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


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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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