JLG 510AJ Articulating Boom Lift Service and Maintenance Manual (Global)

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This service manual PDF download for the 510AJ JLG Articulating Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

TABLE OF CONTENTS :

Section 1. Specifications
1.1 Capacities
1.2 Tires
1.3 Engine
1.4 Specifications and Performance Data
1.5 Function Speeds
1.6 Torque Requirements
1.7 Lubrication
1.8 Operator Maintenance
1.9 Major Component Weights
1.10 Pressure Settings
1.11 Serial Number Location

Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Pins and Composite Bearing Repair Guidelines
2.5 Welding on JLG Equipment

Section 3. Chassis and Turntable
3.1 Tires & Wheels
3.2 Torque Hub (Machines built Before S/N 1300000064)
3.3 Torque Hub (Machines built After S/N 1300000064)
3.4 Re-Aligning torque hub input coupling
3.5 Drive Motor
3.6 Adjustment Procedure For Lockout Valve
3.7 Oscillating Axle Bleeding Procedure and Lockout Test
3.8 Swing Bearing
3.9 Generator
3.10 Deutz Engine
3.11 Deutz EMR 2 (S/N 1300000981 to Present)
3.12 Perkins Engine General Maintenance
3.13 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.14 DGC Diagnostic Support and Trouble Code Definitions
3.15 Diagnostic Trouble Code Fault Descriptions

Section 4. Boom and Platform
4.1 Boom Maintenance
4.2 Rotator
4.3 Rotary Actuator (S/N 1300006433 to Present)

Section 5. Hydraulics and Hydraulic Schematics
5.1 O-Ring Lubrication
5.2 Hydraulic Cylinders
5.3 Hydraulic Pump (Gear)
5.4 Variable Pump
5.5 Hydraulic Component Start-Up Procedures and Recommendations
5.6 Pressure Setting Procedure

Section 6. JLG Control System
6.1 introduction
6.4 To Connect the JLG Control System Analyzer
6.5 Using the Analyzer
6.6 Changing the Access Level of the Hand Held Analyzer
6.7 Adjusting Parameters Using the Hand Held Analyzer
6.8 Machine Setup
6.9 Machine Personality Settings
6.10 System Test

Section 7. Basic Electrical Information and Electrical Schematics
7.1 General
7.2 Multimeter Basics
7.3 Applying Silicone Dielectric Compound to Electrical Connections
7.4 AMP Connector
7.5 Deutsch Connectors

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121181
Total Pages : 402

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Section A. Introduction – Maintenance Safety Precautions
A General
B Hydraulic System Safety
C Maintenance

Section 1. Specifications
1.1 Capacities
1.2 Tires
1.3 Engine
1.4 Specifications and Performance Data
Dimensional Data
Reach Specifications
Chassis
1.5 Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes
1.6 Torque Requirements
1.7 Lubrication
Hydraulic Oil
1.8 Operator Maintenance
1.9 Major Component Weights
1.10 Pressure Settings
1.11 Serial Number Location

Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
Cylinder Drift Test
Platform Drift
Cylinder Drift
2.4 Pins and Composite Bearing Repair Guidelines
2.5 Welding on JLG Equipment

Section 3. Chassis and Turntable
3.1 Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Torque Hub (Machines built Before S/N 1300000064)
Roll, Leak and Brake Testing
Tightening and Torquing Bolts
Main Disassembly
Input Carrier Disassembly
Output Carrier Disassembly
Housing-Spindle Disassembly
Spindle-Brake Disassembly
Input Carrier Sub-Assembly
Output Carrier Sub-Assembly
Spindle-Brake Sub-Assembly
Housing-Spindle Sub-Assembly
Integral Brake Check
Main Assembly
3.3 Torque Hub (Machines built After S/N 1300000064)
Roll and Leak Testing
Tightening and Torquing Bolts
Oil Information
Main Disassembly for ”B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Carrier Assembly
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List
3.4 Re-Aligning torque hub input coupling
Equipment Required
Procedure
3.5 Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures
3.6 Adjustment Procedure For Lockout Valve
3.7 Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding (Early Cylinders)
Lockout Cylinder Bleeding (Ram Cylinders)
Oscillating Axle Lockout Test
3.8 Swing Bearing
Description
Removal
Disassembly
Assembly
Installation
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Torque Value
3.9 Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
3.10 Deutz Engine
Checking Oil Level
Changing Engine Oil
Changing the Oil Filter
Replacing Fuel Filter
Cleaning Fuel Strainer
3.11 Deutz EMR 2 (S/N 1300000981 to Present)
3.12 Perkins Engine General Maintenance
Replacing the Engine Crankcase Breather
Engine Oil Level – Check
Engine Oil and Filter – Change
Fuel Filter/Water Separator
Setting the Actuator
Speed Sensor Installation
3.13 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.14 DGC Diagnostic Support and Trouble Code Definitions
Section Layout
List of Abbreviations in this Section
Fault Code Broadcast
Diagnostic Trouble Codes
CAN
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test
3.15 Diagnostic Trouble Code Fault Descriptions
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
Diagnostic Aids
DTC 1652- TPS1 Loss of Communications
Diagnostic Aids
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

Section 4. Boom and Platform
4.1 Boom Maintenance
Remove Boom Assembly
Disassemble Main Boom
Inspection
Assemble Main Boom
Install Boom Assembly
4.2 Rotator
Disassembly and Inspection
Assembly and Testing
4.3 Rotary Actuator (S/N 1300006433 to Present)
Theory of Operation
Required Tools
Disassembly
Inspection
Assembly
Installing Counterbalance Valve

Section 5. Hydraulics and Hydraulic Schematics
5.1 O-Ring Lubrication
Cup and Brush
Dip
Spray
Brush-On
5.2 Hydraulic Cylinders
Tower Lift Cylinder
Main Lift Cylinder
Master Cylinder
Telescope Cylinder
Platform Level (Slave) Cylinder
Jib Lift Cylinder
Steer Cylinder
Axle Lockout Cylinder (Outside Frame)
Axle Lockout Cylinder (Inside Frame)
5.3 Hydraulic Pump (Gear)
Disassembly
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Assembly
Placing Pump Back Into Service
5.4 Variable Pump
Ports and Pressure Gauges
NFPE Control
Removal and Installation of FNR and NFPE Modules
Removal and Installation of FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Charge Pump
5.5 Hydraulic Component Start-Up Procedures and Recommendations
5.6 Pressure Setting Procedure
Telescope Main Relief
Steer
Platform Level Up
Platform Level Down
Articulating Jib
Proportional Main Relief
Lift Down
Swing

Section 6. JLG Control System
6.1 introduction
6.4 To Connect the JLG Control System Analyzer
6.5 Using the Analyzer
6.6 Changing the Access Level of the Hand Held Analyzer
6.7 Adjusting Parameters Using the Hand Held Analyzer
6.8 Machine Setup
6.9 Machine Personality Settings
6.10 System Test
Test from the Platform
Test from the Ground Station

Section 7. Basic Electrical Information and Electrical Schematics
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.3 Applying Silicone Dielectric Compound to Electrical Connections
7.4 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service – Voltage Reading
7.5 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly

 

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JLG 510AJ Articulating Boom Lift Service and Maintenance Manual (Global).pdf

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