JLG 510AJ Series II Service & Maintenance Manual (3121293) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 510AJ Series II Service & Maintenance Manual (3121293) – PDF DOWNLOAD
Section A. Introduction - Maintenance Safety Precautions......................................................................................................................................................................................................................... 3
A General.................................................................................................................................................................................................................................................................... 3
B Hydraulic System Safety.................................................................................................................................................................................................................................................... 3
C Maintenance................................................................................................................................................................................................................................................................ 3
Section 1. Specifications........................................................................................................................................................................................................................................................ 17
1.1 Operating specifications and Performance Data............................................................................................................................................................................................................................ 17
1.1 Reach Specifications..................................................................................................................................................................................................................................................... 17
1.2 Dimensional Data......................................................................................................................................................................................................................................................... 17
1.3 Chassis.................................................................................................................................................................................................................................................................. 17
1.4 Capacities............................................................................................................................................................................................................................................................... 17
1.5 Function Speeds.......................................................................................................................................................................................................................................................... 18
Machine Orientation When Doing Speed Tests............................................................................................................................................................................................................................... 18
Test Notes............................................................................................................................................................................................................................................................... 18
1.6 Torque Requirements...................................................................................................................................................................................................................................................... 18
1.7 Tires.................................................................................................................................................................................................................................................................... 19
1.8 Engine................................................................................................................................................................................................................................................................... 19
1.9 Major Component Weights.................................................................................................................................................................................................................................................. 19
1.10 Hydraulic Oil........................................................................................................................................................................................................................................................... 19
1.11 Serial Number Location.................................................................................................................................................................................................................................................. 21
1.10 Operator Maintenance.................................................................................................................................................................................................................................................... 22
Section 2. General............................................................................................................................................................................................................................................................... 31
2.1 Machine Preparation, Inspection, and Maintenance......................................................................................................................................................................................................................... 31
General.................................................................................................................................................................................................................................................................. 31
Preparation, Inspection, and Maintenance................................................................................................................................................................................................................................. 31
Pre-Start Inspection..................................................................................................................................................................................................................................................... 31
Pre-Delivery Inspection and Frequent Inspection.......................................................................................................................................................................................................................... 31
Annual Machine Inspection................................................................................................................................................................................................................................................ 31
Preventative Maintenance................................................................................................................................................................................................................................................. 31
2.2 Service and Guidelines................................................................................................................................................................................................................................................... 32
General.................................................................................................................................................................................................................................................................. 32
Safety and Workmanship................................................................................................................................................................................................................................................... 32
Cleanliness.............................................................................................................................................................................................................................................................. 32
Components Removal and Installation...................................................................................................................................................................................................................................... 32
Component Disassembly and Reassembly..................................................................................................................................................................................................................................... 33
Pressure-Fit Parts....................................................................................................................................................................................................................................................... 33
Bearings................................................................................................................................................................................................................................................................. 33
Gaskets.................................................................................................................................................................................................................................................................. 33
Battery.................................................................................................................................................................................................................................................................. 33
Bolt Usage and Torque Application........................................................................................................................................................................................................................................ 33
Hydraulic Lines and Electrical Wiring.................................................................................................................................................................................................................................... 33
Hydraulic System......................................................................................................................................................................................................................................................... 33
Lubrication.............................................................................................................................................................................................................................................................. 33
2.3 Lubrication and Information.............................................................................................................................................................................................................................................. 34
Hydraulic System......................................................................................................................................................................................................................................................... 34
Hydraulic Oil............................................................................................................................................................................................................................................................ 34
Changing Hydraulic Oil................................................................................................................................................................................................................................................... 34
Lubrication Specifications............................................................................................................................................................................................................................................... 34
2.4 Cylinder Drift Test...................................................................................................................................................................................................................................................... 34
Platform Drift........................................................................................................................................................................................................................................................... 34
Cylinder Drift........................................................................................................................................................................................................................................................... 34
2.5 Pins and Composite Bearing Repair Guidelines............................................................................................................................................................................................................................. 35
2.6 Welding on JLG Equipment................................................................................................................................................................................................................................................. 35
Do the Following When Welding on JLG Equipment........................................................................................................................................................................................................................... 35
Do NOT Do the Following When Welding on JLG Equipment.................................................................................................................................................................................................................... 35
3.1 TIRES AND WHEELS................................................................................................................................................................................................................................................. 39
Tire Inflation....................................................................................................................................................................................................................................................... 39
Tire Damage.......................................................................................................................................................................................................................................................... 39
Pneumatic Tires...................................................................................................................................................................................................................................................... 39
Polyurethane Foam Filled Tires....................................................................................................................................................................................................................................... 39
