • High Pressure Relief Valve Adjustments
    • Removal and inspection of charge pump
    • Routine Maintenance
    • Removal and Installation of Shaft Seal
  • 5.6 Function Pump
    • Spare Parts
    • Sealing the Drive Shaft
    • Disassembly and Assembly of the Complete Unit
    • Assembly
    • Adjustments
    • Tightening Torques
    • Pump Control Disassembly For Cleaning
  • 5.7 Drive & Function Pump Start Up Procedures
    • Start-Up Procedure
• Section 6. JLG CONTROL SYSTEM
  • 6.1 Introduction
  • 6.2 CANbus Communications
  • 6.3 Calibration Instructions
  • 6.4 To Connect the JLG Control System Analyzer
  • 6.5 Using the Analyzer
  • 6.6 Changing the Access Level of the Hand Held Analyzer
  • 6.7 Adjusting Parameters Using the Hand Held Analyzer
  • 6.8 Machine Setup
  • 6.9 Machine Personality Settings/Function Speeds
  • 6.10 Machine Orientation When Setting Function Speeds
    • Test Notes
  • 6.11 System Test
    • Test from the Platform
    • Test from the Ground Station
  • 6.12 Calibrating Steer
  • 6.13 Calibrating Drive
  • 6.14 Electronic Platform Leveling
    • Platform Leveling Fault Warning
    • Fault Response
    • CAN Errors
    • Additional Platform and Jib Valves
    • Platform Leveling Calibration Procedure
  • 6.15 Calibrating Platform Level
    • STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
    • STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS
    • STEP 3: BLEEDING THE PLATFORM VALVES
    • STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS
  • 6.16 Calibrating Lift Crack Point
  • 6.17 Calibrating Telescope Crack point
  • 6.18 Calibrating Tilt Sensor
  • 6.19 Calibrating the Boom Sensors
    • Boom Control System Check Procedure
  • 6.20 CANbus Troubleshooting
    • CANbus Communication Failure
    • Load Moment Pin Troubleshooting
• Section 7. BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS
  • 7.1 General
  • 7.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Voltage Measurement
    • Resistance Measurement
    • Continuity Measurement
    • Current Measurement
  • 7.3 Applying Silicone Dielectric Compound to Electrical Connections
  • 7.4 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.5 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly