Jlg 1250AJP Service Manual manuels

Manuels d'utilisation et guides de l'utilisateur pour Machines spéciales Jlg 1250AJP Service Manual.
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Jlg 1250AJP Service Manual Manuel d'utilisateur (606 pages)

marque: Jlg | Catégorie: Machines spéciales | Taille: 44.36 MB |

Anglais

Table des matières

P/N - 3121171

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

10

SECTION 5 - HYDRAULICS

10

TABLE OF CONTENTS

11

LIST OF FIGURES

13

SECTION 1. SPECIFICATIONS

19

1.5 DIMENSIONAL DATA

20

1.6 ENGINE DATA

20

Caterpillar

20

1.9 PRESSURE SETTINGS

21

1.10 HYDRAULIC OIL

22

SECTION 1 - SPECIFICATIONS

23

MAINTENANCE

24

SOCKET HEAD CAP SCREWS

33

Magni Coating (Ref 4150701)*

37

SECTION 2. GENERAL

39

2.2 SERVICE AND GUIDELINES

40

Safety and Workmanship

40

Cleanliness

40

SECTION 2 - GENERAL

41

Hydraulic Oil

42

Changing Hydraulic Oil

42

Lubrication Specifications

42

2.4 CYLINDER DRIFT TEST

42

Platform Drift

42

3121171 – JLG Lift – 2-9

47

2-10 – JLG Lift – 3121171

48

3.1 TIRES & WHEELS

49

Tire Inflation

49

Tire Damage

49

Tire Replacement

49

Wheel and Tire Replacement

49

Wheel Installation

50

3.2 AXLE EXTENSION SYSTEM

51

PROCEDURE

51

3.4 DRIVE SYSTEM

52

3.5 STEERING CONTROL SYSTEM

52

3.7 TRACTION CONTROL SYSTEM

53

3.8 DRIVE ORIENTATION SYSTEM

53

3-6 – JLG Lift – 3121171

54

3121171 – JLG Lift – 3-7

55

3-8 – JLG Lift – 3121171

56

3121171 – JLG Lift – 3-9

57

DETAIL B

58

3-12 – JLG Lift – 3121171

60

3121171 – JLG Lift – 3-13

61

3.10 OSCILLATING AXLE SYSTEM

62

PROCEDURE AND LOCKOUT TEST

62

Lockout Cylinder Bleeding

62

Oscillating Axle Lockout Test

63

3-16 – JLG Lift – 3121171

64

3121171 – JLG Lift – 3-17

65

3-18 – JLG Lift – 3121171

66

3121171 – JLG Lift – 3-19

67

3-20 – JLG Lift – 3121171

68

General Information

69

3-22 – JLG Lift – 3121171

70

Gearbox Disengagement

71

3-24 – JLG Lift – 3121171

72

Maintenance Information

73

Disassembly Information

74

3121171 – JLG Lift – 3-27

75

3-28 – JLG Lift – 3121171

76

3121171 – JLG Lift – 3-29

77

3-30 – JLG Lift – 3121171

78

3121171 – JLG Lift – 3-31

79

3-32 – JLG Lift – 3121171

80

3121171 – JLG Lift – 3-33

81

Inspection of Parts

82

3-36 – JLG Lift – 3121171

84

3121171 – JLG Lift – 3-37

85

3-38 – JLG Lift – 3121171

86

3121171 – JLG Lift – 3-39

87

3-40 – JLG Lift – 3121171

88

3121171 – JLG Lift – 3-41

89

3-42 – JLG Lift – 3121171

90

3121171 – JLG Lift – 3-43

91

3-44 – JLG Lift – 3121171

92

Final Test and Reinstallation

93

3-46 – JLG Lift – 3121171

94

3121171 – JLG Lift – 3-47

95

3-48 – JLG Lift – 3121171

96

3121171 – JLG Lift – 3-49

97

134389 TO PRESENT)

98

Symbol Nomenclature

98

3121171 – JLG Lift – 3-51

99

3-52 – JLG Lift – 3121171

100

3121171 – JLG Lift – 3-53

101