Tire Replacement..................................................................................................................................................................................................................................................... 39
Wheel Replacement.................................................................................................................................................................................................................................................... 39
Wheel Installation................................................................................................................................................................................................................................................... 40
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.................................................................................................................................................................. 40
3.2 Torque Hub................................................................................................................................................................................................................................................... 41
Oil Information...................................................................................................................................................................................................................................................... 41
1. 1. TYPE – EP90 Use EP90 for normal applications. For applications where lubricant must meet special requirements, the O.E.M can recommend a suitable substitute............................................................................................... 41
Roll and Leak Testing................................................................................................................................................................................................................................................ 41
Tightening and Torquing Bolts........................................................................................................................................................................................................................................ 41
1. Tighten (but do not torque) bolt ”A” until snug............................................................................................................................................................................................................... 41
MAIN DISASSEMBLY for “B” Drives...................................................................................................................................................................................................................................... 45
1. Turn hub (1G) on side, Remove coupling (14) from wide end of spindle (1A)..................................................................................................................................................................................... 45
Hub-Spindle Disassembly.............................................................................................................................................................................................................................................. 46
1. Remove retaining ring (1I) from around spindle (1A) ia hub (1G)............................................................................................................................................................................................... 46
Cover Disassembly.................................................................................................................................................................................................................................................... 46
1. Remove two bolts (6C) holding disconnect cap (6D) to cover (6A)............................................................................................................................................................................................... 46
Carrier Disassembly.................................................................................................................................................................................................................................................. 46
1. Using a punch and hammer, drive roll pin (3G) into planet shaft (3E).......................................................................................................................................................................................... 46
Assemble Carrier..................................................................................................................................................................................................................................................... 47
1. Apply grease to inside of one cluster gear (3F) and line one half of cluster gear with 16 needle rollers (3C)................................................................................................................................................. 47
Cover Sub-Assembly................................................................................................................................................................................................................................................... 48
1. Using disconnect rod, push O-ring (6F) into groove inside cover cap (6B)...................................................................................................................................................................................... 48
Hub-Spindle Sub-Assembly............................................................................................................................................................................................................................................. 50
1. Set hub (1G) on large end. Press bearing cup (1C) into counterbore in small end of hub (1G)................................................................................................................................................................... 50
Main Assembly........................................................................................................................................................................................................................................................ 52
1. Grease O-ring (5) and place it into counterbore in hub (1G)................................................................................................................................................................................................... 52
Tool List............................................................................................................................................................................................................................................................ 57
3.3 Re-Align Torque Hub Input Coupling........................................................................................................................................................................................................................... 58
Equipment Required................................................................................................................................................................................................................................................... 58
1. Hydraulic power supply (hand pump) capable of producing 200 psi (13.8 bar).................................................................................................................................................................................... 58
Procedure............................................................................................................................................................................................................................................................ 58
1. Using appropriate fittings, connect a line from hydraulic power supply to brake port.......................................................................................................................................................................... 58
3.4 Drive Motor.................................................................................................................................................................................................................................................. 58
Description.......................................................................................................................................................................................................................................................... 58
Shaft Seal Replacement............................................................................................................................................................................................................................................... 59
Removal.......................................................................................................................................................................................................................................................... 59
1. Remove snap ring (1) and support washer (2)............................................................................................................................................................................................................... 59
1. Snap Ring................................................................................................................................................................................................................................................. 59
2. Support Washer............................................................................................................................................................................................................................................ 59
3. Shaft Seal................................................................................................................................................................................................................................................ 59
Inspect components............................................................................................................................................................................................................................................... 59
installation..................................................................................................................................................................................................................................................... 59
1. Cover shaft splines with an installation sleeve to protect shaft seal during installation................................................................................................................................................................. 59
Loop Flushing Valve.................................................................................................................................................................................................................................................. 59
Removal.......................................................................................................................................................................................................................................................... 59
1. Remove plug (1) and (2) with 11/16" internal hex wrench................................................................................................................................................................................................... 59
1. Plug...................................................................................................................................................................................................................................................... 59
2. Plug...................................................................................................................................................................................................................................................... 59
3. Plug...................................................................................................................................................................................................................................................... 59
4. O-ring.................................................................................................................................................................................................................................................... 59
5. O-ring.................................................................................................................................................................................................................................................... 59
6. O-ring.................................................................................................................................................................................................................................................... 59
7. Spring.................................................................................................................................................................................................................................................... 59
8. Spring.................................................................................................................................................................................................................................................... 59
9. Spring.................................................................................................................................................................................................................................................... 59
10. Washer................................................................................................................................................................................................................................................... 59
11. Washer................................................................................................................................................................................................................................................... 59
12. Shift Spool.............................................................................................................................................................................................................................................. 59
13. Orifice Poppet........................................................................................................................................................................................................................................... 59
installation..................................................................................................................................................................................................................................................... 59
1. Install orifice poppet (13)............................................................................................................................................................................................................................... 59
Troubleshooting...................................................................................................................................................................................................................................................... 60
Disassembly.......................................................................................................................................................................................................................................................... 61
1. Plug.......................................................................................................................................................................................................................................................... 61
2. Plug.......................................................................................................................................................................................................................................................... 61
3. Plug.......................................................................................................................................................................................................................................................... 61
4. O-ring........................................................................................................................................................................................................................................................ 61
5. O-ring........................................................................................................................................................................................................................................................ 61
6. O-ring........................................................................................................................................................................................................................................................ 61
7. Spring........................................................................................................................................................................................................................................................ 61
8. Spring........................................................................................................................................................................................................................................................ 61
9. Spring........................................................................................................................................................................................................................................................ 61
10. Washer....................................................................................................................................................................................................................................................... 61
11. Washer....................................................................................................................................................................................................................................................... 61
12. Shift Spool.................................................................................................................................................................................................................................................. 61
13. Orifice Poppet............................................................................................................................................................................................................................................... 61
1. Using a 11/16" wrench, remove plug (1) and (2)............................................................................................................................................................................................................ 61
14. Lock Nut..................................................................................................................................................................................................................................................... 61
15. O-ring Plug.................................................................................................................................................................................................................................................. 61
16. Control Line Plug............................................................................................................................................................................................................................................ 61
17. Control Line Plug............................................................................................................................................................................................................................................ 61
18. Cavity Plug.................................................................................................................................................................................................................................................. 61
19. Drain Plug................................................................................................................................................................................................................................................... 61
20. Drain Plug................................................................................................................................................................................................................................................... 61
21. Work Port Plug............................................................................................................................................................................................................................................... 61
22. Screw........................................................................................................................................................................................................................................................ 62
23. End Cap...................................................................................................................................................................................................................................................... 62
24. O-ring....................................................................................................................................................................................................................................................... 62
25. Valve Plate.................................................................................................................................................................................................................................................. 62
26. End Cap...................................................................................................................................................................................................................................................... 62
27. O-ring....................................................................................................................................................................................................................................................... 62
28. O-ring....................................................................................................................................................................................................................................................... 62
29. Angle Stop................................................................................................................................................................................................................................................... 62
30. Cylinder Kit Assembly........................................................................................................................................................................................................................................ 63
31. Snap Ring.................................................................................................................................................................................................................................................... 63
32. Support Washer............................................................................................................................................................................................................................................... 63
33. Shaft Seal................................................................................................................................................................................................................................................... 63
34. Inner Snap Ring.............................................................................................................................................................................................................................................. 63
35. Snap Ring.................................................................................................................................................................................................................................................... 63
36. Bearing...................................................................................................................................................................................................................................................... 63
37. Shaft........................................................................................................................................................................................................................................................ 63
38. Swashplate................................................................................................................................................................................................................................................... 64
39. Servo Piston................................................................................................................................................................................................................................................. 64
40. Piston Seal.................................................................................................................................................................................................................................................. 64
41. O-ring....................................................................................................................................................................................................................................................... 64
42. Journal Bearings............................................................................................................................................................................................................................................. 64
43. Piston....................................................................................................................................................................................................................................................... 64
44. Slipper Retainer............................................................................................................................................................................................................................................. 64
45. Cylinder Block............................................................................................................................................................................................................................................... 64
46. Ball Guide................................................................................................................................................................................................................................................... 64
47. Holddown Pins................................................................................................................................................................................................................................................ 64
48. Retaining Ring............................................................................................................................................................................................................................................... 64
49. Block Spring Washer.......................................................................................................................................................................................................................................... 64
50. Spiral Retaining Ring........................................................................................................................................................................................................................................ 64
51. Block Spring................................................................................................................................................................................................................................................. 64
52. Inner Block Spring Washer.................................................................................................................................................................................................................................... 64
Inspection........................................................................................................................................................................................................................................................... 65
Piston........................................................................................................................................................................................................................................................... 65
Slippers......................................................................................................................................................................................................................................................... 65
Ball Guide and Slipper Retainer.................................................................................................................................................................................................................................. 65
Cylinder Block................................................................................................................................................................................................................................................... 65
Valve Plate...................................................................................................................................................................................................................................................... 66
Swashplate and Journal Bearings.................................................................................................................................................................................................................................. 66
Shaft Bearings................................................................................................................................................................................................................................................... 66
Shaft............................................................................................................................................................................................................................................................ 66
Servo Piston and Minimum Angle Stop.............................................................................................................................................................................................................................. 66
Loop Flushing Spool.............................................................................................................................................................................................................................................. 66
Assembly............................................................................................................................................................................................................................................................. 67
1. Install new O-ring (1) and piston seal (2) to servo piston (3). Install piston seal over O-ring............................................................................................................................................................... 67
1. O-ring........................................................................................................................................................................................................................................................ 67
2. Piston Seal................................................................................................................................................................................................................................................... 67
3. Servo Piston.................................................................................................................................................................................................................................................. 67
4. Block Spring Washer........................................................................................................................................................................................................................................... 67
5. Block Spring.................................................................................................................................................................................................................................................. 67
6. Outer Washer.................................................................................................................................................................................................................................................. 67
7. Spiral Retaining Ring......................................................................................................................................................................................................................................... 67
8. Retaining Ring................................................................................................................................................................................................................................................ 67
9. Holddown Pins................................................................................................................................................................................................................................................. 67
10. Ball Guide................................................................................................................................................................................................................................................... 67
11. Piston....................................................................................................................................................................................................................................................... 67
12. Slipper Retainer............................................................................................................................................................................................................................................. 67
13. Journal Bearings............................................................................................................................................................................................................................................. 68
14. Swash Plate.................................................................................................................................................................................................................................................. 68
15. Front Shaft Bearing.......................................................................................................................................................................................................................................... 68
16. Shaft........................................................................................................................................................................................................................................................ 68
17. Snap Ring.................................................................................................................................................................................................................................................... 68
18. Snap Ring.................................................................................................................................................................................................................................................... 68
19. Cylinder Kit................................................................................................................................................................................................................................................. 69
20. Servo Spring................................................................................................................................................................................................................................................. 69
21. Minimum Angle Stop........................................................................................................................................................................................................................................... 69
22. Rear Shaft Bearing........................................................................................................................................................................................................................................... 69
23. Timing Pin................................................................................................................................................................................................................................................... 69
24. Valve Plate.................................................................................................................................................................................................................................................. 69
25. End Cap...................................................................................................................................................................................................................................................... 70
26. Screw........................................................................................................................................................................................................................................................ 70
27. Shaft Seal................................................................................................................................................................................................................................................... 70
28. Seal Support Washer.......................................................................................................................................................................................................................................... 70
29. Snap Ring.................................................................................................................................................................................................................................................... 70
30. Orifice Poppet............................................................................................................................................................................................................................................... 71
31. Shift Spool.................................................................................................................................................................................................................................................. 71
32. Spring....................................................................................................................................................................................................................................................... 71
33. Spring....................................................................................................................................................................................................................................................... 71
34. Spring....................................................................................................................................................................................................................................................... 71
35. Spring....................................................................................................................................................................................................................................................... 71
36. Spring....................................................................................................................................................................................................................................................... 71
37. O-ring....................................................................................................................................................................................................................................................... 71
38. O-ring....................................................................................................................................................................................................................................................... 71
39. O-ring....................................................................................................................................................................................................................................................... 71
40. Plug......................................................................................................................................................................................................................................................... 71
41. Plug......................................................................................................................................................................................................................................................... 71
42. Plug......................................................................................................................................................................................................................................................... 71
Initial Start-Up Procedures.......................................................................................................................................................................................................................................... 71
1. Fill reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into reservoir. Never reuse hydraulic fluid...................................................................................................... 71
3.5 Adjustment Procedure For Lockout Valve....................................................................................................................................................................................................................... 73
2. Bracket................................................................................................................................................................................................................................................... 73
3. Lockout Valve............................................................................................................................................................................................................................................. 73
3.6 Oscillating Axle Bleeding Procedure and Lockout Test......................................................................................................................................................................................................... 73
Lockout Cylinder Bleeding (Ram Cylinders)............................................................................................................................................................................................................................ 73
1. Position turntable to normal stowed position so axle is free to oscillate. Drive charge pressure will pass through lockout valve built into swivel and down to pilot section of holding valves on cylinders. This will automatically purge air from pil....... 73
Oscillating Axle Lockout Test........................................................................................................................................................................................................................................ 74
1. Place a 6" (15 cm) high block with ascension ramp in front of left front wheel................................................................................................................................................................................ 74
3.7 Swing Bearing................................................................................................................................................................................................................................................ 74
Description.......................................................................................................................................................................................................................................................... 74
Removal.............................................................................................................................................................................................................................................................. 74
1. Clean area around swing motor (3) to prevent any dirt from entering system.................................................................................................................................................................................... 74
