Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Capacities
  • 1.2 Operating Specifications & Performance Data
  • 1.3 Chassis Specifications
  • 1.4 Tires
  • 1.5 Dimensional Data
  • 1.6 Engine Data
    • Engine Data Prior to S/N 0300127698
    • Engine Data S/N 0300127698 to Present
    • Caterpillar
  • 1.7 Torque Requirements
  • 1.8 Major Component Weights
  • 1.9 Pressure Settings
  • 1.10 Hydraulic Oil
  • 1.11 Lubrication & 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. 1Chassis & Turntable
  • 3.1 Tires & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Axle Extension System
  • 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 Ground Control Enable System
  • 3.10 Oscillating Axle System
  • 3.11 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.12 Drive Hub (Prior to S/N 100128)
    • 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
  • 3.13 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
    • Periodic Maintenance
    • Changing the Lubricating oil
    • Troubleshooting
    • Disassembly Information
    • Disassembly
    • Inspection of Parts
    • Assembly
    • Final Test and Reinstallation
  • 3.14 Drive Hub - Reggiana Riduttori (S/N 134389 to Present)
    • Symbol Nomenclature
    • Tools
    • Disassembly
    • Assembly
  • 3.15 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
  • 3.16 Swing Brake
    • Pre-Installation Checks
    • Installation
    • Maintenance
    • Disassembly
    • Examination
    • Assembly
  • 3.17 Swing Motor
    • Disassembly and inspection
    • Assembly
    • One Piece Stator Construction
  • 3.18 Procedure For Setting Gear Backlash
  • 3.19 Swing Drive Lubrication
  • 3.20 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Removal
    • Swing Bearing Installation
    • Swing Bearing Torque Values
  • 3.21 Swing Speed Proportioning
  • 3.22 Chassis Tilt Indicator System
  • 3.23 Rotary Coupling
  • 3.24 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
    • inspecting brush position
    • inspecting brushes
    • CLEANING SLIP RINGS
  • 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
    • Removal
    • Installation
  • 3.27 Deutz EMR 2 (S/N 87575 to Present)
  • 3.28 Bio Fuel in Deutz Engines
    • General
    • Bio Fuel
    • Permitted bio-diesel fuels
    • approved engines
    • Basic conditions to be observed
    • Plant oil
    • Biological Contamination In Fuels
    • Symptoms
    • Cause
    • Preventive measures
    • Fuel additives
  • 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
  • 3.30 Auxiliary Power System
  • 3.31 Counterweight
• Section 4. Boom & Platform
  • 4.1 Platform Control Enable System
  • 4.2 Transport Position Sensing System
  • 4.3 Beyond Transport - Drive Speed Cutback System
  • 4.4 Drive/Steer – Boom Function Interlock System (CE ONLY)
  • 4.5 Jib Stow System
  • 4.6 Envelope Control System
  • 4.7 Tower Path Control System
  • 4.8 Automatic Main Boom Control System
  • 4.9 Electrical Retrieval System
  • 4.10 Hydraulic Retrieval System
  • 4.11 Controlled Boom Angle System
  • 4.12 Slow Down System
  • 4.13 Dual Capacity System
  • 4.14 Hydraulic System Warm Up
  • 4.15 Reduced Platform Heights
  • 4.16 Electronic Platform Leveling
  • 4.17 Main Boom
    • Disassembly
    • Assembly
  • 4.18 Tower Boom
    • Installation and Assembly
    • Pin Clamp Installation Procedure
  • 4.19 Main Boom Transport Angle Switch
    • Analyzer Readings
    • Possible Faults
  • 4.20 Tower Transport Length Switch
    • Analyzer Readings
    • Possible Faults
  • 4.21 Main Boom Transport Length Switches
    • Analyzer Readings
    • Possible Faults
  • 4.22 Dual Capacity Switches
    • Analyzer Readings
    • Possible Faults
  • 4.23 Tower Telescope Cylinder
    • Removal
    • Installation
  • 4.24 Tower Lift Cylinder
    • Removal
    • Installation
  • 4.25 Main Lift Cylinder
    • Removal
    • Installation
  • 4.26 Main Boom Telescope Cylinder
    • Removal
    • Installation
  • 4.27 Powertrack Maintenance
    • One Piece Bracket Maintenance
    • Two Piece Bracket Maintenance
    • Snap Rings and Screws
  • 4.28 Hose Routing Procedure
  • 4.29 Electronic Platform Leveling
    • Description
    • Normal Operation
  • 4.30 Tower Boom Drift Test
  • 4.31 Rotary Actuator
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Greasing Thrust Washers
    • 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 Counterbalance Valve Check
  • 5.4 Hydraulic Tank
  • 5.5 Hydraulic Return Filter
  • 5.6 Enable Valves
    • Removal
    • Installation
    • Air Purge Procedure for Non-Calibrated Machines
    • Air Purge Procedure for Calibrated Machines
  • 5.7 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
  • 5.8 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
  • 5.9 Function Pump
    • Spare Parts
    • Sealing the Drive Shaft
    • Disassembly and Assembly of the Complete Unit
    • Assembly
    • Adjustments
    • Tightening Torques
    • Pump Control Disassembly For Cleaning
  • 5.10 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 Orientation When Setting Speeds
    • Test Notes
  • 6.10 System Test
    • Test from the Platform
    • Test from the Ground Station
  • 6.11 Calibrating Steer
  • 6.12 Calibrating Drive
  • 6.13 Calibrating Boom Valves
  • 6.14 Electronic Platform Leveling
    • Platform Leveling Fault Warning
    • Fault Response
    • CAN Errors
    • Additional Platform and Jib Valves
  • 6.15 Calibrating Platform Level
    • STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
    • STEP 2: BLEEDING THE PLATFORM VALVES
    • STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS
  • 6.16 Calibrating Tilt Sensor
  • 6.17 Boom Sensor Calibration
    • General Notes:
    • Step 1 - Position 1
    • Step 2 - Position 2
    • Step 3 - Position 3
    • Step 4 - Position 4
    • Step 5 - Position 5
    • Step 6 - Position 6
    • Step 7 - Position 7
    • Step 8 - Position 8
    • Step 9 - Position 9
    • Step 10 - Position 10
    • Step 11 - Position 11
  • 6.18 Boom Control System (BCS) Violation
    • “UNLOCK BOOM” Calibration Procedure
  • 6.19 CANbus Troubleshooting
    • CANbus Communication Failure
    • Load Moment Pin Troubleshooting
• 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 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