Jlg 800A_AJ Service Manual manuels

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Jlg 800A_AJ Service Manual Manuel d'utilisateur (466 pages)

marque: Jlg | Catégorie: Machines spéciales | Taille: 40.26 MB |

Anglais

Table des matières

P/N - 3120858

1

INTRODUCTION

3

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

10

TABLE OF CONTENTS

11

LIST OF FIGURES

13

LIST OF TABLES

19

SECTION 1. SPECIFICATIONS

21

SECTION 1 - SPECIFICATIONS

22

Hydraulic Filter - In-line

24

1.3 FUNCTION SPEEDS

24

Test Notes

24

1.4 TORQUE REQUIREMENTS

25

1.5 LUBRICATION

25

Hydraulic Oil

25

1.6 PRESSURE SETTINGS

26

1.7 CYLINDER SPECIFICATIONS

27

1.8 MAJOR COMPONENT WEIGHTS

28

Critical Stability Weights

29

1.9 LUBRICATION AND OPERATOR

30

MAINTENANCE

30

Regulator

34

SOCKET HEAD CAP SCREWS

39

Magni Coating (Ref 4150701)*

43

SECTION 2. GENERAL

45

2.2 SERVICE AND GUIDELINES

46

Safety and Workmanship

46

Cleanliness

46

SECTION 2 - GENERAL

47

3120858 – JLG Lift – 2-9

53

4150548 E

54

3120858 – JLG Lift – 2-11

55

3120858 – JLG Lift – 3-1

57

PROCEDURE AND LOCKOUT TEST

58

Lockout Cylinder Bleeding

58

3120858 – JLG Lift – 3-3

59

3.4 TORQUE HUB, DRIVE

60

3120858 – JLG Lift – 3-5

61

3120858 – JLG Lift – 3-7

63

3-8 – JLG Lift – 3120858

64

3120858 – JLG Lift – 3-9

65

3-10 – JLG Lift – 3120858

66

3120858 – JLG Lift – 3-11

67

3120858 – JLG Lift – 3-13

69

3120858 – JLG Lift – 3-15

71

Bleeding

72

3-18 – JLG Lift – 3120858

74

Spare Parts Kits

75

3-20 – JLG Lift – 3120858

76

Disassembly and Assembly

77

3-22 – JLG Lift – 3120858

78

3120858 – JLG Lift – 3-23

79

3-24 – JLG Lift – 3120858

80

Assembly Notes

81

3-26 – JLG Lift – 3120858

82

Testing and Setup

83

3.9 DRIVE MOTOR ADJUSTMENT

83

Description

84

Loop Flushing Valve

85

Slipper retainer

92

Ball guide

92

3-38 – JLG Lift – 3120858

94

3120858 – JLG Lift – 3-39

95

3-40 – JLG Lift – 3120858

96

3120858 – JLG Lift – 3-41

97

Initial Start-up Procedures

98

3.11 SWING BEARING

99

3-44 – JLG Lift – 3120858

100

3120858 – JLG Lift – 3-45

101

Wear Tolerance

102

Swing Bearing Replacement

102

3120858 – JLG Lift – 3-47

103

Swing Bearing Torque Values

104

3.12 SWING HUB INSTALLATION

105

3.13 SWING HUB (PRIOR TO S/N

106

0300068040)

106

Disassembly

106

Assembly

106

3120858 – JLG Lift – 3-51

107

3-52 – JLG Lift – 3120858

108

Hub Shaft Sub-Assembly

109

3-54 – JLG Lift – 3120858

110

3120858 – JLG Lift – 3-55

111

Carrier Sub-Assembly

112

3120858 – JLG Lift – 3-57

113

3-58 – JLG Lift – 3120858

114

Inspection

115

3-60 – JLG Lift – 3120858

116

Reassembly

118

Motor Timing

119

3-64 – JLG Lift – 3120858

120

PRESENT)

121

Main Assembly Procedure

121

3-66 – JLG Lift – 3120858

122

3120858 – JLG Lift – 3-67

123

3120858 – JLG Lift – 3-69

125

3120858 – JLG Lift – 3-71

127

3-72 – JLG Lift – 3120858

128

3-74 – JLG Lift – 3120858

130

3-76 – JLG Lift – 3120858

132

Inspection and Cleaning

133

3-78 – JLG Lift – 3120858

134

Timing Procedure

135

3-80 – JLG Lift – 3120858

136

3120858 – JLG Lift – 3-81

137

3.19 ROTARY COUPLING

138

3120858 – JLG Lift – 3-83

139

3-84 – JLG Lift – 3120858

140

3120858 – JLG Lift – 3-85

141

0300065534)

