Jlg 1850SJ Service Manual manuals

Jlg 1850SJ Service Manual User Manual (452 pages)

Brand: Jlg | Category: Special machinery | Size: 46.10 MB |

English

Table of contents

P/N - 3121619

1

AGENERAL

3

BHYDRAULIC SYSTEM SAFETY

3

CMAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

10

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

19

1.5 ENGINE DATA

20

1.6 MAJOR COMPONENT WEIGHTS

20

1.7 HYDRAULIC OIL

20

SECTION 1 - SPECIFICATIONS

21

SECTION 2. GENERAL

33

2.2 SERVICE AND GUIDELINES

34

Safety and Workmanship

34

Cleanliness

34

SECTION 2 - GENERAL

35

Hydraulic Oil

36

Changing Hydraulic Oil

36

Lubrication Specifications

36

2.4 CYLINDER DRIFT TEST

36

Platform Drift

36

3.1 TIRES AND WHEELS

43

Tire Damage

43

Wheel and Tire Replacement

43

Wheel Installation

43

3.2 AXLE EXTENSION SYSTEM

44

3.3 DRIVE ORIENTATION SYSTEM

44

3.4 STEERING CONTROL SYSTEM

45

3.6 TRACTION CONTROL SYSTEM

46

3121619 – JLG Lift – 3-5

47

3-6 – JLG Lift – 3121619

48

3121619 – JLG Lift – 3-7

49

3-8 – JLG Lift – 3121619

50

3121619 – JLG Lift – 3-9

51

3-10 – JLG Lift – 3121619

52

3121619 – JLG Lift – 3-11

53

3.7 DRIVE ASSEMBLY

54

3.8 DRIVE HUB

55

3121619 – JLG Lift – 3-15

57

3-16 – JLG Lift – 3121619

58

3-18 – JLG Lift – 3121619

60

3121619 – JLG Lift – 3-19

61

3-20 – JLG Lift – 3121619

62

3121619 – JLG Lift – 3-21

63

3-22 – JLG Lift – 3121619

64

3.11 DRIVE MOTOR

65

Description

65

Shaft Seal Replacement

65

Loop Flushing Valve

66

3121619 – JLG Lift – 3-27

69

3-28 – JLG Lift – 3121619

70

3121619 – JLG Lift – 3-29

71

3121619 – JLG Lift – 3-31

73

CYLINDER BLOCK

73

VALVE PLATE

73

3121619 – JLG Lift – 3-33

75

(47-61 Nm)

77

35-45 ft-lbs

77

Initial Start-up Procedures

79

BACKLASH

79

3-38 – JLG Lift – 3121619

80

31 .7 " (8 0 cm)

81

3-40 – JLG Lift – 3121619

82

Main Boom Pivot

83

Turntable Cutouts Closest to

84

This Side of Turntable

84

83.3" (212 cm)