Disassembly.......................................................................................................................................................................................................................................................... 76
1. Clean area around swing motor (1) to prevent any dirt from entering system.................................................................................................................................................................................... 76
1. Remove two bolts (5) and washers (6) that hold turntable bearing (7) to housing (4)........................................................................................................................................................................... 76
Assembly............................................................................................................................................................................................................................................................. 78
Installation......................................................................................................................................................................................................................................................... 78
Turntable Bearing Mounting Bolt Checks............................................................................................................................................................................................................................... 80
Check Frame To Bearing Bolts......................................................................................................................................................................................................................................... 80
1. Fully retracted boom and elevate to 70° (full elevation)...................................................................................................................................................................................................... 80
Check Turntable To Bearing Bolts..................................................................................................................................................................................................................................... 80
Wear Tolerance....................................................................................................................................................................................................................................................... 80
a. Metal particles in grease..................................................................................................................................................................................................................................... 80
b. Increased drive power......................................................................................................................................................................................................................................... 80
c. Noise......................................................................................................................................................................................................................................................... 80
d. Rough rotation................................................................................................................................................................................................................................................ 80
3.8 Swing Motor.................................................................................................................................................................................................................................................. 81
Preparation Before Disassembly....................................................................................................................................................................................................................................... 81
1. Hose fittings loose, worn or damaged.......................................................................................................................................................................................................................... 82
2. Oil seal rings (4) deteriorated by excess heat................................................................................................................................................................................................................ 82
3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion........................................................................................................................................................................... 82
4. Internal shaft seal (16) worn or damaged...................................................................................................................................................................................................................... 82
5. Worn coupling shaft (12) and internal seal (16)............................................................................................................................................................................................................... 82
1. Lack of sufficient oil supply................................................................................................................................................................................................................................. 82
2. High internal motor leakage................................................................................................................................................................................................................................... 82
3. Severely worn or damaged internal splines..................................................................................................................................................................................................................... 82
4. Excessive heat................................................................................................................................................................................................................................................ 82
1. Line blockage................................................................................................................................................................................................................................................. 82
2. Internal interference......................................................................................................................................................................................................................................... 82
3. Lack of pumping pressure...................................................................................................................................................................................................................................... 82
4. Excessive binding or loading in system external to motor unit................................................................................................................................................................................................. 82
Removal.............................................................................................................................................................................................................................................................. 82
1. Thoroughly clean area around swing motor to prevent dirt from entering system................................................................................................................................................................................. 82
Preparation Before Disassembly....................................................................................................................................................................................................................................... 82
Disassembly and Inspection........................................................................................................................................................................................................................................... 84
1. Bolt.......................................................................................................................................................................................................................................................... 90
2. End Cover..................................................................................................................................................................................................................................................... 90
3. Seal Ring..................................................................................................................................................................................................................................................... 90
4. O-Ring........................................................................................................................................................................................................................................................ 90
5. Commutator.................................................................................................................................................................................................................................................... 90
6. Commutator Ring............................................................................................................................................................................................................................................... 90
7. Manifold...................................................................................................................................................................................................................................................... 90
8. Rotor Set..................................................................................................................................................................................................................................................... 90
9. Wear Plate.................................................................................................................................................................................................................................................... 90
10. Drive Link................................................................................................................................................................................................................................................... 90
11. Coupling Shaft 12A. Key...................................................................................................................................................................................................................................... 90
12. Inner Bushing................................................................................................................................................................................................................................................ 90
13. Thrust Washer................................................................................................................................................................................................................................................ 90
14. Thrust Bearing............................................................................................................................................................................................................................................... 90
15. Inner Shaft Seal............................................................................................................................................................................................................................................. 90
16. Backup Ring.................................................................................................................................................................................................................................................. 90
17. Housing...................................................................................................................................................................................................................................................... 90
18. Bearing...................................................................................................................................................................................................................................................... 90
19. Outer Shaft Seal............................................................................................................................................................................................................................................. 90
Assembly............................................................................................................................................................................................................................................................. 91
1. If housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease. Press new bearing/bushing into counterbore at mounting flange end of housing, using a....... 91
One Piece Stator Assembly............................................................................................................................................................................................................................................ 97
1. Place stator on wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure seal ring is in place.................................................................................................................. 97
Two Piece Stator Assembly............................................................................................................................................................................................................................................ 98
1. Place stator half on wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure seal ring is in place....................................................................................................... 98
Final Checks......................................................................................................................................................................................................................................................... 98
1. Pressurize motor with 100 psi dry air or nitrogen and submerge in solvent to check for external leaks......................................................................................................................................................... 98
Installation......................................................................................................................................................................................................................................................... 98
3.9 Generator....................................................................................................................................................................................................................................................100
