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JLG Models 1200SJP 1350SJP Service and Maintenance Manual P/N – 3121142 PDF download

This is the Most Practical Service Repair Manual for the JLG 1200SJP, 13500SJP Workshop Service Repair Manual Download ever compiled by mankind. This DOWNLOAD contains of high quality diagrams and instructions on how to service and repair your JLG.

JLG Models 1200SJP 1350SJP Service and Maintenance Manual

Download JLG 1200SJP, 13500SJP Workshop Service Repair Manual 3121142

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SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Tires 1-1
1 3 Engine Data 1-1
Engine Data Prior to S/N 0300127698 1-1
Engine Data S/N 0300127698 to Present 1-1
1 4 Specifications and Performance Data 1-2
Reach Specifications 1-2
Dimensional Data 1-2
Chassis 1-2
1 5 Torque Requirements 1-3
1 6 Hydraulic Oil 1-3
1 7 Major Component Weights 1-5
1 8 Pressure Settings 1-5
1 9 Lubrication and Operator Maintenance 1-7
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-2
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-3
Hydraulic System 2-3
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-4
Platform Drift 2-4
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
2 6 Welding on JLG Equipment 2-5
Do the Following When Welding on JLG Equipment 2-5
Do NOT Do the Following When Welding on JLG Equipment 2-5
SECTION 3 – CHASSIS & TURNTABLE
3 1 Tires & Wheels 3-1
Tire Inflation 3-1
Tire Damage 3-1
Wheel and Tire Replacement 3-1
Wheel Installation 3-1
3 2 Extending Axles 3-2
3 3 Axle Limit Switch Adjustment Procedure 3-2
3 4 Drive System 3-3
3 5 Steering Control System 3-3
3 6 Drive/Steering Speed Control 3-4
3 7 Traction Control System 3-4
3 8 Drive Orientation System 3-4
3 9 Oscillating Axle System 3-14
3 10 Oscillating Axle Bleeding Procedure and Lockout Test 3-14
Lockout Cylinder Bleeding 3-14
Oscillating Axle Lockout Test 3-15
3 11 Drive Hub (Prior to S/N 100131) 3-16
Disassembly 3-16
Disassembly of Cover 3-16
Disassembly of the First Stage Planetary Assembly (7) 3-16
Disassembly of Second Stage Planet Gears (1) 3-16
Assembly of First Stage Planetary Assembly (7) 3-17
Assembly of End Cover Unit (8) 3-17
Final Assembly 3-17
Initial Start-up And After Repairs 3-17
Oil Change Interval-Gear Drive 3-17
3 12 Drive Hub – Bonfiglioli (S/N 100128 to Present) 3-20
Product Identification 3-20
Hydraulic Motor Installation 3-20
Installation of the Wheel Drive on the Machine 3-20
Start Up and Running In 3-20
General Information 3-21
Connecting the Brake 3-21
Filling-up the Gearbox with Lubricating Oil 3-21
Gearbox Disengagement 3-23
Maintenance Information 3-25
Changing the Lubricating oil 3-25
Troubleshooting 3-26
Disassembly Information 3-26
Disassembly Procedure 3-26
Inspection of Parts 3-34
Assembly 3-35
Final Test and Reinstallation 3-45
3 13 Drive Hub – Reggiana Riduttori (S/N 134389 to Present) 3-50
Symbol Nomenclature 3-50
Tools 3-50
Disassembly 3-55
Assembly 3-59
3 14 Swing Drive 3-65
Roll and Leak Testing 3-65
Tightening and Torquing Bolts 3-65
Motor Control Valve Disassembly 3-66
Motor and Brake Disassembly 3-67
Main Disassembly 3-68
Hub-Shaft Disassembly 3-69
Carrier Disassembly 3-70
SECTION NO TITLE PAGE NO
Hub-Shaft Sub-Assembly 3-71
Carrier Sub-Assembly 3-72
Main Assembly 3-74
Motor and Brake Assembly 3-76
Motor Control Valve Assembly 3-77
3 15 Swing Brake 3-78
Pre-Installation Checks 3-78
Installation 3-79
Maintenance 3-79
Disassembly 3-79
Examination 3-79
Assembly 3-79
3 16 Swing Motor 3-81
Disassembly and inspection 3-81
Assembly 3-88
One Piece Stator Construction 3-95
3 17 Procedure For Setting Gear Backlash 3-96
3 18 Swing Drive Lubrication 3-97
3 19 Swing Bearing 3-98
Turntable Bearing Mounting Bolt Condition Check 3-98
Wear Tolerance 3-101
Swing Bearing Removal 3-101
Swing Bearing Installation 3-103
Swing Bearing Torque Values 3-104
3 20 Swing Speed Proportioning 3-105
3 21 Chassis Tilt Indicator System 3-105
3 22 Rotary Coupling 3-106
3 23 Generator 3-110
Every 250 hours 3-110
Every 500 hours 3-110
Overload Protection 3-111
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings 3-111
3 24 Auxiliary Power System 3-113
3 25 Cold Weather Package 3-115
3 26 Engine 3-115
Glow Plugs 3-115
Checking Oil Level 3-115
Changing Engine Oil 3-115
Changing the Oil Filter 3-116
Replacing the Fuel Filter 3-117
Cleaning the Fuel Strainer 3-117
3 27 Deutz EMR 2 (S/N 87579 to Present) 3-118
3 28 Bio Fuel in Deutz Engines 3-131
General 3-131
Bio Fuel 3-131
Biological Contamination In Fuels 3-132
SECTION 4 – BOOM & PLATFORM
4 1 Boom Systems 4-1
Broken Cable Indicator System 4-1
Platform Control Enable System 4-1
Transport Position Sensing System 4-1
Beyond Transport – Drive Speed Cutback System 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) 4-2
Jib Stow System 4-2
Envelope Tracking System 4-2
Moment Control System 4-3
Boom Control System (BCS) Functional Check (Push to Test) System 4-3
Controlled Arc System 4-3
Controlled Boom Angle System 4-4
Envelope Tracking 4-4
Slow Down System 4-4
Dual Capacity System 4-5
Electronic Platform Leveling 4-5
Boom Control Select 4-6
4 2 Boom Assembly 4-7
Removal 4-7
Disassembly 4-16
Assembly 4-18
4 3 Jib Rotator Orientation 4-29
4 4 Jib Lift End of Stroke Dampening 4-29
4 5 Load Sensing Pin Removal and Installation 4-29
4 6 Hose Routing Procedure 4-44
4 7 Wire Rope 4-44
Inspection 4-44
Three Month Inspection 4-44
Seven Year Inspection 4-44
Replacement Criteria 4-44
Wire Rope Tensioning Procedure 4-45
4 8 Broken Boom Cable Proximity Switch 4-49
Adjusting the Proximity Switch 4-49
4 9 Electronic Platform Leveling 4-49
Description 4-49
Normal Operation 4-50
4 10 Rotary Actuator 4-51
Theory of Operation 4-51
Required Tools 4-51
Disassembly 4-54
Inspection 4-58
Assembly 4-58
Bleeding After Installation 4-63
SECTION 5 – HYDRAULICS
5 1 Lubricating O-Rings in the Hydraulic System 5-1
Cup and Brush 5-1
Dip Method 5-2
Spray Method 5-2
Brush-on Method 5-2
5 2 Cylinder Repair 5-3
Disassembly 5-3
Cleaning and Inspection 5-12
Assembly 5-14
5 3 Hydraulic Tank 5-24
5 4 Pressure Setting Procedure 5-24
SECTION NO TITLE PAGE NO
Set Up of the Function Pump 5-24
Adjustments made at the Main Valve Bank 5-25
Adjustments Made at the Frame Valve Bank 5-26
Adjustments Made at the Platform Valve Bank 5-30
5 5 Drive Pumps 5-31
Troubleshooting Procedure 5-31
Charge Pressure Relief Valve Adjustment 5-34
Mechanical Centering of Pump 5-35
Hydraulic Centering of Control Modules 5-35
High Pressure Relief Valve Adjustments 5-36
Removal and inspection of charge pump 5-36
Routine Maintenance 5-37
Removal and Installation of Shaft Seal 5-39
5 6 Function Pump 5-40
Spare Parts 5-40
Sealing the Drive Shaft 5-41
Disassembly and Assembly of the Complete Unit 5-42
Assembly 5-45
Adjustments 5-46
Tightening Torques 5-46
Pump Control Disassembly For Cleaning 5-48
5 7 Drive & Function Pump Start Up Procedures 5-50
Start-Up Procedure 5-50
SECTION 6 – JLG CONTROL SYSTEM
6 1 Introduction 6-1
6 2 CANbus Communications 6-2
6 3 Calibration Instructions 6-4
6 4 To Connect the JLG Control System Analyzer 6-14
6 5 Using the Analyzer 6-14
6 6 Changing the Access Level of the Hand Held Analyzer 6-15
6 7 Adjusting Parameters Using the Hand Held Analyzer 6-16
6 8 Machine Setup 6-16
6 9 Machine Personality Settings/Function Speeds 6-23
6 10 Machine Orientation When Setting Function Speeds 6-27
Test Notes 6-27
6 11 System Test 6-28
Test from the Platform 6-28
Test from the Ground Station 6-31
6 12 Calibrating Steer 6-46
6 13 Calibrating Drive 6-49
6 14 Electronic Platform Leveling 6-52
Platform Leveling Fault Warning 6-52
Fault Response 6-52
CAN Errors 6-53
Additional Platform and Jib Valves 6-53
Platform Leveling Calibration Procedure 6-54
6 15 Calibrating Platform Level 6-55
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 6-55
STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS 6-56
STEP 3: BLEEDING THE PLATFORM VALVES 6-57
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 6-58
SECTION NO TITLE PAGE NO
6 16 Calibrating Lift Crack Point 6-59
6 17 Calibrating Telescope Crack point 6-62
6 18 Calibrating Tilt Sensor 6-65
6 19 Calibrating the Boom Sensors 6-67
Boom Control System Check Procedure 6-80
6 20 CANbus Troubleshooting 6-108
CANbus Communication Failure 6-115
Load Moment Pin Troubleshooting 6-128
SECTION 7 – BASIC ELECTRICAL INFORMATION & SCHEMATICS
7 1 General 7-1
7 2 Multimeter Basics 7-1
Grounding 7-1
Backprobing 7-1
Min/Max 7-1
Polarity 7-1
Scale 7-1
Voltage Measurement 7-1
Resistance Measurement 7-2
Continuity Measurement 7-2
Current Measurement 7-3
7 3 Applying Silicone Dielectric Compound to Electrical Connections 7-3
7 4 AMP Connector 7-4
Applying Silicone Dielectric Compound to AMP Connectors 7-4
Assembly 7-4
Disassembly 7-6
Wedge Lock 7-6
Service – Voltage Reading 7-6
7 5 Deutsch Connectors 7-8
DT/DTP Series Assembly 7-8
DT/DTP Series Disassembly 7-8
HD30/HDP20 Series Assembly 7-9
HD30/HDP20 Series Disassembly 7-9
FIGURE NO TITLE PAGE NO
1-1 Lubrication and Operator Maintenance Diagram 1-6
1-2 Torque Chart (SAE Fasteners – Sheet 1 of 3) 1-11
1-3 Torque Chart (SAE Fasteners – Sheet 2 of 3)) 1-12
1-4 Torque Chart (SAE Fasteners – Sheet 3 of 3) 1-13
1-5 Torque Chart (METRIC Fasteners – Sheet 1 of 3) 1-14
1-6 Torque Chart (METRIC Fasteners – Sheet 2 of 3) 1-15
1-7 Torque Chart (METRIC Fasteners – Sheet 3 of 3) 1-16
2-1 Engine Operating Temperature Specifications – Deutz 2-9
3-1 Axle Limit Switch Adjustment 3-2
3-2 Conventional Two Wheel Steer Mode 3-3
3-3 Crab Steer Mode 3-3
3-4 Coordinated Steer Mode 3-3
3-5 Chassis Component Location – Sheet 1 of 2 3-6
3-6 Chassis Component Location – Sheet 2 of 2 3-7
3-7 Turntable and Boom Component Location – Sheet 1 of 2 3-8
3-8 Turntable and Boom Component Location – Sheet 2 of 2 3-9
3-9 Oscillating Axle – Sheet 1 of 2 3-10
3-10 Oscillating Axle – Sheet 2 of 2 3-11
3-11 Axle Loctite Application 3-12
3-12 Steering Installation 3-13
3-13 Drive Hub – Sheet 1 of 2) 3-18
3-14 Drive Hub – Sheet 2 of 2 3-19
3-15 Drive Hub Identification Plate 3-20
3-16 Hub Assembly 3-22
3-17 Gearbox engaged 3-24
3-18 Gearbox Disengaged 3-25
3-19 Drive Hub S/N 100128 to Present 3-28
3-20 Drive Hub Special Tools – Sheet 1 of 4 3-46
3-21 Drive Hub Special Tools – Sheet 2 of 4 3-47
3-22 Drive Hub Special Tools – Sheet 3 of 4 3-48
3-23 Drive Hub Special Tools – Sheet 4 of 4 3-49
3-24 Bearing Track Spacer Mounting C016117 3-50
3-25 Oil Seal Spacer Mounting C125049 3-50
3-26 Bearing Spacer Mountng CO16117 3-51
3-27 Assembly Diagram 1 3-51
3-28 Wrench For Ring Nut 3-52
3-29 Anti-rotation Flange 3-52
3-30 Anti-rotation Block 3-52
3-31 Anti-rotation Pin 3-52
3-32 Assembly Diagram 2 3-53
3-33 Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 3-54
3-34 Reggiana Riduttori Hub – Sheet 1 of 2 3-56
3-35 Reggiana Riduttori Hub – Sheet 2 of 2 3-57
3-36 Swing System 3-64
3-37 Swing Drive – Motor Control Valve Disassembly 3-66
3-38 Swing Drive – Motor and Brake Disassembly 3-67
3-39 Swing Drive – Main Disassembly 3-68
3-40 Swing Drive – Hub Shaft Disassembly 3-69
3-41 Swing Drive – Carrier Disassembly 3-70
3-42 Swing Drive – Hub Shaft Sub-Assembly 3-71
3-43 Swing Drive – Carrier Sub-Assembly 3-73
3-44 Swing Drive – Main Assembly 3-75
3-45 Swing Drive – Motor and Brake Assembly 3-76
3-46 Swing Drive – Motor Control Valve Assembly 3-77
3-47 Swing Brake 3-78
3-48 Swing Brake Assembly 3-80
3-49 Swing Drive Motor 3-82
FIGURE NO TITLE PAGE NO
3-50 Swing Drive Ports 3-97
3-51 Swing Drive Lubrication 3-97
3-52 Swing Bearing Tolerance Boom Placement – Sheet 1 of 2 3-99
3-53 Swing Bearing Tolerance Boom Placement – Sheet 2 of 2 3-100
3-54 Swing Bolt Feeler Gauge Check 3-101
3-55 Swing Bearing Removal 3-102
3-56 Swing Bearing Torque Sequence 3-105
3-57 Rotary Coupling Seal Installation 3-106
3-58 Rotary Coupling Cutaway 3-107
3-59 Rotary Coupling Installation 3-108
3-60 Rotary Coupling Port Location 3-109
3-61 Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-112
3-62 Auxiliary Pump Installation 3-113
3-63 Cold Weather Package 3-114
3-64 Engine Oil Viscosity 3-116