142

Manual Adjustment

142

3.21 SPARK ARRESTER CLEANING

142

INSTRUCTIONS

142

3120858 – JLG Lift – 3-87

143

3-88 – JLG Lift – 3120858

144

3120858 – JLG Lift – 3-89

145

3-90 – JLG Lift – 3120858

146

INSPECTING BRUSH POSITION

146

INSPECTING BRUSHES

146

CLEANING SLIP RINGS

146

3120858 – JLG Lift – 3-91

147

3.23 DUAL FUEL SYSTEM

148

3.24 EFI ENGINE

148

Performing Diagnostics

148

ECM and Sensors

149

3-94 – JLG Lift – 3120858

150

3-96 – JLG Lift – 3120858

152

3120858 – JLG Lift – 3-97

153

ENGINE CONTROL MODULE (ECM)

153

3-98 – JLG Lift – 3120858

154

ECM INPUTS/OUTPUTS

154

ECM SERVICE PRECAUTIONS

154

THROTTLE POSITION (TP) SENSOR

154

Fuel System

155

3-100 – JLG Lift – 3120858

156

FUEL METERING SYSTEM PURPOSE

156

FUEL PRESSURE REGULATOR

156

3-102 – JLG Lift – 3120858

158

ELECTRONIC IGNITION

158

IGNITION COIL

158

3120858 – JLG Lift – 3-103

159

Megajector

160

Regulator Lockoff Solenoid

160

Lockoff Solenoid

161

Quick-start Installations

162

Mounting-Actuator

163

Mounting-Controller

164

Power Distribution

164

3120858 – JLG Lift – 3-109

165

3-110 – JLG Lift – 3120858

166

Troubleshooting

167

3-112 – JLG Lift – 3120858

168

3.27 THROTTLE CHECKS AND

169

ADJUSTMENTS - DEUTZ ENGINE

169

(PRIOR TO S/N 0300065534)

169

Procedure

170

Controller Status

170

Failure Modes

171

3-116 – JLG Lift – 3120858

172

3120858 – JLG Lift – 3-117

173

3-118 – JLG Lift – 3120858

174

3120858 – JLG Lift – 3-119

175

3-120 – JLG Lift – 3120858

176

3120858 – JLG Lift – 3-121

177

3-122 – JLG Lift – 3120858

178

3120858 – JLG Lift – 3-123

179

3-124 – JLG Lift – 3120858

180

3120858 – JLG Lift – 3-125

181

3-126 – JLG Lift – 3120858

182

3120858 – JLG Lift – 3-127

183

3-128 – JLG Lift – 3120858

184

Maintenance of the Drive Belt

185

Changing The Engine Oil

186

3120858 – JLG Lift – 3-131

187

Fuel Filter

188

Electric Lock Off

188

EPR Assembly

188

Low Pressure Regulator (LPR)