Every 250 hours......................................................................................................................................................................................................................................................100
Every 500 hours......................................................................................................................................................................................................................................................100
Overload Protection..................................................................................................................................................................................................................................................100
Brushes and Slip Rings...............................................................................................................................................................................................................................................100
inspecting brush position........................................................................................................................................................................................................................................100
inspecting brushes...............................................................................................................................................................................................................................................100
CLEANING SLIP RINGS..............................................................................................................................................................................................................................................100
1. Brush Holder Assembly.....................................................................................................................................................................................................................................101
2. Brushes...................................................................................................................................................................................................................................................101
3. Slip Rings................................................................................................................................................................................................................................................101
3.10 Deutz Engine............................................................................................................................................................................................................................................102
Check Oil Level......................................................................................................................................................................................................................................................102
Change Engine Oil....................................................................................................................................................................................................................................................102
1. Allow engine to warm up. Engine oil should reach approximately 176° F (80° C).................................................................................................................................................................................102
Change Oil Filter....................................................................................................................................................................................................................................................102
1. Wipe area around filter to remove any dirt from area..........................................................................................................................................................................................................102
Replace Fuel Filter..................................................................................................................................................................................................................................................103
1. Wipe area around filter to clean any dirt from area...........................................................................................................................................................................................................103
Clean Fuel Strainer..................................................................................................................................................................................................................................................103
1. Unscrew hexagonal nut (1).....................................................................................................................................................................................................................................103
3.11 Deutz EMR 2.................................................................................................................................................................................................................................................104
3.12 Bio Fuel in Deutz Engines...................................................................................................................................................................................................................................116
General..............................................................................................................................................................................................................................................................116
Bio Fuel.............................................................................................................................................................................................................................................................116
Permitted bio-diesel fuels.......................................................................................................................................................................................................................................116
approved engines.................................................................................................................................................................................................................................................116
Basic conditions to be observed..................................................................................................................................................................................................................................116
Plant oil........................................................................................................................................................................................................................................................116
Biological Contamination In Fuels....................................................................................................................................................................................................................................116
Symptoms.........................................................................................................................................................................................................................................................116
Cause............................................................................................................................................................................................................................................................117
Preventive measures..............................................................................................................................................................................................................................................117
Fuel additives...................................................................................................................................................................................................................................................117
3.13 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS.....................................................................................................................................................................................................118
Section Layout.......................................................................................................................................................................................................................................................118
Fault Code Broadcast.................................................................................................................................................................................................................................................120
Diagnostic Trouble Codes.............................................................................................................................................................................................................................................120
CAN..................................................................................................................................................................................................................................................................120
MIL Output...........................................................................................................................................................................................................................................................120
Diagnostic Calibration Configuration and Corrective Actions..........................................................................................................................................................................................................120
Fault/Diagnostic Trouble Code Interaction............................................................................................................................................................................................................................121
DBW Diagnostic Test..................................................................................................................................................................................................................................................124
3.14 Diagnostic Trouble Code Fault Descriptions..................................................................................................................................................................................................................127
DTC 116- ECT Higher Than Expected Stage 1............................................................................................................................................................................................................................127
DTC 117- ECT/CHT Low Voltage.........................................................................................................................................................................................................................................128
DTC 118- ECT/CHT High Voltage........................................................................................................................................................................................................................................129
DTC 122- TPS1 Signal Voltage Low.....................................................................................................................................................................................................................................132
DTC 123- TPS1 Signal Voltage High....................................................................................................................................................................................................................................134
DTC 217- ECT Higher Than Expected 2..................................................................................................................................................................................................................................136
DTC 219- RPM Higher Than Max Allowed Governed Speed..................................................................................................................................................................................................................137
DTC 336- Crank Signal Input Noise....................................................................................................................................................................................................................................138
DTC 337- Loss of Crank Input Signal..................................................................................................................................................................................................................................140
DTC 521- Oil Pressure Sender/Switch High Pressure....................................................................................................................................................................................................................141
DTC 524- Oil Pressure Low............................................................................................................................................................................................................................................144
DTC 562- Battery Voltage (VBat) Low..................................................................................................................................................................................................................................148
DTC 563- Battery Voltage (VBat) High.................................................................................................................................................................................................................................150
DTC 601- Microprocessor Failure - FLASH..............................................................................................................................................................................................................................152
DTC 604- Microprocessor Failure - RAM................................................................................................................................................................................................................................154
DTC 606- Microprocessor Failure - COP................................................................................................................................................................................................................................156
DTC 642- 5 Volt External Low Voltage.................................................................................................................................................................................................................................157
DTC 643- 5 Volt External High Voltage................................................................................................................................................................................................................................158
