JLG H800AJ PVC 2007 Service & Maintenance Manual (31217194) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG H800AJ PVC 2007 Service & Maintenance Manual (31217194) – PDF DOWNLOAD
31217194_A_H800AJ_JLG Service English.............................................................. 1 Section A. Introduction - Maintenance Safety Precautions....................................... 3 A General.................................................................................. 3 B Hydraulic System Safety.................................................................. 3 C Maintenance.............................................................................. 4 Table of Contents.............................................................................. 7 List of Figures................................................................................ 15 List of Tables................................................................................. 22 Section 1. Specifications...................................................................... 25 1.1 Operating Specifications............................................................... 25 1.2 Tires.................................................................................. 25 1.3 Capacities............................................................................. 25 1.4 Engine Data............................................................................ 25 1.5 Hydraulic Oil.......................................................................... 26 1.6 Critical Stability Weights............................................................. 27 1.7 Maintenance and Lubrication............................................................ 29 1.8 ThreadLocking Compound................................................................. 32 1.9 Torque Charts.......................................................................... 33 SAE Fastener Torque Chart.............................................................. 33 SAE Fastener Torque Chart (Continued).................................................. 34 SAE Fastener Torque Chart (Continued).................................................. 35 SAE Fastener Torque Chart (Continued).................................................. 36 SAE Fastener Torque Chart (Continued).................................................. 37 SAE Fastener Torque Chart (Continued).................................................. 38 Metric Fastener Torque Chart........................................................... 39 Metric Fastener Torque Chart (Continued)............................................... 40 Metric Fastener Torque Chart (Continued)............................................... 41 Metric Fastener Torque Chart (Continued)............................................... 42 Section 2. General............................................................................. 43 2.1 Machine Preparation, Inspection, and Maintenance....................................... 43 General................................................................................ 43 Preparation, Inspection, and Maintenance............................................... 43 Pre-Start Inspection................................................................... 43 Pre-Delivery Inspection and Frequent Inspection........................................ 43 Annual Machine Inspection.............................................................. 43 Preventive Maintenance................................................................. 43 2.2 Service and Guidelines................................................................. 44 General................................................................................ 44 Safety and Workmanship................................................................. 44 Cleanliness............................................................................ 44 Components Removal and Installation.................................................... 44 Component Disassembly and Reassembly................................................... 45 Pressure-Fit Parts..................................................................... 45 Bearings............................................................................... 45 Gaskets................................................................................ 45 Bolt Usage and Torque Application...................................................... 45 Hydraulic Lines and Electrical Wiring.................................................. 45 Hydraulic System....................................................................... 45 Lubrication............................................................................ 46 Battery................................................................................ 46 Lubrication and Servicing.............................................................. 46 2.3 Lubrication and Information............................................................ 46 Hydraulic System....................................................................... 46 Hydraulic Oil.......................................................................... 46 Changing Hydraulic Oil................................................................. 46 Lubrication Specifications............................................................. 46 2.4 Cylinder Drift......................................................................... 47 Theory................................................................................. 47 Cylinder Leakage Test.................................................................. 47 Cylinder Thermal Drift................................................................. 47 2.5 Pins and Composite Bearing Repair Guidelines........................................... 48 2.6 Welding on JLG Equipment............................................................... 48 Do the Following When Welding on JLG Equipment......................................... 48 DO NOT Do the Following When Welding on JLG Equipment.................................. 48 Section 3. Chassis & Turntable................................................................. 55 3.1 Tires & Wheels......................................................................... 55 Tire Damage............................................................................ 55 Tire Replacement....................................................................... 55 Wheel Replacement...................................................................... 55 Wheel Installation..................................................................... 55 3.2 Powertrain Operating Modes............................................................. 56 Hybrid Mode............................................................................ 56 Electric Mode.......................................................................... 56 Switching Between Modes on the Fly..................................................... 56 Idle Reduction Stop Start.............................................................. 57 3.3 Drive Orientation System............................................................... 58 3.4 Oscillating Axle System................................................................ 58 3.5 Lockout Cylinder Bleeding.............................................................. 59 3.6 Oscillating Axle Lockout Test.......................................................... 62 3.7 Drive System........................................................................... 64 3.8 Drive Hub (Torque)..................................................................... 65 Removal................................................................................ 65 Installation........................................................................... 65 3.9 Drive Hub.............................................................................. 66 Assembly/Disassembly................................................................... 66 3.10 Drive brake........................................................................... 66 3.11 Drive Motor........................................................................... 66 Removal................................................................................ 66 Installation........................................................................... 66 Description............................................................................ 67 Shaft Seal Replacement................................................................. 67 Loop Flushing Valve.................................................................... 68 Troubleshooting........................................................................ 69 Disassembly............................................................................ 70 Inspection............................................................................. 74 Assembly............................................................................... 76 Initial Start-up Procedures............................................................ 81 3.12 Swing Drive........................................................................... 84 Roll, Leak And Brake Testing........................................................... 84 Tightening and Torquing Bolts.......................................................... 85 Motor Control Valve Disassembly........................................................ 86 Motor and Brake Disassembly............................................................ 87 Main Drive Disassembly................................................................. 88 Hub-Shaft Disassembly.................................................................. 89 Carrier Disassembly.................................................................... 90 Hub-Shaft Assembly..................................................................... 91 Carrier Assembly....................................................................... 91 Main Drive Assembly.................................................................... 92 Motor and Brake Assembly............................................................... 93 Motor Control Valve Assembly........................................................... 94 3.13 Swing Motor...........................................................................101 Disassembly and inspection.............................................................101 Assembly...............................................................................108 One Piece Stator Construction..........................................................116 3.14 Swing Hub Installation................................................................117 Procedure For Setting Swing Gear Backlash..............................................117 Swing Drive Lubrication................................................................118 3.15 Swing Hub Removal.....................................................................118 3.16 Swing Bearing.........................................................................119 Turntable Bearing Mounting Bolt Condition Check........................................119 Wear Tolerance.........................................................................122 Swing Bearing Replacement..............................................................122 Swing Bearing Torque Values............................................................123 3.17 Chassis Tilt Indicator System.........................................................125 3.18 Rotary Coupling.......................................................................126 3.19 Generator.............................................................................132 Maintenance Schedule...................................................................132 Overload Protection....................................................................133 Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings.........................133 Troubleshooting........................................................................135 Generator Disassembly and Assembly.....................................................136 Lead Connection List for Generator.....................................................144 3.20 Cold Start System.....................................................................150 Engine Warmup..........................................................................150 3.21 Clutch Adapter Plate Installation.....................................................150 3.22 Clutch Kit & Release Shaft Installation...............................................151 Clutch Kit.............................................................................151 Release Shaft..........................................................................152 3.23 Clutch Installation...................................................................153 3.24 Clutch Linear Actuator/Throwout Bearing Positioning installation Procedure............153 3.25 Counterweight.........................................................................156 Section 4. Boom & Platform.....................................................................157 4.1 Boom Systems...........................................................................157 Switch Systems.........................................................................157 Above Elevation (Above Horizontal) Cutout System.......................................157 Beyond Transport Position - Drive Speed Cutback System.................................157 Drive/Steer – Boom Function Interlock System (CE Only).................................157 Transport Position Interlock System (CE only)..........................................157 Platform Control Enable System.........................................................157 Function Speed Control System..........................................................157 Platform...............................................................................158 Main Lift End Stroke Dampening System..................................................158 QuikStick Lift System..................................................................158 Tower Boom Sequence Valve System.......................................................158 Upright Level Override System..........................................................158 Ground Control Keyswitch System........................................................158 4.2 Main Boom Assembly.....................................................................162 Removal................................................................................162 Disassembly............................................................................163 Inspection.............................................................................163 Assembly...............................................................................163 Installation...........................................................................164 4.3 Upright................................................................................165 Removal................................................................................165 Installation...........................................................................166 4.4 Tower Boom Assembly....................................................................168 Removal................................................................................168 Inspection.............................................................................168 Assembly...............................................................................169 Installation...........................................................................169 Tower Out of Sync......................................................................170 4.5 Upright Monitoring System (UMS)........................................................172 Re-Synchronizing Upright...............................................................172 Calibration............................................................................174 Calibration Faults.....................................................................178 Function Check.........................................................................178 Service Mode/Tower Boom Retrieval......................................................180 4.6 UMS Troubleshooting And Diagnostic Trouble Codes (DTC).................................184 Backward Stability Concern DTC (2532)..................................................184 Forward Stability Concern DTC (2530)...................................................184 Out of Usable Range DTC (2531).........................................................184 UMS Sensor Not Calibrated DTC (816)....................................................184 UMS Sensor Faulted DTC (817)...........................................................184 Calibration Faults.....................................................................184 4.7 Platform...............................................................................185 Platform Valve Removal.................................................................185 Platform Valve Installation............................................................185 Platform Support Removal...............................................................186 Support Installation...................................................................187 4.8 Bolt-on External Fall Arrest...........................................................189 Inspection Before Use..................................................................189 Installation...........................................................................189 4.9 Articulating Jib.......................................................................191 Removal................................................................................191 Disassembly............................................................................191 Inspection.............................................................................191 Assembly...............................................................................192 Installation...........................................................................192 4.10 Rotator and Slave Cylinder............................................................193 Removal................................................................................193 Installation...........................................................................193 4.11 Sequence For Hose Replacement In