84

3.13 SWING CONTROL SYSTEM

85

3.15 AUXILIARY POWER SYSTEM

85

3-44 – JLG Lift – 3121619

86

3121619 – JLG Lift – 4-1

87

Moment Control System

88

(Push to Test) System

88

Controlled Arc System

88

3121619 – JLG Lift – 4-3

89

Boom Control Select

90

3121619 – JLG Lift – 4-5

91

4.3 BOOM ASSEMBLY

93

4-8 – JLG Lift – 3121619

94

3121619 – JLG Lift – 4-9

95

4-10 – JLG Lift – 3121619

96

3121619 – JLG Lift – 4-11

97

4-12 – JLG Lift – 3121619

98

3121619 – JLG Lift – 4-13

99

4-14 – JLG Lift – 3121619

100

3121619 – JLG Lift – 4-15

101

4-16 – JLG Lift – 3121619

102

3121619 – JLG Lift – 4-17

103

4-18 – JLG Lift – 3121619

104

3121619 – JLG Lift – 4-19

105

4-20 – JLG Lift – 3121619

106

3121619 – JLG Lift – 4-21

107

4-22 – JLG Lift – 3121619

108

3121619 – JLG Lift – 4-23

109

4-24 – JLG Lift – 3121619

110

3121619 – JLG Lift – 4-25

111

4-26 – JLG Lift – 3121619

112

3121619 – JLG Lift – 4-27

113

4-28 – JLG Lift – 3121619

114

3121619 – JLG Lift – 4-29

115

4-30 – JLG Lift – 3121619

116

3121619 – JLG Lift – 4-31

117

4-32 – JLG Lift – 3121619

118

4.4 TELESCOPE CYLINDER

119

4.5 BOOM SHIMMING PROCEDURE

120

3121619 – JLG Lift – 4-35

121

4.8 HOSE ADJUSTMENT PROCEDURE

122

3121619 – JLG Lift – 4-37

123

4-38 – JLG Lift – 3121619

124

3121619 – JLG Lift – 4-39

125

4-40 – JLG Lift – 3121619

126

3121619 – JLG Lift – 4-41

127

1001157243-C

128

1001157243- C

129

JIB LOCK CYLINDER

130

JIB CONTROL VALVE

130

PLATFORM VALVE

131

300 MAI NTAI N H OSE LO OP

133

AT T HIS DIM E NS I ON

133

4-48 – JLG Lift – 3121619

134

WITH JIB ASSEMBLY AS SHOWN

135

4-50 – JLG Lift – 3121619

136

3121619 – JLG Lift – 4-51

137

SECTION A-A

138

3121619 – JLG Lift – 4-53

139

Stowed Jib Shimming Procedure

140

4.11 WIRE ROPE

141

Inspection

141

Three Month Inspection

141

Eight Year Inspection

141

Replacement Criteria

141

4-56 – JLG Lift – 3121619

142

3121619 – JLG Lift – 4-57

143

4-58 – JLG Lift – 3121619

144

3121619 – JLG Lift – 4-59

145

4-60 – JLG Lift – 3121619

146

3121619 – JLG Lift – 4-61

147

4-62 – JLG Lift – 3121619

148

3121619 – JLG Lift – 4-63

149

Re-Assembly

150

Boom Calibration

150

3121619 – JLG Lift – 4-65

151

4-66 – JLG Lift – 3121619

152

3121619 – JLG Lift – 4-67

153

4-68 – JLG Lift – 3121619

154

3121619 – JLG Lift – 4-69

155

4-70 – JLG Lift – 3121619

156

#0100081

157

#0100011

158

3121619 – JLG Lift – 4-73

159

4-74 – JLG Lift – 3121619

160

3121619 – JLG Lift – 4-75

161

4-76 – JLG Lift – 3121619

162

3121619 – JLG Lift – 4-77

163

4-78 – JLG Lift – 3121619

164

4.14 POWERTRACK MAINTENANCE

165

One Piece Bracket Maintenance

165

4-80 – JLG Lift – 3121619

166

Two Piece Bracket Maintenance

167

Snap Rings and Screws

168

3121619 – JLG Lift – 4-83

169

4-84 – JLG Lift – 3121619

170

Cup and Brush

171

Dip Method

172

Spray Method

172

Brush-on Method

172

3121619 – JLG Lift – 5-3

173

5-4 – JLG Lift – 3121619

174