M- 1546 M- 1548

102

Disassembly

103

3-56 – JLG Lift – 3121171

104

3121171 – JLG Lift – 3-57

105

3-58 – JLG Lift – 3121171

106

Assembly

107

3-60 – JLG Lift – 3121171

108

3121171 – JLG Lift – 3-61

109

3-62 – JLG Lift – 3121171

110

3121171 – JLG Lift – 3-63

111

3-64 – JLG Lift – 3121171

112

3.15 SWING DRIVE

113

Roll and Leak Testing

113

Tightening and Torquing Bolts

113

3-66 – JLG Lift – 3121171

114

Motor and Brake Disassembly

115

Main Disassembly

116

Hub-Shaft Disassembly

117

Carrier Disassembly

118

Hub-Shaft Sub-Assembly

119

Carrier Sub-Assembly

120

3121171 – JLG Lift – 3-73

121

Main Assembly

122

3121171 – JLG Lift – 3-75

123

Motor and Brake Assembly

124

Motor Control Valve Assembly

125

3.16 SWING BRAKE

126

Pre-Installation Checks

126

Installation

127

Maintenance

127

Examination

127

3-80 – JLG Lift – 3121171

128

3.17 SWING MOTOR

129

Disassembly and inspection

129

3-82 – JLG Lift – 3121171

130

3121171 – JLG Lift – 3-83

131

3121171 – JLG Lift – 3-85

133

3-86 – JLG Lift – 3121171

134

3121171 – JLG Lift – 3-87

135

3121171 – JLG Lift – 3-89

137

3-90 – JLG Lift – 3121171

138

3121171 – JLG Lift – 3-91

139

3-92 – JLG Lift – 3121171

140

3121171 – JLG Lift – 3-93

141

3-94 – JLG Lift – 3121171

142

One Piece Stator Construction

143

BACKLASH

144

3.19 SWING DRIVE LUBRICATION

145

3.20 SWING BEARING

146

3121171 – JLG Lift – 3-99

147

MAIN TELESCOPE

148

FULLY EXTENDED

148

TOWER TELESCOPE

148

Wear Tolerance

149

Swing Bearing Removal

149

29,100 lbs

150

Swing Bearing Installation

151

Swing Bearing Torque Values

151

3-104 – JLG Lift – 3121171

152

3121171 – JLG Lift – 3-105

153

3.23 ROTARY COUPLING

154

3121171 – JLG Lift – 3-107

155

3-108 – JLG Lift – 3121171

156

3.24 GENERATOR

157

Every 250 hours

157

Every 500 hours

157

Overload Protection

158

Cleaning Slip Rings

158

3121171 – JLG Lift – 3-111

159

3.25 COLD WEATHER PACKAGE

160

3.26 ENGINE

160

Glow Plugs

160

Checking Oil Level

160

Changing Engine Oil

160

VIEW A-A

161

VIEW B-B

161

Changing the Oil Filter

162

Replacing the Fuel Filter

163

Cleaning the Fuel Strainer

163

3-116 – JLG Lift – 3121171

164

3121171 – JLG Lift – 3-117

165

3-118 – JLG Lift – 3121171

166

3-120 – JLG Lift – 3121171

168

3121171 – JLG Lift – 3-121

169

3-122 – JLG Lift – 3121171

170

3121171 – JLG Lift – 3-123

171

3-124 – JLG Lift – 3121171

172

3121171 – JLG Lift – 3-125

173

3-126 – JLG Lift – 3121171

174

3121171 – JLG Lift – 3-127

175

3-128 – JLG Lift – 3121171

176

3121171 – JLG Lift – 3-129

177

3-130 – JLG Lift – 3121171

178

3121171 – JLG Lift – 3-131

179

3-132 – JLG Lift – 3121171

180

Bio Fuel

181

TROUBLE CODE DEFINITIONS

183

3-136 – JLG Lift – 3121171

184

3121171 – JLG Lift – 3-137

185

3-138 – JLG Lift – 3121171