189

Air Fuel Mixer

189

Engine Control Module

190

3120858 – JLG Lift – 3-135

191

3-136 – JLG Lift – 3120858

192

3120858 – JLG Lift – 3-137

193

Assembly Replacement

194

3120858 – JLG Lift – 3-139

195

(TMAP) Sensor

196

MIXER REPLACEMENT

197

Coolant Hose Replacement

198

Vapor Hose Replacement

198

Replacement

198

DIAGNOSIS

199

Fuel System Description

199

Diagnostic Aids

199

3-144 – JLG Lift – 3120858

200

3120858 – JLG Lift – 3-145

201

3-146 – JLG Lift – 3120858

202

3120858 – JLG Lift – 3-147

203

3-148 – JLG Lift – 3120858

204

3120858 – JLG Lift – 3-149

205

3-150 – JLG Lift – 3120858

206

3120858 – JLG Lift – 3-151

207

3-152 – JLG Lift – 3120858

208

3120858 – JLG Lift – 3-153

209

3-154 – JLG Lift – 3120858

210

3120858 – JLG Lift – 3-155

211

3-156 – JLG Lift – 3120858

212

3120858 – JLG Lift – 3-157

213

3-158 – JLG Lift – 3120858

214

4.1 PLATFORM

215

Support Removal

215

Support Installation

216

Platform Sections Replacement

216

3120858 – JLG Lift – 4-3

217

4.3 UPPER BOOM POWERTRACK

218

4.4 UPPER BOOM

218

3120858 – JLG Lift – 4-5

219

Installation

221

4.5 UPRIGHT

222

Removal

222

4.6 TOWER BOOM ASSEMBLY

223

Tower Out of Sync

226

3120858 – JLG Lift – 4-13

227

4.7 ARTICULATING JIB

228

3120858 – JLG Lift – 4-15

229

4-16 – JLG Lift – 3120858

230

3120858 – JLG Lift – 4-17

231

4-18 – JLG Lift – 3120858

232

3120858 – JLG Lift – 4-19

233

4-20 – JLG Lift – 3120858

234

3120858 – JLG Lift – 4-21

235

4-22 – JLG Lift – 3120858

236

4.10 BOOM VALVE ADJUSTMENT

237

4.11 WEAR PADS

238

Tower Boom

238

Upper Boom

238

3120858 – JLG Lift – 4-27

241

4.13 ROTATOR ASSEMBLY (S/N

242

0300067538 TO PRESENT)

242

Theory of Operation

242

Required Tools

242

3120858 – JLG Lift – 4-29

243

4-30 – JLG Lift – 3120858

244

4-32 – JLG Lift – 3120858

246

3120858 – JLG Lift – 4-33

247

4-34 – JLG Lift – 3120858

248

4-36 – JLG Lift – 3120858

250

3120858 – JLG Lift – 4-37

251

4-38 – JLG Lift – 3120858

252

3120858 – JLG Lift – 4-39

253

4-40 – JLG Lift – 3120858

254

Testing the Actuator

255

Installation and Bleeding

255

Lift, Swing, and Drive Cards

257

Flow Control Card

257

4-44 – JLG Lift – 3120858

258

BUILT TO S/N 0300062045

259

Functional Check

260

Calibration

260

3120858 – JLG Lift – 4-47

261

4-48 – JLG Lift – 3120858

262

3120858 – JLG Lift – 4-49

263

4-50 – JLG Lift – 3120858

264

3120858 – JLG Lift – 4-51

265

4-52 – JLG Lift – 3120858

266

3120858 – JLG Lift – 4-53

267

4-54 – JLG Lift – 3120858

268

3120858 – JLG Lift – 4-55

269

4-56 – JLG Lift – 3120858

270

Calibration Faults

271

Function Check

272

3120858 – JLG Lift – 4-59

273

4-60 – JLG Lift – 3120858

274

3120858 – JLG Lift – 4-61

275

THIS SENSOR

276

ON NON ADE

276

MACHINES ONLY

276

MACHINES

277

4-64 – JLG Lift – 3120858

278

3120858 – JLG Lift – 4-65

279

4-66 – JLG Lift – 3120858

280

3120858 – JLG Lift – 4-67

281

Out of Usable Range Message

282

UMS Sensor Faulted Message

282

SECTION 5. HYDRAULICS

283

Dip Method

284

Spray Method

284

Brush-on Method

284

Relief Valves

285

5.3 HOLDING VALVE CHECKS

285

Cylinders

286

SECTION 5 - HYDRAULICS

287

5.6 CYLINDER REPAIR

289

1683605 A

298

1683740 B

298

Cleaning and Inspection

301

3120858 – JLG Lift – 5-23

305

5.7 CYLINDER REMOVAL AND

306

INSTALLATION

306

Upper Lift Cylinder Removal

307

Slave Cylinder Removal

310

Slave Cylinder Installation

311

DRIVE COUPLING LUBRICATION

311

Valve Block

318

PROCEDURE

319

PROCEDURES AND

320

RECOMMENDATIONS

320

PUMP PRIOR TO S/N 0300121643

322

Initial start-up procedures

325

Shaft Seal Replacement

329

Control Assembly

329

6.1 INTRODUCTION

333

6-2 – JLG Lift – 3120858

334

3120858 – JLG Lift – 6-3

335

6-4 – JLG Lift – 3120858

336

3120858 – JLG Lift – 6-5