The Tower Boom.......................................194 4.12 Limit Switches Adjustment.............................................................194 Main Boom Horizontal Limit Switch......................................................194 Tower Boom Horizontal Limit Switch.....................................................194 4.13 Boom Valve Adjustment.................................................................198 Tower Boom.............................................................................198 Main Boom..............................................................................198 4.14 Boom Cleanliness Guidelines...........................................................199 4.15 Main Boom Powertrack..................................................................200 Removal................................................................................200 Installation...........................................................................200 4.16 Powertrack Maintenance................................................................205 Flat Bar Removal.......................................................................205 Round Bar/Poly Bar Removal.............................................................205 Removing and Installing Links..........................................................206 Installing a New Flat Bar..............................................................209 Installing a New Round Bar/Poly Roller.................................................210 Replacing a Fixed End Bracket..........................................................210 Replacing a Moving End Bracket.........................................................211 Replacing a One Piece Bracket..........................................................211 4.17 Rotator Assembly......................................................................213 Theory of Operation....................................................................213 Required Tools.........................................................................213 Disassembly............................................................................216 Inspection.............................................................................220 Assembly...............................................................................220 Installing Counterbalance Valve........................................................226 Greasing Thrust Washers................................................................227 Testing the Actuator...................................................................227 Installation and Bleeding..............................................................228 4.18 Foot Switch Adjustment................................................................228 Troubleshooting........................................................................229 4.19 Skyguard..............................................................................230 Operation..............................................................................230 Function Test..........................................................................230 Diagnostics & Troubleshooting..........................................................231 Section 5. Basic Hydraulic Information & Hydraulic Schematics..................................233 5.1 Lubricating O-Rings in the Hydraulic System............................................233 Cup and Brush..........................................................................233 Dip Method.............................................................................234 Spray Method...........................................................................234 Brush-on Method........................................................................234 5.2 Hydraulic Connection Assembly and Torque Specification.................................235 Tapered Thread Types...................................................................235 Straight Thread Types, Tube and Hose Connections.......................................235 Straight Thread Types, Port Connections................................................236 Flange Connection Types................................................................236 Tightening Methods.....................................................................236 Assembly And Torque Specifications.....................................................237 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....238 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......239 Assembly Instructions for 37° (JIC) Flare Fittings.....................................240 Assembly Instructions for 45° SAE Flare Fittings.......................................244 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings.............................246 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............248 Assembly Instructions for Bulkhead (BH) Fittings.......................................250 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................270 Assembly instructions for Adjustable Port End (BSPP) Fittings..........................272 Assembly Instructions for Flange Connections: (FL61 and FL62)..........................280 Double Wrench Method...................................................................283 FFWR and TFFT Methods..................................................................284 Adjustable Stud End Assembly...........................................................284 O-ring Installation (Replacement)......................................................285 5.3 Hydraulic cylinders....................................................................286 Axle Lockout Cylinder..................................................................286 Slave Cylinder.........................................................................288 Upright Level Cylinder.................................................................294 Jib Lift Cylinder......................................................................295 Main Boom Lift Cylinder................................................................301 Tower Boom Lift Cylinder...............................................................302 Master Cylinder........................................................................303 Steer Cylinder.........................................................................309 Cleaning and Inspection................................................................311 Main Boom Telescope Cylinder...........................................................314 Tower Boom Telescope Cylinder..........................................................320 5.4 Cylinder Removal And Installation......................................................326 Main Boom Telescope Cylinder Removal...................................................326 Main Boom Telescope Cylinder Installation..............................................328 Main Lift Cylinder Removal.............................................................329 Main Lift Cylinder Installation........................................................330 Upright Level Cylinder Removal.........................................................331 Upright Level Cylinder Installation....................................................332 Tower Boom Lift Cylinder Removal.......................................................332 Tower Boom Lift Cylinder Installation..................................................333 Tower Telescope Cylinder Removal.......................................................334 Tower Telescope Cylinder Installation..................................................334 Master Cylinder Removal................................................................335 Master Cylinder Installation...........................................................335 5.5 Pressure Setting Procedures............................................................336 Set Up the Function Pump...............................................................336 Adjustments Made at the Main Valve Block...............................................337 Adjustments Made at the Platform Valve Block...........................................337 5.6 Hydraulic Component Start-Up Procedures and Recommendations............................339 5.7 Hydraulic drive pump pre-fill procedure................................................340 5.8 Function Pump..........................................................................341 Removal................................................................................341 Installation...........................................................................341 Initial Start-up Procedures............................................................343 Troubleshooting........................................................................344 Shaft Seal Replacement.................................................................348 Control Assembly.......................................................................348 Plug and Fitting Sizes and Torques.....................................................350 5.9 Drive Pump.............................................................................351 Removal................................................................................351 