3-65 EMR 2 Engine Side Equipment 3-119
3-66 Deutz EMR 2 Troubleshooting Flow Chart 3-120
3-67 Deutz EMR 2 Vehicle Side Connection Diagram 3-121
3-68 Deutz EMR 2 Engine Side Connection Diagram – Sheet 1 of 2 3-122
3-69 Deutz EMR 2 Engine Side Connection Diagram – Sheet 2 of 2 3-123
3-70 EMR 2 Engine Plug Pin Identification 3-124
3-71 EMR 2 Vehicle Plug Pin Identification 3-125
3-72 EMR2 Fault Codes – Sheet 1 of 5 3-126
3-73 EMR2 Fault Codes – Sheet 2 of 5 3-127
3-74 EMR2 Fault Codes – Sheet 3 of 5 3-128
3-75 EMR2 Fault Codes – Sheet 4 of 5 3-129
3-76 EMR2 Fault Codes – Sheet 5 of 5 3-130
4-1 Boom Assembly – Sheet 1 of 7 4-8
4-2 Boom Assembly – Sheet 2 of 7 4-9
4-3 Boom Assembly – Sheet 3 of 7 4-10
4-4 Boom Assembly – Sheet 4 of 7 4-11
4-5 Boom Assembly – Sheet 5 of 7 4-12
4-6 Boom Assembly – Sheet 6 of 7 4-13
4-7 Boom Assembly – Sheet 7 of 7 4-14
4-8 Boom Assembly Torque Values – Sheet 1 of 2 4-20
4-9 Boom Assembly Torque Values – Sheet 2 of 2 4-21
4-10 Locations for Loctite Application – Sheet 1 of 4 4-24
4-11 Locations for Loctite Application – Sheet 2 of 4 4-25
4-12 Locations for Loctite Application – Sheet 3 of 4 4-26
4-13 Locations for Loctite Application – Sheet 4 of 4 4-27
4-14 Jib Rotator Orientation 4-29
4-15 Load Pin Removal Tool, JLG P/N 4846765 4-31
4-16 Boom/Jib Sensors and Switches Installation – Sheet 1 of 4 4-32
4-17 Boom/Jib Sensors and Switches Installation – Sheet 2 of 4 4-33
4-18 Boom/Jib Sensors and Switches Installation – Sheet 3 of 4 4-34
4-19 Boom/Jib Sensors and Switches Installation – Sheet 4 of 4 4-35
4-20 Boom Wiper Installation 4-36
4-21 Pivot Pin Installation 4-37
4-22 Powertrack Installation – Sheet 1 of 4 4-38
4-23 Powertrack Installation – Sheet 2 of 4 4-39
4-24 Powertrack Installation – Sheet 3 of 6 4-40
4-25 Powertrack Installation – Sheet 4 of 6 4-41
4-26 Powertrack Installation – Sheet 5 of 6 4-42
4-27 Powertrack Installation – Sheet 6 of 6 4-43
4-28 Wire Rope Tensioning Figure A 4-46
4-29 Wire Rope Adjustment Tools (Optional) 4-48
4-30 Broken Boom Cable Proximity Switch Location 4-49
FIGURE NO TITLE PAGE NO
4-31 Rotary Actuator – Exploded View 4-52
4-32 Rotary Actuator – Assembly Drawing 4-53
4-33 Platform Support Torque Values 4-63
5-1 Cylinder Barrel Support 5-3
5-2 Cap Screw Removal 5-3
5-3 Axle Extension Cylinder 5-4
5-4 Axle Lockout Cylinder 5-5
5-5 Level Cylinder 5-6
5-6 Lift Cylinder 5-7
5-7 Jib Cylinder 5-8
5-8 Steer Cylinder – Prior to S/N 73367 5-9
5-9 Steer Cylinder – S/N 73367 to Present 5-10
5-10 Telescope Cylinder 5-11
5-11 Cylinder Rod Support 5-12
5-12 Tapered Bushing Removal 5-12
5-13 Composite Bearing Installation 5-13
5-14 Rod Seal Installation 5-14
5-15 Poly-Pak Piston Seal Installation 5-14
5-16 Wiper Seal Installation 5-14
5-17 Installation of Head Seal Kit 5-15
5-18 Piston Seal Kit Installation 5-15
5-19 Tapered Bushing Installation 5-16
5-20 Seating the Tapered Bearing 5-16
5-21 Rod Assembly Installation 5-17
5-22 Hydraulic Tank 5-18
5-23 Chassis Control Valve Locations 5-19