186

Diagnostic Trouble Codes

187

MIL Output

187

Diagnostic Aids

188

DTC 117- ECT/CHT Low Voltage

189

3-142 – JLG Lift – 3121171

190

DTC 118- ECT/CHT High Voltage

191

3-144 – JLG Lift – 3121171

192

3121171 – JLG Lift – 3-145

193

3-146 – JLG Lift – 3121171

194

3121171 – JLG Lift – 3-147

195

3-148 – JLG Lift – 3121171

196

Governed Speed

198

3121171 – JLG Lift – 3-151

199

3-152 – JLG Lift – 3121171

200

Pressure

202

DTC 524- Oil Pressure Low

203

Normally Closed Switch

204

3121171 – JLG Lift – 3-157

205

3-158 – JLG Lift – 3121171

206

3121171 – JLG Lift – 3-159

207

3-160 – JLG Lift – 3121171

208

Microprocessor

209

3-162 – JLG Lift – 3121171

210

3-164 – JLG Lift – 3121171

212

3-166 – JLG Lift – 3121171

214

SFC 555- RTI 2 Loss

219

SFC 556- RTI 3 Loss

221

SFC 513- A/D Loss

223

SFC 512- Invalid Interrupt

225

3121171 – JLG Lift – 3-181

229

3-182 – JLG Lift – 3121171

230

3121171 – JLG Lift – 3-185

233

3-186 – JLG Lift – 3121171

234

3121171 – JLG Lift – 3-187

235

Spring Failure

236

DTC to SPN/FMI Table

237

3.30 AUXILIARY POWER SYSTEM

238

3.31 COUNTERWEIGHT

238

3121171 – JLG Lift – 3-191

239

3-192 – JLG Lift – 3121171

240

3121171 – JLG Lift – 4-1

241

4.5 JIB STOW SYSTEM

242

4.6 ENVELOPE CONTROL SYSTEM

242

4.7 TOWER PATH CONTROL SYSTEM

243

4-4 – JLG Lift – 3121171

244

3121171 – JLG Lift – 4-5

245

4-6 – JLG Lift – 3121171

246

3121171 – JLG Lift – 4-7

247

4.12 SLOW DOWN SYSTEM

248

4.13 DUAL CAPACITY SYSTEM

249

4.14 HYDRAULIC SYSTEM WARM UP

249

4.15 REDUCED PLATFORM HEIGHTS

249

4.17 MAIN BOOM

250

3121171 – JLG Lift – 4-11

251

3121171 – JLG Lift – 4-13

253

4-14 – JLG Lift – 3121171

254

3121171 – JLG Lift – 4-15

255

4-16 – JLG Lift – 3121171

256

3121171 – JLG Lift – 4-17

257

4-18 – JLG Lift – 3121171

258

4.18 TOWER BOOM

259

Installation and Assembly

259

4-20 – JLG Lift – 3121171

260

3121171 – JLG Lift – 4-21

261

4-22 – JLG Lift – 3121171

262

3121171 – JLG Lift – 4-23

263

4-24 – JLG Lift – 3121171

264

DETAIL A

265

4-26 – JLG Lift – 3121171

266

3121171 – JLG Lift – 4-27

267

4-28 – JLG Lift – 3121171

268

3121171 – JLG Lift – 4-29

269

4-30 – JLG Lift – 3121171

270

3121171 – JLG Lift – 4-31

271

4-32 – JLG Lift – 3121171

272

3121171 – JLG Lift – 4-33

273

4-34 – JLG Lift – 3121171

274

3121171 – JLG Lift – 4-35

275

4-36 – JLG Lift – 3121171

276

3121171 – JLG Lift – 4-37

277

4-38 – JLG Lift – 3121171

278

3121171 – JLG Lift – 4-39

279

4-40 – JLG Lift – 3121171

280

3121171 – JLG Lift – 4-41

281

4-42 – JLG Lift – 3121171

282

3121171 – JLG Lift – 4-43

283

4-44 – JLG Lift – 3121171

284

ANY SENSOR

285

TOWER LIFT CYLINDER

286

ANGLE SENSOR DETAIL

286

DUAL CAPACITY

287

LENGTH SWITCH DETAIL

287

MAIN BOOM TRANSPORT

287

LEVER FULLY

288

EXTENDED

288