3121619 – JLG Lift – 5-5

175

5-6 – JLG Lift – 3121619

176

3121619 – JLG Lift – 5-7

177

5-8 – JLG Lift – 3121619

178

3121619 – JLG Lift – 5-9

179

5-10 – JLG Lift – 3121619

180

3121619 – JLG Lift – 5-11

181

ROD SUPPORT

182

PROTECTED ROD CLAMP

182

BARREL CLAMP

182

SUPPORT TABLE

182

3121619 – JLG Lift – 5-13

183

5-14 – JLG Lift – 3121619

184

CLEANING AND INSPECTION

184

3121619 – JLG Lift – 5-15

185

ASSEMBLY

185

5-16 – JLG Lift – 3121619

186

5-18 – JLG Lift – 3121619

188

3121619 – JLG Lift – 5-19

189

5-20 – JLG Lift – 3121619

190

3121619 – JLG Lift – 5-21

191

5-22 – JLG Lift – 3121619

192

3121619 – JLG Lift – 5-23

193

DISASSEMBLY

193

1001139999

194

3121619 – JLG Lift – 5-25

195

5-26 – JLG Lift – 3121619

196

3121619 – JLG Lift – 5-27

197

5-28 – JLG Lift – 3121619

198

3121619 – JLG Lift – 5-29

199

1001158853

200

3121619 – JLG Lift – 5-33

203

5-34 – JLG Lift – 3121619

204

Jib Lift Cylinder

205



205



205



205



205

5-36 – JLG Lift – 3121619

206

3121619 – JLG Lift – 5-37

207

5-38 – JLG Lift – 3121619

208

3121619 – JLG Lift – 5-39

209

5-40 – JLG Lift – 3121619

210

Jib Lock Cylinder

211

1001119313

212

3121619 – JLG Lift – 5-43

213

1001155986

215

5-46 – JLG Lift – 3121619

216

3121619 – JLG Lift – 5-47

217

Jib Telescope Cylinder

218

3121619 – JLG Lift – 5-49

219

5-50 – JLG Lift – 3121619

220

3121619 – JLG Lift – 5-51

221

5-52 – JLG Lift – 3121619

222

Boom Telescope Cylinder

223

5-54 – JLG Lift – 3121619

224

3121619 – JLG Lift – 5-55

225

5-56 – JLG Lift – 3121619

226

3121619 – JLG Lift – 5-57

227

5-58 – JLG Lift – 3121619

228

5.3 CYLINDER LENGTH SENSOR

229

5-60 – JLG Lift – 3121619

230

Installation

231

5.4 OIL SAMPLING

232

Procedure

232

3121619 – JLG Lift – 5-63

233

5-64 – JLG Lift – 3121619

234

3121619 – JLG Lift – 5-65

235

5-66 – JLG Lift – 3121619

236

3121619 – JLG Lift – 5-67

237

5-68 – JLG Lift – 3121619

238

REDUCED PRESSURE SECTION

238

3121619 – JLG Lift – 5-69

239

5-70 – JLG Lift – 3121619

240

LIFT DOWN

240

3121619 – JLG Lift – 5-71

241

TELESCOPE OUT

241

5-72 – JLG Lift – 3121619

242

TELESCOPE IN

242

3121619 – JLG Lift – 5-73

243

5-74 – JLG Lift – 3121619

244

STEERING, FRONT AND REAR

244

PLATFORM LEVEL UP

244

PLATFORM LEVEL DOWN

244

3121619 – JLG Lift – 5-75

245

JIB LEVEL UP

245

5-76 – JLG Lift – 3121619

246

JIB LEVEL DOWN

246

JIB TELESCOPE OUT

246

3121619 – JLG Lift – 5-77

247

JIB TELESCOPE IN

247

JIB LIFT UP

247

5-78 – JLG Lift – 3121619

248

JIB LIFT DOWN

248

CHARGE PRESSURE RELIEF

248

LOOP FLUSHING RELIEF

248

5.6 DRIVE PUMPS

249

Troubleshooting Procedure

249

5-80 – JLG Lift – 3121619

250

3121619 – JLG Lift – 5-81

251

5-82 – JLG Lift – 3121619

252

Mechanical Centering of Pump

253

5-84 – JLG Lift – 3121619

254

Routine Maintenance

255

5-86 – JLG Lift – 3121619

256

3121619 – JLG Lift – 5-87

257

5.7 FUNCTION PUMP

258

Pump Operation

258

Compensator (PC)