5-24 Platform Valve Identification – JLG P/N 4641266 5-20
5-25 Platform Valve Identification – JLG P/N 4641460 5-21
5-26 Main Valve Identification 5-22
5-27 Main Valve Cartridge Torque Values 5-23
5-27 Hydraulic Oil Level Gauge 5-24
5-28 Steer Pressure Adjustments 5-27
5-29 Function Pump – Sectional View 5-40
5-30 Function Pump, Pressure and Flow Control – Sheet 1 5-47
5-31 Function Pump, Pressure and Flow Control – Sheet 2 5-47
5-32 Function Pump, Pressure and Flow Control – Sheet 3 5-48
6-1 Hand Held Analyzer 6-1
6-2 Control System Block Diagram 6-3
6-3 Analyzer Flow Chart 6-5
6-4 Analyzer Flow Chart – Personalities (Software Version 7 X to Present) 6-6
6-5 Analyzer Flow Chart – Machine Setup (Software Version 7 X to Present) 6-7
6-6 Analyzer Flow Chart – Calibrations (Software Version 7 X to Present) 6-8
6-7 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 1 of 3 6-9
6-8 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 2 of 3 6-10
6-9 Analyzer Flow Chart – Diagnostics (Software Version 7 X to Present) – Sheet 3 of 3 6-11
6-10 Control Module Location 6-12
6-11 Analyzer Connecting Points 6-13
6-12 System Test Flow Chart – Platform Tests 6-30
6-13 System Test Flow Chart – Ground Station Tests 6-32
6-14 Boom Sensor Calibration Position 1 6-67
6-15 Boom Sensor Calibration Position 2 6-72
6-16 Boom Sensor Calibration Position 3 6-73
6-17 Boom Sensor Calibration Position 4 6-74
6-18 Boom Sensor Calibration Position 5 6-75
6-19 Boom Sensor Calibration Position 6 6-76
6-20 Boom Sensor Calibration Position 7 6-76
6-21 Boom Sensor Calibration Position 8 6-77
FIGURE NO TITLE PAGE NO
6-22 Boom Sensor Calibration Position 9 6-78
6-23 Boom Sensor Calibration Position 10 6-79
6-24 Fault Code Light Location 6-81
6-25 CANbus Connections Diagram 6-108
6-26 CANbus Connections – Sheet 1 of 5 6-109
6-27 CANbus Connections – Sheet 2 of 5 6-110
6-28 CANbus Connections – Sheet 3 of 5 6-111
6-29 CANbus Connections – Sheet 4 of 5 6-112
6-30 CANbus Connections – Sheet 5 of 5 6-113
6-31 CANbus Circuit 6-114
6-32 Moment Chart 6-132
7-1 Voltage Measurement (DC) 7-1
7-2 Resistance Measurement 7-2
7-3 Continuity Measurement 7-2
7-4 Current Measurement (DC) 7-3
7-5 Connector Assembly Figure 1 7-4
7-6 AMP Connector 7-4
7-7 Connector Assembly Figure 2 7-5
7-8 Connector Assembly Figure 3 7-5
7-9 Connector Assembly Figure 4 7-5
7-10 Connector Disassembly 7-6
7-11 Connector Installation 7-7
7-12 DT/DTP Contact Installation 7-8
7-13 DT/DTP Contact Removal 7-8
7-14 HD/HDP Contact Installation 7-9
7-15 HD/HDP Locking Contacts Into Position 7-9
7-16 HD/HDP Contact Removal 7-9
7-17 HD/HDP Unlocking Contacts 7-9
7-18 Chassis Electrical Components – Sheet 1 of 2 7-10
7-19 Chassis Electrical Components – Sheet 2 of 2 7-11
7-20 Turntable Electrical Components – Prior to S/N 87579 – Sheet 1 of 2 7-12
7-21 Turntable Electrical Components – Prior to S/N 87579 – Sheet 2 of 2 7-13
7-22 Turntable Electrical Components – S/N 87579 to Present – Sheet 1 of 2 7-14
7-23 Turntable Electrical Components – S/N 87579 to Present – Sheet 2 of 2 7-15