337

6-6 – JLG Lift – 3120858

338

3120858 – JLG Lift – 6-7

339

6-8 – JLG Lift – 3120858

340

3120858 – JLG Lift – 6-9

341

6-10 – JLG Lift – 3120858

342

3120858 – JLG Lift – 6-11

343

6-12 – JLG Lift – 3120858

344

3120858 – JLG Lift – 6-13

345

6.2 CANBUS COMMUNICATIONS

346

SYSTEM ANALYZER

346

6.4 USING THE ANALYZER

346

HAND HELD ANALYZER

347

6.7 MACHINE SETUP

349

6.8 LEVEL VEHICLE DESCRIPTION

349

6-18 – JLG Lift – 3120858

350

3120858 – JLG Lift – 6-19

351

6-20 – JLG Lift – 3120858

352

3120858 – JLG Lift – 6-21

353

6-22 – JLG Lift – 3120858

354

3120858 – JLG Lift – 6-23

355

6-24 – JLG Lift – 3120858

356

3120858 – JLG Lift – 6-25

357

6-26 – JLG Lift – 3120858

358

3120858 – JLG Lift – 6-27

359

6-28 – JLG Lift – 3120858

360

3120858 – JLG Lift – 6-29

361

6-30 – JLG Lift – 3120858

362

3120858 – JLG Lift – 6-31

363

6-32 – JLG Lift – 3120858

364

3120858 – JLG Lift – 6-35

367

6-36 – JLG Lift – 3120858

368

3120858 – JLG Lift – 6-37

369

6-38 – JLG Lift – 3120858

370

3120858 – JLG Lift – 6-39

371

6-40 – JLG Lift – 3120858

372

3120858 – JLG Lift – 6-41

373

6-42 – JLG Lift – 3120858

374

3120858 – JLG Lift – 6-43

375

6-44 – JLG Lift – 3120858

376

3120858 – JLG Lift – 6-45

377

6-46 – JLG Lift – 3120858

378

3120858 – JLG Lift – 6-47

379

6-48 – JLG Lift – 3120858

380

3120858 – JLG Lift – 6-49

381

6-50 – JLG Lift – 3120858

382

3120858 – JLG Lift – 6-51

383

6-52 – JLG Lift – 3120858

384

3120858 – JLG Lift – 6-53

385

6-54 – JLG Lift – 3120858

386

3120858 – JLG Lift – 6-55

387

6-56 – JLG Lift – 3120858

388

3120858 – JLG Lift – 6-57

389

6-58 – JLG Lift – 3120858

390

3120858 – JLG Lift – 6-59

391

6-60 – JLG Lift – 3120858

392

3120858 – JLG Lift – 6-61

393

6-62 – JLG Lift – 3120858

394

3120858 – JLG Lift – 6-63

395

6-64 – JLG Lift – 3120858

396

3120858 – JLG Lift – 6-65

397

6-66 – JLG Lift – 3120858

398

3120858 – JLG Lift – 6-67

399

6-68 – JLG Lift – 3120858

400

3120858 – JLG Lift – 7-1

401

Resistance Measurement

402

Continuity Measurement

402

Current Measurement

403

COMPOUND TO ELECTRICAL

403

CONNECTIONS

403

7.4 AMP CONNECTOR

404

AMP Connectors

404

3120858 – JLG Lift – 7-5

405

Wedge Lock

406

Service - Voltage Reading

406

3120858 – JLG Lift – 7-7

407

7.5 DEUTSCH CONNECTORS

408

DT/DTP Series Assembly

408

DT/DTP Series Disassembly

408

HD30/HDP20 Series Assembly

409

HD30/HDP20 Series Disassembly

409

7-10 – JLG Lift – 3120858

410

3120858 – JLG Lift – 7-11

411

7-12 – JLG Lift – 3120858

412

3120858 – JLG Lift – 7-13

413

7-14 – JLG Lift – 3120858

414

3120858 – JLG Lift – 7-15

415

7-16 – JLG Lift – 3120858

416

3120858 – JLG Lift – 7-17

417

7-18 – JLG Lift – 3120858

418

1870063 I

419

7-20 – JLG Lift – 3120858

420

1870062 B

421

7-22 – JLG Lift – 3120858

422

7-24 – JLG Lift – 3120858

424

1870100 G

425

7-26 – JLG Lift – 3120858

426

1870120 G

427

7-28 – JLG Lift – 3120858

428

1870160 C

429

7-30 – JLG Lift – 3120858

430

1870134 C

431

7-32 – JLG Lift – 3120858

432

7-34 – JLG Lift – 3120858

434

1870132 M

435

7-36 – JLG Lift – 3120858

436

7-38 – JLG Lift – 3120858

438

7-40 – JLG Lift – 3120858

440

1870191 G

441

7-42 – JLG Lift – 3120858

442

7-44 – JLG Lift – 3120858

444

7-46 – JLG Lift – 3120858

446

1001096461 C

447

7-48 – JLG Lift – 3120858

448

7-50 – JLG Lift – 3120858

450

7-52 – JLG Lift – 3120858

452

3120858 – JLG Lift – 7-53

453

7-54 – JLG Lift – 3120858

454

3120858 – JLG Lift – 7-55

455

7-56 – JLG Lift – 3120858

456

3120858 – JLG Lift – 7-57

457

7-58 – JLG Lift – 3120858

458

2792629 B

459

7-60 – JLG Lift – 3120858

460

7-62 – JLG Lift – 3120858

462

7-64 – JLG Lift – 3120858

464

JLG Worldwide Locations

466

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