258

Control Adjustment

259

5-90 – JLG Lift – 3121619

260

LS CONTROL SETTING

260

Troubleshooting

261

5-92 – JLG Lift – 3121619

262

SYSTEM OPERATING HOT

262

LOW PUMP OUTPUT

262

UNSTABLE PRESSURE OR FLOW

262

3121619 – JLG Lift – 5-93

263

HIGH INLET VACUUM

263

5-94 – JLG Lift – 3121619

264

Disassemble Pump

265

5-96 – JLG Lift – 3121619

266

DISASSEMBLE PC/ LS CONTROL

266

Assembly

269

5-100 – JLG Lift – 3121619

270

CYLINDER ASSEMBLY

270

3121619 – JLG Lift – 5-101

271

VALVE PLATE AND ENDCAP

271

SHAFT SEAL

271

PC CONTROL ASSEMBLY

271

5-102 – JLG Lift – 3121619

272

LS CONTROL ASSEMBLY

272

CONTROL ASSEMBLY INSTALLATION

272

PROCEDURES

273

Start-Up Procedure

273

5-104 – JLG Lift – 3121619

274

3121619 – JLG Lift – 5-105

275

5-106 – JLG Lift – 3121619

276

3121619 – JLG Lift – 5-107

277

5-108 – JLG Lift – 3121619

278

3121619 – JLG Lift – 5-109

279

5-110 – JLG Lift – 3121619

280

3121619 – JLG Lift – 5-111

281

5-112 – JLG Lift – 3121619

282

INSTRUCTIONS

283

Introduction

283

Using the Analyzer

284

Analyzer

285

Machine Setup

287

Level Vehicle Description

287

6-6 – JLG Lift – 3121619

288

3121619 – JLG Lift – 6-7

289

6-8 – JLG Lift – 3121619

290

3121619 – JLG Lift – 6-9

291

6-10 – JLG Lift – 3121619

292

3121619 – JLG Lift – 6-11

293

1001128802--C

294

3121619 – JLG Lift – 6-13

295

FUNCTION SPEEDS

296

3121619 – JLG Lift – 6-15

297

6-16 – JLG Lift – 3121619

298

1001172159-A

299

Test Notes

300

6.4 CANBUS COMMUNICATIONS

301

6-20 – JLG Lift – 3121619

302

3121619 – JLG Lift – 6-21

303

6.5 CALIBRATION INSTRUCTIONS

304

3121619 – JLG Lift – 6-23

305

6-24 – JLG Lift – 3121619

306

3121619 – JLG Lift – 6-25

307

6-26 – JLG Lift – 3121619

308

3121619 – JLG Lift – 6-27

309

6-28 – JLG Lift – 3121619

310

3121619 – JLG Lift – 6-29

311

6-30 – JLG Lift – 3121619

312

3121619 – JLG Lift – 6-31

313

6-32 – JLG Lift – 3121619

314

3121619 – JLG Lift – 6-33

315

6-34 – JLG Lift – 3121619

316

3121619 – JLG Lift – 6-35

317

6-36 – JLG Lift – 3121619

318

Sensor #1 - Load Pin (1)

319

6-38 – JLG Lift – 3121619

320

3121619 – JLG Lift – 6-39

321

6-40 – JLG Lift – 3121619

322

3121619 – JLG Lift – 6-41

323

SENSOR INSTALLATION

323

LOCK PIN SENSOR ADJUSTMENT

323

P/N-0100011

323

DETAIL B

324

3121619 – JLG Lift – 6-43

325

Switches (2)

326

PIN # DESC SENSOR HARNESS

327

ANGLE SENSOR #2 (LEFT)