7-24 Electrical Schematic – Sheet 1 of 6 7-16
7-25 Electrical Schematic – Sheet 2 of 6 7-17
7-26 Electrical Schematic – Sheet 3 of 6 7-18
7-27 Electrical Schematic – Sheet 4 of 6 7-19
7-28 Electrical Schematic – Sheet 5 of 6 7-20
7-29 Electrical Schematic – Sheet 6 of 6 7-21
7-30 Hydraulic Schematic – Boom Control – Sheet 1 of 2 7-22
7-31 Hydraulic Schematic – Boom Control – Sheet 2 of 2 7-23
7-32 Hydraulic Schematic – Pump Circuit – Sheet 1 of 2 7-24
7-33 Hydraulic Schematic – Pump Circuit – Sheet 2 of 2 7-25
7-34 Hydraulic Schematic – Platform Control – Sheet 1 of 2 7-26
7-35 Hydraulic Schematic – Platform Control – Sheet 2 of 2 7-27
7-36 Hydraulic Schematic – Axle Steer Control – Sheet 1 of 2 7-28
7-37 Hydraulic Schematic – Axle Steer Control – Sheet 2 of 2 7-29
7-38 Hydraulic Schematic – Traction Control – Sheet 1 of 2 7-30
7-39 Hydraulic Schematic – Traction Control – Sheet 2 of 2 7-31
TABLE NO TITLE PAGE NO
1-1 Capacities 1-1
1-2 Tire Specifications 1-1
1-3 Deutz BF4M2011 Specifications 1-1
1-4 Deutz TD2011L4 Specifications 1-1
1-5 Reach Specifications 1-2
1-6 Dimensional Data 1-2
1-7 Chassis Specifications 1-2
1-8 Torque Requirements 1-3
1-9 Engine Torque Requirements 1-3
1-10 Hydraulic Oil Specifications 1-3
1-11 Mobilfluid 424 Specs 1-3
1-12 Mobil DTE 13M Specs 1-4
1-13 UCon Hydrolube HP-5046 1-4
1-14 Mobil EAL H 46 Specs 1-4
1-15 Exxon Univis HVI 26 Specs 1-4
1-16 Component Weights 1-5
1-17 Pressure Settings 1-5
1-18 Lubrication Specifications 1-7
2-1 Inspection and Maintenance 2-2
2-2 Cylinder Drift 2-5
2-3 Inspection and Preventive Maintenance Schedule 2-6
3-1 Wheel Torque Chart 3-1
3-2 Steering Assembly Notes 3-13
3-2 Brake Technical Data 3-21
3-3 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade 3-23
3-4 Drive Hub Maintenance Schedule 3-25
3-5 Troubleshooting 3-26
3-6 Coupling Port Information Table 3-110
4-1 Hose/Cable Pull Chart 4-42
4-1 Hose/Cable Pull Chart 4-42
5-1 Cylinder Head and Tapered Bushing Torque Specifications 5-17
5-2 Holding Valve Torque Specifications 5-17
5-3 Cartridge Torque Values 5-23
5-4 Torque Specs for Relief Valves into Port Block 5-36
5-5 Tightening Torques 5-46
6-1 Calibration Instructions 6-4
6-2 Machine Configuration Programming Information – Version P7 X to Present 6-17
6-3 Personality Ranges/Defaults 6-23
6-4 System Test Messages 6-33
6-5 Machine Diagnostics Parameters 6-36
6-6 Diagnostic Trouble Code Chart 6-82
6-7 Troubleshooting: Platform Can Communications Lost 6-117
6-8 Troubleshooting: BLAM Can Communications Lost 6-123
6-9 Troubleshooting: Chassis Can Communications Lost 6-127
6-10 Load Moment Pin Troubleshooting: Can Communications Lost 6-128
6-11 Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range 6-129
6-12 Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range 6-130
6-13 Load Moment Pin Troubleshooting: Moment Pin Sensor Fault 6-131
6-14 Load Moment Pin Troubleshooting: New Moment Pin Detected Fault 6-131

 

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