JIB SWITCH DETAIL

289

LEVEL SENSOR DETAIL

289

PUSH NUT DETAIL

289

TOWER BOOM ANGLE

290

SENSOR DETAIL

290

TOWER BOOM LENGTH

290

3121171 – JLG Lift – 4-51

291

4-52 – JLG Lift – 3121171

292

3121171 – JLG Lift – 4-53

293

Analyzer Readings

294

Possible Faults

295

SWITCHES

297

4.22 DUAL CAPACITY SWITCHES

298

4-60 – JLG Lift – 3121171

300

3121171 – JLG Lift – 4-61

301

4.23 TOWER TELESCOPE CYLINDER

302

Removal

302

3121171 – JLG Lift – 4-63

303

4-64 – JLG Lift – 3121171

304

3121171 – JLG Lift – 4-65

305

3121171 – JLG Lift – 4-67

307

4.24 TOWER LIFT CYLINDER

308

3121171 – JLG Lift – 4-69

309

4-70 – JLG Lift – 3121171

310

3121171 – JLG Lift – 4-71

311

3121171 – JLG Lift – 4-73

313

4-74 – JLG Lift – 3121171

314

3121171 – JLG Lift – 4-75

315

4.25 MAIN LIFT CYLINDER

316

3121171 – JLG Lift – 4-77

317

4-78 – JLG Lift – 3121171

318

4-80 – JLG Lift – 3121171

320

3121171 – JLG Lift – 4-81

321

4-82 – JLG Lift – 3121171

322

3121171 – JLG Lift – 4-83

323

3121171 – JLG Lift – 4-85

325

4.27 POWERTRACK MAINTENANCE

326

One Piece Bracket Maintenance

326

3121171 – JLG Lift – 4-87

327

Two Piece Bracket Maintenance

328

Snap Rings and Screws

329

4-90 – JLG Lift – 3121171

330

3121171 – JLG Lift – 4-91

331

4-92 – JLG Lift – 3121171

332

3121171 – JLG Lift – 4-93

333

4.28 HOSE ROUTING PROCEDURE

334

Description

335

Normal Operation

335

4-96 – JLG Lift – 3121171

336

4.30 TOWER BOOM DRIFT TEST

337

4-98 – JLG Lift – 3121171

338

4.31 ROTARY ACTUATOR

339

Theory of Operation

339

Required Tools

339

4-100 – JLG Lift – 3121171

340

3121171 – JLG Lift – 4-101

341

3121171 – JLG Lift – 4-103

343

4-104 – JLG Lift – 3121171

344

3121171 – JLG Lift – 4-105

345

Inspection

346

3121171 – JLG Lift – 4-107

347

4-108 – JLG Lift – 3121171

348

3121171 – JLG Lift – 4-109

349

4-110 – JLG Lift – 3121171

350

Greasing Thrust Washers

351

Testing the Actuator

351

4-112 – JLG Lift – 3121171

352

Bleeding After Installation

353

4-114 – JLG Lift – 3121171

354

SECTION 5. HYDRAULICS

355

Dip Method

356

Spray Method

356

Brush-on Method

356

5.2 CYLINDER REPAIR

357

SECTION 5 - HYDRAULICS

358

GO (PISTON) GAUGE

369

Cleaning and Inspection

372

FULL LEVEL (HOT OIL)

379

FULL LEVEL (COLD OIL)

379

5.5 HYDRAULIC RETURN FILTER

380

5.6 ENABLE VALVES

399

Machines

400

Set Up of the Function Pump

401

5.8 DRIVE PUMPS

411

Troubleshooting Procedure

411

Mechanical Centering of Pump

415

Routine Maintenance

417

5.9 FUNCTION PUMP

421

Spare Parts

421

Sealing the Drive Shaft

422

Adjustments

427

Tightening Torques

427

PROCEDURES

431

Start-Up Procedure

431

6.1 INTRODUCTION

433

6.2 CANBUS COMMUNICATIONS

434

3121171 – JLG Lift – 6-3

435

6-4 – JLG Lift – 3121171

436

6.3 CALIBRATION INSTRUCTIONS

437

(See Figure 6-4.)