327

6.7 SYSTEM TEST

328

Test from the Platform

328

3121619 – JLG Lift – 6-47

329

6-48 – JLG Lift – 3121619

330

3121619 – JLG Lift – 6-49

331

Test from the Ground Station

332

3121619 – JLG Lift – 6-51

333

6-52 – JLG Lift – 3121619

334

3121619 – JLG Lift – 6-53

335

6-54 – JLG Lift – 3121619

336

6.8 CALIBRATION PROCEDURES

337

Axle Calibration

337

Boom Sensor Calibration

337

6-56 – JLG Lift – 3121619

338

3121619 – JLG Lift – 6-57

339

Fault Response

340

3121619 – JLG Lift – 6-59

341

6-60 – JLG Lift – 3121619

342

3121619 – JLG Lift – 6-61

343

6-62 – JLG Lift – 3121619

344

3121619 – JLG Lift – 6-63

345

6-64 – JLG Lift – 3121619

346

3121619 – JLG Lift – 6-65

347

6-66 – JLG Lift – 3121619

348

3121619 – JLG Lift – 6-67

349

6-68 – JLG Lift – 3121619

350

3121619 – JLG Lift – 6-69

351

6-70 – JLG Lift – 3121619

352

3121619 – JLG Lift – 6-71

353

6-72 – JLG Lift – 3121619

354

3121619 – JLG Lift – 6-73

355

6-74 – JLG Lift – 3121619

356

3121619 – JLG Lift – 6-75

357

6-76 – JLG Lift – 3121619

358

3121619 – JLG Lift – 6-77

359

6-78 – JLG Lift – 3121619

360

3121619 – JLG Lift – 7-1

361

Resistance Measurement

362

Continuity Measurement

362

Current Measurement

363

TO ELECTRICAL CONNECTIONS

363

AMP Seal

364

AMP Mate-N-Lok

365

DIN Connectors

365

Exclusions

365

7-6 – JLG Lift – 3121619

366

AMP JUNIOR TIMER

366

7.4 AMP CONNECTOR

367

7-8 – JLG Lift – 3121619

368

Disassembly

369

Wedge Lock

369

Service - Voltage Reading

369

7-10 – JLG Lift – 3121619

370

7.5 DEUTSCH CONNECTORS

371

DT/DTP Series Assembly

371

DT/DTP Series Disassembly

371

HD30/HDP20 Series Assembly

372

HD30/HDP20 Series Disassembly

372

Connector Labels

373

Component Labels

373

7-14 – JLG Lift – 3121619

374

1001149976-D

375

7-16 – JLG Lift – 3121619

376

3121619 – JLG Lift – 7-17

377

1001149977-D

378

3121619 – JLG Lift – 7-19

379

1001149978-D

380

3121619 – JLG Lift – 7-21

381

7-22 – JLG Lift – 3121619

382

1001149979-B

383

7-24 – JLG Lift – 3121619

384

CO128-J4

385

1001158015-C

386

3121619 – JLG Lift – 7-27

387

1001158411-B

388

A C B1 4 3 21 4 3 2

389

SN221 SN401

389

001158989-A

390

001156135-C

391

001149972-D

392

3121619 – JLG Lift – 7-33

393

7-34 – JLG Lift – 3121619

394

3121619 – JLG Lift – 7-35

395

7-36 – JLG Lift – 3121619

396

3121619 – JLG Lift – 7-37

397

7-38 – JLG Lift – 3121619

398

3121619 – JLG Lift – 7-39

399

MS83 MS 82

400

001149973-C

401

7-42 – JLG Lift – 3121619

402

3121619 – JLG Lift – 7-43

403

001149975-E

404

3121619 – JLG Lift – 7-45

405

7-46 – JLG Lift – 3121619

406

3121619 – JLG Lift – 7-47

407

7-48 – JLG Lift – 3121619

408

3121619 – JLG Lift – 7-49

409

001149974-C

410

3121619 – JLG Lift – 7-51

411

7-52 – JLG Lift – 3121619

412

001149970-B

413

001149971-C

414

3121619 – JLG Lift – 7-55

415

7-56 – JLG Lift – 3121619

416

3121619 – JLG Lift – 7-57

417

001156001-B

418

3121619 – JLG Lift – 7-59

419

001156522-H

420

1001156522-H

421

1001156216-H

428

7-70 – JLG Lift – 3121619

430

3121619 – JLG Lift – 7-71

431

7-72 – JLG Lift – 3121619

432

3121619 – JLG Lift – 7-73

433

7-74 – JLG Lift – 3121619

434

3121619 – JLG Lift – 7-75

435

7-76 – JLG Lift – 3121619

436

3121619 – JLG Lift – 7-77

437

7-78 – JLG Lift – 3121619

438

3121619 – JLG Lift – 7-79

439

7-80 – JLG Lift – 3121619

440

3121619 – JLG Lift – 7-81

441

1001150162

442

3121619 – JLG Lift – 7-83

443

7-84 – JLG Lift – 3121619

444

3121619 – JLG Lift – 7-85

445

7-86 – JLG Lift – 3121619

446

3121619 – JLG Lift – 7-87

447

7-88 – JLG Lift – 3121619

448

3121619 – JLG Lift – 7-89

449

7-90 – JLG Lift – 3121619

450

JLG Worldwide Locations

452

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