Installation...........................................................................351 Servo Controlled Piston Pump...........................................................352 Charge Pump Adapter Assembly...........................................................355 Manual Servo Control Basic Assembly....................................................356 Manual Servo Control Assembly Options..................................................357 Rotating Kit Assembly..................................................................359 Fault- logic Trouble Shooting..........................................................360 Start-up Procedure.....................................................................365 Section 6. JLG Control System..................................................................371 6.1 Introduction...........................................................................371 6.2 JLG Control System Analyzer Kit Instructions...........................................372 To Connect the JLG Control System Analyzer.............................................373 Using the Analyzer.....................................................................373 Changing the Access Level of the Hand Held Analyzer....................................375 Adjusting Parameters Using the Hand Held Analyzer......................................376 Machine Setup..........................................................................376 Level Vehicle Description..............................................................377 Ground Control Console Display Gauge...................................................378 6.3 Platform Load Sensing System...........................................................381 Diagnostic Menu........................................................................382 Calibration Procedure..................................................................383 Testing & Evaluation...................................................................388 Troubleshooting........................................................................389 6.4 Resetting The MSSO System..............................................................390 6.5 Machine Configuration Programming Information..........................................392 6.6 Machine Personality Settings and Function Speeds.......................................399 6.7 Machine Orientation When Setting Function Speeds.......................................400 Test Notes.............................................................................401 6.8 CANbus Communications..................................................................423 6.9 Diagnostic Trouble Code Chart..........................................................428 6.10 Diagnostic Trouble Code Chart- Additional Hec Faults..................................444 6.11 Diagnostic Trouble Code Chart - Hybrid UGM............................................464 Section 7. Basic Electrical Information & Electrical Schematics................................485 7.1 General................................................................................485 7.2 Multimeter Basics......................................................................485 Grounding..............................................................................485 Backprobing............................................................................485 Min/Max................................................................................485 Polarity...............................................................................485 Scale..................................................................................485 Voltage Measurement....................................................................485 Resistance Measurement.................................................................486 Continuity Measurement.................................................................486 Current Measurement....................................................................487 7.3 Applying Silicone Dielectric Compound to Electrical Connections........................487 Installation of Dielectric Grease......................................................488 AMP Mate-N-Lok.........................................................................488 AMP Faston.............................................................................488 AMP Micro-Fit..........................................................................488 AMP Mini Fit Jr........................................................................488 Mini Fit Sr............................................................................489 DIN Connectors.........................................................................489 Exceptions.............................................................................489 Enclosures.............................................................................489 Carling Switch Connectors..............................................................489 7.4 AMP Connector..........................................................................490 Applying Silicone Dielectric Compound to AMP Connectors................................490 Assembly...............................................................................490 Disassembly............................................................................492 Wedge Lock.............................................................................492 Service - Voltage Reading..............................................................492 7.5 Deutsch Connectors.....................................................................494 DT/DTP Series Assembly.................................................................494 DT/DTP Series Disassembly..............................................................494 HD30/HDP20 Series Assembly.............................................................495 HD30/HDP20 Series Disassembly..........................................................495 7.6 DC Power Systems.......................................................................496 7.7 Hot Weather Operation..................................................................496 7.8 Cold Weather Operation.................................................................496 7.9 Disconnecting Battery Box Connectors...................................................497 7.10 Battery Pack..........................................................................498 Reducing System Voltage................................................................498 Restoring System Voltage...............................................................499 Battery Pack Charging System...........................................................500 Long Term Storage Guidelines...........................................................500 7.11 IMG Box...............................................................................516 Partially Isolating System Voltage.....................................................516 7.12 IMG Controller........................................................................517 Removal................................................................................517 Installation...........................................................................521 7.13 Hybrid Electric Controller............................................................530 7.14 Resolver/Converter....................................................................530 7.15 State of Charge Device................................................................530 7.16 Battery Equalizer.....................................................................530 7.17 Battery Chargers......................................................................531 Battery Charging.......................................................................531 Ground Panel Indicators................................................................531 Indications on the Charger 3-LED Display...............................................532 Troubleshooting Instructions (Wall - Charge)...........................................534 Instructions for using the Delta-Q QuiQ Programmer CTQuiQ Programming Kit..............538 Connecting a QuiQ Charger to your Computer.............................................539 Starting QuiQ Programmer CT............................................................540 Programming Delta-Q QuiQ and QuiQ-dci Chargers.........................................541 View Charge Tracking Data with QuiQ Programmer CT......................................542 Selecting a Charge Profile.............................................................542 Battery Testing........................................................................543 7.18 ClearSky™ / Telematics Gateway........................................................543 7.19 Wiring Harness Connector Labels and Wiring Harnesses..................................554 Connector Labels.......................................................................554 Component Labels.......................................................................554 7.20 Electrical Schematics.................................................................659
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