438

(See Figure 6-7.)

438

3121171 – JLG Lift – 6-7

439

6-8 – JLG Lift – 3121171

440

3121171 – JLG Lift – 6-9

441

6-10 – JLG Lift – 3121171

442

3121171 – JLG Lift – 6-11

443

6-12 – JLG Lift – 3121171

444

3121171 – JLG Lift – 6-13

445

6-14 – JLG Lift – 3121171

446

3121171 – JLG Lift – 6-15

447

6-16 – JLG Lift – 3121171

448

3121171 – JLG Lift – 6-17

449

SYSTEM ANALYZER

450

6.5 USING THE ANALYZER

450

HAND HELD ANALYZER

451

6.8 MACHINE SETUP

452

3121171 – JLG Lift – 6-21

453

6-22 – JLG Lift – 3121171

454

3121171 – JLG Lift – 6-23

455

6-24 – JLG Lift – 3121171

456

6-26 – JLG Lift – 3121171

458

3121171 – JLG Lift – 6-27

459

6-28 – JLG Lift – 3121171

460

3121171 – JLG Lift – 6-29

461

Test Notes

462

6.10 SYSTEM TEST

463

Test from the Platform

463

6-32 – JLG Lift – 3121171

464

3121171 – JLG Lift – 6-33

465

Test from the Ground Station

466

3121171 – JLG Lift – 6-35

467

6-36 – JLG Lift – 3121171

468

3121171 – JLG Lift – 6-37

469

6-38 – JLG Lift – 3121171

470

6.11 CALIBRATING STEER

471

6-40 – JLG Lift – 3121171

472

3121171 – JLG Lift – 6-41

473

6.12 CALIBRATING DRIVE

474

3121171 – JLG Lift – 6-43

475

6-44 – JLG Lift – 3121171

476

6.13 CALIBRATING BOOM VALVES

477

6-46 – JLG Lift – 3121171

478

3121171 – JLG Lift – 6-47

479

Fault Response

480

CAN Errors

481

MINIMUMS

482

UP AND DOWN VALVE CRACKPOINTS

483

6.16 CALIBRATING TILT SENSOR

484

3121171 – JLG Lift – 6-53

485

6.17 BOOM SENSOR CALIBRATION

486

General Notes:

486

Step 1 - Position 1

487

Step 2 - Position 2

488

Step 3 - Position 3

489

Step 4 - Position 4

490

Step 5 - Position 5

491

Step 6 - Position 6

492

Step 7 - Position 7

493

Step 8 - Position 8

494

Step 9 - Position 9

495

Step 10 - Position 10

496

Step 11 - Position 11

497

VIOLATION

498

3121171 – JLG Lift – 6-67

499

6-68 – JLG Lift – 3121171

500

3121171 – JLG Lift – 6-69

501

6-70 – JLG Lift – 3121171

502

3121171 – JLG Lift – 6-71

503

6-72 – JLG Lift – 3121171

504

3121171 – JLG Lift – 6-73

505

6-74 – JLG Lift – 3121171

506

3121171 – JLG Lift – 6-75

507

6-76 – JLG Lift – 3121171

508

3121171 – JLG Lift – 6-77

509

6-78 – JLG Lift – 3121171

510

3121171 – JLG Lift – 6-79

511

6-80 – JLG Lift – 3121171

512

3121171 – JLG Lift – 6-81

513

6-82 – JLG Lift – 3121171

514

3121171 – JLG Lift – 6-83

515

6-84 – JLG Lift – 3121171

516

3121171 – JLG Lift – 6-85

517

6-86 – JLG Lift – 3121171

518

3121171 – JLG Lift – 6-87

519

6-88 – JLG Lift – 3121171

520

3121171 – JLG Lift – 6-89

521

6-90 – JLG Lift – 3121171

522

3121171 – JLG Lift – 6-91

523

6-92 – JLG Lift – 3121171

524

3121171 – JLG Lift – 6-93

525

6-94 – JLG Lift – 3121171

526

3121171 – JLG Lift – 6-95

527

6-96 – JLG Lift – 3121171

528

3121171 – JLG Lift – 6-97

529

6-98 – JLG Lift – 3121171

530

3121171 – JLG Lift – 6-99

531

6-100 – JLG Lift – 3121171

532

3121171 – JLG Lift – 6-101

533

6-102 – JLG Lift – 3121171

534

3121171 – JLG Lift – 6-103

535

6-104 – JLG Lift – 3121171

536

3121171 – JLG Lift – 6-105

537

6.19 CANBUS TROUBLESHOOTING

538

PLATFORM MODULE

539

CANbus Link

539

6-108 – JLG Lift – 3121171

540

3121171 – JLG Lift – 6-109

541

6-110 – JLG Lift – 3121171

542

3121171 – JLG Lift – 6-111

543

CANbus Communication Failure

544

3121171 – JLG Lift – 6-113

545

6-114 – JLG Lift – 3121171

546

3121171 – JLG Lift – 6-115

547

6-116 – JLG Lift – 3121171

548

3121171 – JLG Lift – 6-117

549

6-118 – JLG Lift – 3121171

550

3121171 – JLG Lift – 6-119

551

6-120 – JLG Lift – 3121171

552

3121171 – JLG Lift – 6-121

553

6-122 – JLG Lift – 3121171

554

3121171 – JLG Lift – 6-123

555

6-124 – JLG Lift – 3121171

556

3121171 – JLG Lift – 6-125

557

6-126 – JLG Lift – 3121171

558

3121171 – JLG Lift – 6-127

559

6-128 – JLG Lift – 3121171

560

3121171 – JLG Lift – 7-1

561

Resistance Measurement

562

Continuity Measurement

562

Current Measurement

563

COMPOUND TO ELECTRICAL

563

CONNECTIONS

563

7.4 AMP CONNECTOR

564

AMP Connectors

564

3121171 – JLG Lift – 7-5

565

Wedge Lock

566

Service - Voltage Reading

566

3121171 – JLG Lift – 7-7

567

7.5 DEUTSCH CONNECTORS

568

DT/DTP Series Assembly

568

DT/DTP Series Disassembly

568

HD30/HDP20 Series Assembly

569

HD30/HDP20 Series Disassembly

569

7-10 – JLG Lift – 3121171

570

3121171 – JLG Lift – 7-11

571

7-12 – JLG Lift – 3121171

572

3121171 – JLG Lift – 7-13

573

7-14 – JLG Lift – 3121171

574

3121171 – JLG Lift – 7-15

575

7-16 – JLG Lift – 3121171

576

3121171 – JLG Lift – 7-17

577

7-18 – JLG Lift – 3121171

578

3121171 – JLG Lift – 7-19

579

7-20 – JLG Lift – 3121171

580

3121171 – JLG Lift – 7-21

581

7-22 – JLG Lift – 3121171

582

3121171 – JLG Lift – 7-23

583

7-24 – JLG Lift – 3121171

584

3121171 – JLG Lift – 7-25

585

7-26 – JLG Lift – 3121171

586

3121171 – JLG Lift – 7-27

587

7-28 – JLG Lift – 3121171

588

3121171 – JLG Lift – 7-29

589

7-30 – JLG Lift – 3121171

590

3121171 – JLG Lift – 7-31

591

7-32 – JLG Lift – 3121171

592

3121171 – JLG Lift – 7-33

593

7-34 – JLG Lift – 3121171

594

3121171 – JLG Lift – 7-35

595

7-36 – JLG Lift – 3121171

596

3121171 – JLG Lift – 7-37

597

7-38 – JLG Lift – 3121171

598

3121171 – JLG Lift – 7-39

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7-40 – JLG Lift – 3121171

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3121171 – JLG Lift – 7-41

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7-42 – JLG Lift – 3121171

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3121171 – JLG Lift – 7-43

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7-44 – JLG Lift – 3121171

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