DTC 1612- Microprocessor Failure - RTI 1.............................................................................................................................................................................................................................159
DTC 1613- Microprocessor Failure - RTI 2.............................................................................................................................................................................................................................159
DTC 1614- Microprocessor Failure - RTI 3.............................................................................................................................................................................................................................161
DTC 1615- Microprocessor Failure - A/D...............................................................................................................................................................................................................................163
DTC 1616- Microprocessor Failure - interrupt.........................................................................................................................................................................................................................165
DTC 1625- CAN J1939 Shutdown Request.................................................................................................................................................................................................................................167
DTC 1626- CAN J1939 Transmit (Tx) Fault..............................................................................................................................................................................................................................167
DTC 1627- CAN J1939 Receive (Rx) Fault...............................................................................................................................................................................................................................168
DTC 1628- CAN Address Conflict Failure...............................................................................................................................................................................................................................169
DTC 1629- J1939 TSC1 Message Receipt Loss............................................................................................................................................................................................................................171
Diagnostic Aids..................................................................................................................................................................................................................................................171
DTC 1652- TPS1 Loss of Communications................................................................................................................................................................................................................................ 0
DTC 2111- Unable to Reach Lower TPS.................................................................................................................................................................................................................................. 0
DTC 2112- Unable to Reach Higher TPS.................................................................................................................................................................................................................................174
DTC 9999- Throttle Actuator Failsafe Spring Failure..................................................................................................................................................................................................................175
DTC to SPN/FMI Table.................................................................................................................................................................................................................................................175
Section 4. Boom & Platform.......................................................................................................................................................................................................................................................179
4.1 Boom Maintenance.........................................................................................................................................................................................................................................................179
Remove Boom Assembly.....................................................................................................................................................................................................................................................179
Main Boom Disassembly....................................................................................................................................................................................................................................................180
Inspection...............................................................................................................................................................................................................................................................180
Main Boom Assembly.......................................................................................................................................................................................................................................................181
Install Boom Assembly....................................................................................................................................................................................................................................................181
4.2 Rotary Actuator..........................................................................................................................................................................................................................................................185
Theory of Operation......................................................................................................................................................................................................................................................185
Required Tools...........................................................................................................................................................................................................................................................185
Disassembly..............................................................................................................................................................................................................................................................187
Inspection...............................................................................................................................................................................................................................................................190
Assembly.................................................................................................................................................................................................................................................................191
Installing Counterbalance Valve..........................................................................................................................................................................................................................................196
4.3 Powertrack Maintenance...................................................................................................................................................................................................................................................198
Remove Link..............................................................................................................................................................................................................................................................198
Install New Link.........................................................................................................................................................................................................................................................201
Replace Fixed End Brackets...............................................................................................................................................................................................................................................204
Replace Moving End Brackets..............................................................................................................................................................................................................................................205
Section 5. Basic Hydraulic Information & Hydraulic Schematics....................................................................................................................................................................................................................207
5.1 O-Ring Lubrication.......................................................................................................................................................................................................................................................207
Cup and Brush............................................................................................................................................................................................................................................................207
Dip......................................................................................................................................................................................................................................................................208
Spray....................................................................................................................................................................................................................................................................208
Brush-On.................................................................................................................................................................................................................................................................208
5.2 Hydraulic Cylinders......................................................................................................................................................................................................................................................209
Tower Lift Cylinder......................................................................................................................................................................................................................................................210
Main Lift Cylinder.......................................................................................................................................................................................................................................................215
Master Cylinder..........................................................................................................................................................................................................................................................220
Telescope Cylinder.......................................................................................................................................................................................................................................................225
Slave (Platform Level) Cylinder..........................................................................................................................................................................................................................................230
Jib Lift Cylinder........................................................................................................................................................................................................................................................235
Steer Cylinder...........................................................................................................................................................................................................................................................240
Axle Lockout Cylinder....................................................................................................................................................................................................................................................244
5.3 Hydraulic Pump (Gear)....................................................................................................................................................................................................................................................246
Disassembly..............................................................................................................................................................................................................................................................246
Inspect Parts For Wear...................................................................................................................................................................................................................................................248
General Information......................................................................................................................................................................................................................................................249
Reverse Shaft Rotation of Pump...........................................................................................................................................................................................................................................249
Assembly.................................................................................................................................................................................................................................................................249
Placing Pump Back Into Service...........................................................................................................................................................................................................................................252
5.4 Variable Pump............................................................................................................................................................................................................................................................252
Ports and Pressure Gauges................................................................................................................................................................................................................................................252
