JLG 1500SJ Service Manual User Manual
Service and maintenance manual, Model 1500sj
Table of contents
Document Outline
- Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires and Wheels
- 3.2 Extending Axles
- 3.3 Axle Limit Switch Adjustment Procedure
- 3.4 Drive System
- 3.5 Steering Control System
- 3.6 Drive/Steering Speed Control
- 3.7 Traction Control System
- 3.8 Drive Orientation System
- 3.9 Oscillating Axle System
- 3.10 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.11 Drive Hub - Bonfiglioli
- Product Identification
- Hydraulic Motor Installation
- Installation of the Wheel Drive on the Machine
- Start Up and Running In
- General Information
- Connecting the Brake
- Filling-up the Gearbox with Lubricating Oil
- Gearbox Disengagement
- Maintenance Information
- Changing the Lubricating oil
- Troubleshooting
- Disassembly Information
- Disassembly Procedure
- Inspection of Parts
- Assembly
- Final Test and Reinstallation
- 3.12 Drive Hub - Reggiana Riduttori
- 3.13 Swing Drive
- 3.14 Swing Brake
- 3.15 Swing Motor
- 3.16 Procedure For Setting Gear Backlash
- 3.17 Swing Drive Lubrication
- 3.18 Swing Bearing
- 3.19 Swing Speed Proportioning
- 3.20 Chassis Tilt Indicator System
- 3.21 Generator
- 3.22 Auxiliary Power System
- 3.23 Engine
- 3.24 Deutz EMR 2
- 3.25 Bio Fuel in Deutz Engines
- 3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
- List of Abbreviations in this Section
- Diagnostic Trouble Codes
- CAN
- MIL Output
- DTC 116- ECT Higher Than Expected Stage 1
- DTC 117- ECT/CHT Low Voltage
- DTC 118- ECT/CHT High Voltage
- DTC 122- TPS1 Signal Voltage Low
- DTC 123- TPS1 Signal Voltage High
- DTC 217- ECT Higher Than Expected 2
- DTC 219- RPM Higher Than Max Allowed Governed Speed
- DTC 336- Crank Signal Input Noise
- DTC 337- Loss of Crank Input Signal
- DTC 521- Oil Pressure Sender/Switch High Pressure
- DTC 524- Oil Pressure Low
- DTC 562- Battery Voltage (VBat) Low
- DTC 563- Battery Voltage (VBat) High
- DTC 601- Microprocessor Failure - FLASH
- DTC 604- Microprocessor Failure - RAM
- DTC 606- Microprocessor Failure - COP
- DTC 642- 5 Volt External Low Voltage
- DTC 643- 5 Volt External High Voltage
- DTC 1612- Microprocessor Failure - RTI 1
- DTC 1613- Microprocessor Failure - RTI 2
- DTC 1614- Microprocessor Failure - RTI 3
- DTC 1615- Microprocessor Failure - A/D
- DTC 1616- Microprocessor Failure - interrupt
- DTC 1625- CAN J1939 Shutdown Request
- DTC 1626- CAN J1939 Transmit (Tx) Fault
- DTC 1627- CAN J1939 Receive (Rx) Fault
- DTC 1628- CAN Address Conflict Failure
- DTC 1629- J1939 TSC1 Message Reciept Loss
- DTC 1652- TPS1 Loss of Communications
- DTC 2111- Unable to Reach Lower TPS
- DTC 2112- Unable to Reach Higher TPS
- DTC 9999- Throttle Actuator Failsafe Spring Failure
- DTC to SPN/FMI Table
- 3.27 Counterweight
- Section 4. Boom & Platform
- 4.1 Boom Systems
- Broken Cable Indicator System
- Platform Control Enable System
- Transport Position Sensing System
- Beyond Transport - Drive Speed Cutback System
- Drive/Steer – Boom Function Interlock System (CE ONLY)
- Jib Stow System
- Envelope Tracking System
- Moment Control System
- Boom Control System (BCS) Functional Check (Push to Test) System
- 4.2 Boom/Jib System Functionality
- Main Lift/Jib Velocity Control
- Jib Leveling During Automatic/Manual Envelope Control
- Jib Lift Functionality
- Jib Telescope Functionality
- Jib Swing Functionality
- Jib Swing Stow Sequence (Jib Pin Unlock)
- Jib Swing Deploy Sequence (Jib Pin Lock)
- Jib Lock Pin Lamp Operation
- Swing/Axle Extend Retract Restrictions
- Dual Capacity
- Jib Control During Over/Under Moment
- Boom Recovery Mode
- 4.3 Boom Removal and Installation
- 4.4 Boom Disassembly/Assembly & Cable Replacement
- 4.5 Load Sensing Pin Removal and Installation
- 4.6 Jib
- 4.7 Boom Lubrication Application
- 4.8 Platform Leveling Cylinder
- 4.9 Jib Telescope Cylinder
- 4.10 Jib Lift Cylinder
- 4.11 Jib Straight Shimming Procedure
- 4.12 Boom Cleanliness Guidelines
- 4.13 Hose Routing
- 4.14 Powertrack Maintenance
- 4.15 Wire Rope
- 4.16 Wire Rope Tensioning Adjustment
- 4.17 Broken Boom Cable Proximity Switch
- 4.18 Electronic Platform Leveling
- 4.19 Rotary Actuator
- 4.20 Jib Rotator Torquing Procedure
- 4.1 Boom Systems
- Section 5. Hydraulics
- Section 6. JLG Control System
- 6.1 JLG Control System Analyzer Kit Instructions
- 6.2 Machine Personality Settings and Function Speeds
- 6.3 Machine Orientation When Setting Function Speeds
- 6.4 CANbus Communications
- 6.5 Calibration Instructions
- 6.6 Control System Boom Sensors
- Sensor #1 - Moment Pin
- Sensor #2 - Main Boom Angle Sensors
- Sensor #3 - Main Boom Length Sensor
- Sensor #4 - Main Boom Cylinder Angle Sensor
- Sensor #5 - Main Boom Transport Length Switch
- Sensor #6 - Jib Level Angle Sensor
- Sensor #7 - Jib Lock Pin Switch
- Sensor #8 - Jib Stow Angle Sensor
- Sensor #9 - Jib Lift Cylinder Angle Sensor
- Sensor #10 - Dual Capacity / Jib Transport Length Switches
- Sensor #11 - Platform Level Cylinder Angle Sensor
- Sensor #12 - Platform Level Sensors
- Sensor #13 - Rotary Turntable Angle Sensor
- 6.7 Jib Control Module
- 6.8 CAN Gateway
- 6.9 System Test
- 6.10 Calibrating Steer
- 6.11 Calibrating Drive
- 6.12 Electronic Platform Leveling
- 6.13 Calibrating Platform Level
- 6.14 Calibrating Lift Crack Point
- 6.15 Calibrating Telescope Crack point
- 6.16 Calibrating Tilt Sensor
- 6.17 Jib Sensor Calibrations
- 6.18 Calibrating the Boom Sensors
- Section 7. Basic Electrical Information & Schematics