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