NFPE Control.............................................................................................................................................................................................................................................................252
Remove and Install FNR and NFPE Modules..................................................................................................................................................................................................................................253
Remove and Install FNR and NFPE Control Orifices.........................................................................................................................................................................................................................253
Charge Relief Valve......................................................................................................................................................................................................................................................253
Shaft Seal and Shaft Replacement.........................................................................................................................................................................................................................................256
Charge Pump..............................................................................................................................................................................................................................................................258
5.5 Hydraulic Component Start-Up.............................................................................................................................................................................................................................................259
5.6 Main Valve Block Pressure Setting Procedures.............................................................................................................................................................................................................................260
Telescope................................................................................................................................................................................................................................................................260
Main Relief..............................................................................................................................................................................................................................................................260
Steer....................................................................................................................................................................................................................................................................260
Lift Down................................................................................................................................................................................................................................................................260
Swing....................................................................................................................................................................................................................................................................260
5.7 Platform Valve Block Pressure Setting Procedures.........................................................................................................................................................................................................................260
Platform Level Up........................................................................................................................................................................................................................................................260
Platform Level Down......................................................................................................................................................................................................................................................260
Articulating Jib.........................................................................................................................................................................................................................................................260
5.8 Hydraulic Schematics.....................................................................................................................................................................................................................................................263
Section 6. JLG Control System....................................................................................................................................................................................................................................................267
6.1 introduction.............................................................................................................................................................................................................................................................267
Connect JLG Control System Analyzer......................................................................................................................................................................................................................................269
Using Analyzer...........................................................................................................................................................................................................................................................269
Changing Access Level....................................................................................................................................................................................................................................................270
Adjust Parameters........................................................................................................................................................................................................................................................271
Machine Setup............................................................................................................................................................................................................................................................272
Level Vehicle Description................................................................................................................................................................................................................................................272
6.9 System Test..............................................................................................................................................................................................................................................................296
Test from Platform.......................................................................................................................................................................................................................................................296
Test From Ground Station.................................................................................................................................................................................................................................................298
Section 7. Basic Electrical Information & Electrical Schematics..................................................................................................................................................................................................................331
7.1 General..................................................................................................................................................................................................................................................................331
7.2 Multimeter Basics........................................................................................................................................................................................................................................................331
Grounding................................................................................................................................................................................................................................................................331
Backprobing..............................................................................................................................................................................................................................................................331
Min/Max..................................................................................................................................................................................................................................................................331
Polarity.................................................................................................................................................................................................................................................................331
Scale....................................................................................................................................................................................................................................................................331
Voltage Measurement......................................................................................................................................................................................................................................................331
Resistance Measurement...................................................................................................................................................................................................................................................332
Continuity Measurement...................................................................................................................................................................................................................................................332
Current Measurement......................................................................................................................................................................................................................................................333
7.3 Applying Silicone Dielectric Compound to Electrical Connections..........................................................................................................................................................................................................333
Dielectric Grease Application............................................................................................................................................................................................................................................334
Deutsch HD, DT, DTM, DRC Series..........................................................................................................................................................................................................................................334
AMP Seal.................................................................................................................................................................................................................................................................334
AMP Mate-N-Lok...........................................................................................................................................................................................................................................................335
DIN Connectors...........................................................................................................................................................................................................................................................335
Exclusions...............................................................................................................................................................................................................................................................335
7.4 AMP Connector............................................................................................................................................................................................................................................................336
Contact Assembly.........................................................................................................................................................................................................................................................336
Connector Assembly.......................................................................................................................................................................................................................................................336
Disassembly..............................................................................................................................................................................................................................................................337
Wedge Lock...............................................................................................................................................................................................................................................................337
Service - Voltage Reading................................................................................................................................................................................................................................................337
7.5 Deutsch Connectors.......................................................................................................................................................................................................................................................338
DT/DTP Series Assembly...................................................................................................................................................................................................................................................338
DT/DTP Series Disassembly................................................................................................................................................................................................................................................338
HD30/HDP20 Series Assembly...............................................................................................................................................................................................................................................339
HD30/HDP20 Series Disassembly............................................................................................................................................................................................................................................339
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JLG 510AJ Series II Service & Maintenance Manual (3121293) – PDF DOWNLOADJLG 510AJ Series II Service & Maintenance Manual (3121293) – PDF DOWNLOAD
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