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
  • 1.4 Specifications and Performance Data
    • Dimensional Data
    • Reach Specifications
    • Chassis
  • 1.5 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.6 Torque Requirements
  • 1.7 Lubrication
    • Hydraulic Oil
  • 1.8 Operator Maintenance
  • 1.9 Major Component Weights
  • 1.10 Pressure Settings
  • 1.11 Serial Number Location
• 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
    • Cylinder Drift Test
    • Platform Drift
    • Cylinder Drift
  • 2.4 Pins and Composite Bearing Repair Guidelines
  • 2.5 Welding on JLG Equipment
• Section 3. Chassis and Turntable
  • 3.1 Tires & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Torque Hub (Machines built Before S/N 1300000064)
    • Roll, Leak and Brake Testing
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Input Carrier Disassembly
    • Output Carrier Disassembly
    • Housing-Spindle Disassembly
    • Spindle-Brake Disassembly
    • Input Carrier Sub-Assembly
    • Output Carrier Sub-Assembly
    • Spindle-Brake Sub-Assembly
    • Housing-Spindle Sub-Assembly
    • Integral Brake Check
    • Main Assembly
  • 3.3 Torque Hub (Machines built After S/N 1300000064)
    • Roll and Leak Testing
    • Tightening and Torquing Bolts
    • Oil Information
    • Main Disassembly for ”B” Drives
    • Hub-Spindle Disassembly
    • Cover Disassembly
    • Carrier Disassembly
    • Carrier Assembly
    • Cover Sub-Assembly
    • Hub-Spindle Sub-Assembly
    • Main Assembly
    • Tool List
  • 3.4 Re-Aligning torque hub input coupling
    • Equipment Required
    • Procedure
  • 3.5 Drive Motor
    • Description
    • Shaft Seal Replacement
    • Loop Flushing Valve
    • Troubleshooting
    • Disassembly
    • Inspection
    • Assembly
    • Initial Start-up Procedures
  • 3.6 Adjustment Procedure For Lockout Valve
  • 3.7 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding (Early Cylinders)
    • Lockout Cylinder Bleeding (Ram Cylinders)
    • Oscillating Axle Lockout Test
  • 3.8 Swing Bearing
    • Description
    • Removal
    • Disassembly
    • Assembly
    • Installation
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Torque Value
  • 3.9 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
  • 3.10 Deutz Engine
    • Checking Oil Level
    • Changing Engine Oil
    • Changing the Oil Filter
    • Replacing Fuel Filter
    • Cleaning Fuel Strainer
  • 3.11 Deutz EMR 2 (S/N 1300000981 to Present)
  • 3.12 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
  • 3.13 Engine Radiator Fill Procedure - Perkins & Caterpillar
  • 3.14 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
  • 3.15 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
    • Diagnostic Aids
    • DTC 1652- TPS1 Loss of Communications
    • Diagnostic Aids
    • 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 and Platform
  • 4.1 Boom Maintenance
    • Remove Boom Assembly
    • Disassemble Main Boom
    • Inspection
    • Assemble Main Boom
    • Install Boom Assembly
  • 4.2 Rotator
    • Disassembly and Inspection
    • Assembly and Testing
  • 4.3 Rotary Actuator (S/N 1300006433 to Present)
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
• Section 5. Hydraulics and Hydraulic Schematics
  • 5.1 O-Ring Lubrication
    • Cup and Brush
    • Dip
    • Spray
    • Brush-On
  • 5.2 Hydraulic Cylinders
    • Tower Lift Cylinder
    • Main Lift Cylinder
    • Master Cylinder
    • Telescope Cylinder
    • Platform Level (Slave) Cylinder
    • Jib Lift Cylinder
    • Steer Cylinder
    • Axle Lockout Cylinder (Outside Frame)
    • Axle Lockout Cylinder (Inside Frame)
  • 5.3 Hydraulic Pump (Gear)
    • Disassembly
    • Inspect Parts For Wear
    • General Information
    • Reverse Shaft Rotation of Pump
    • Assembly
    • Placing Pump Back Into Service
  • 5.4 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
  • 5.5 Hydraulic Component Start-Up Procedures and Recommendations
  • 5.6 Pressure Setting Procedure
    • Telescope Main Relief
    • Steer
    • Platform Level Up
    • Platform Level Down
    • Articulating Jib
    • Proportional Main Relief
    • Lift Down
    • Swing
• Section 6. JLG Control System
  • 6.1 introduction
  • 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
  • 6.10 System Test
    • Test from the Platform
    • Test from the Ground Station
• Section 7. Basic Electrical Information and Electrical 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