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22SI All Replaceable Components 10539632 Guide
User manual for 22SI All Replaceable Components 10539632
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Table of contents
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
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