JLG Boom Lift 1850SJ Service & Maintenance Manual 31223045

[Hyundai]

Download this document, you need 2725 Gallons

JLG Boom Lift 1850SJ Service & Maintenance Manual 31223045
Size: 121.65 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 1850SJ Boom Lift
Part Number: 31223045
Publication Date: 2024
Number of Pages: 1060 Pages

Contents:
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

1.1.3 Do Not Operate Tags​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications​

2.1.1 Machine Specification​

2.1.2 Machine Dimensional Data​

2.1.3 Engine Data​

2.1.4 Tires​

2.1.5 Major Component Weights​

Machine Temperature Chart​

Serial Number Location​

Fluids and Lubrication​

2.4.1 Hydraulic System​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Fluids​

2.4.6 Capacities​

2.4.7 Lubrication Schedule​

Machine Characteristics​

2.5.1 Axle Extension System​

2.5.2 Drive Orientation System​

2.5.3 Steering Control System​

2.5.4 Drive/Steering Speed Control​

2.5.5 Traction Control System​

2.5.6 Ground Control Keyswitch System​

2.5.7 Jib Lift End of Stroke Dampening​

2.5.8 Hydraulic System Warm Up​

2.5.9 Function Speed Control System​

2.5.10 Swing Control System​

2.5.11 Chassis Tilt Indicator System​

2.5.12 Auxiliary Power System​

2.5.13 Water in Fuel Sensing System (Optional)​

2.5.14 Deutz Turbocharger Operation​

2.5.15 Deutz Engine with Diesel Exhaust Fluid (DEF)​

2.5.16 Selective Catalytic Reduction (SCR) - Machines Using Diesel Exhaust Fluid (DEF)​

2.5.17 Wire Rope Service Indicator​

2.5.18 Transport Position Sensing System​

2.5.19 Beyond Transport - Drive Speed Cutback System​

2.5.20 Drive/Steer - Boom Function Interlock System (UKCA/CE ONLY)​

2.5.21 Jib Stow System​

2.5.22 Envelope Control System​

2.5.23 Moment Control System​

2.5.24 Boom Control System (BCS) Functional Check (Push to Test) System​

2.5.25 Controlled Arc System​

2.5.26 Controlled Boom Angle System​

2.5.27 Envelope Tracking​

2.5.28 Slow Down System​

2.5.29 Dual Capacity System​

2.5.30 Swing Speed Proportioning​

2.5.31 Platform Load Sensing System​

2.5.32 Electronic Platform Leveling​

2.5.33 Boom Control Select​

2.5.34 Platform Control Enable System​

2.5.35 Bolt-on External Fall Arrest​

2.5.36 Control System Boom Sensors​

Clearsky Smart Fleet (If Equipped)​

2.6.1 General​

2.6.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventive Maintenance​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule​

3.3.1 Maintenance Schedules​

3.3.2 Diesel Exhaust Fluid (DEF) Tank​

Pins and Composite Bearing Repair Guidelines​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Fuel Tank Inspection​

Boom Inspection and Maintenance​

3.7.1 Wire Rope​

3.7.2 Wire Rope Tensioning Adjustment​

3.7.3 Boom Preparation for Section Repositioning​

3.7.4 Wire Rope Tensioning Procedure​

3.7.5 Confirm Proper Boom Deployment Function​

3.7.6 Re-Assembly​

3.7.7 Boom Calibration​

3.7.8 Wire Rope Proximity Switch​

3.7.9 Powertrack Maintenance​

3.7.10 Boom Cleanliness Guidelines​

Hydraulic Filter Replacement​

3.8.1 Removal​

3.8.2 Installation​

Turntable Bearing Inspection​

3.9.1 Turntable Bearing Mounting Bolt Condition Check​

3.9.2 Wear Tolerance​

Generator Inspection​

3.10.1 Every 250 hours​

3.10.2 Every 500 hours​

3.10.3 Overload Protection​

3.10.4 Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings​

3.10.5 Troubleshooting​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter Basics​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

4.2.2 SkyGuard®​

4.2.3 LSS Testing and Evaluation​

4.2.4 System Test​

Calibration Procedures​

4.3.1 Load Sensing System Calibration​

4.3.2 Axle Calibration​

4.3.3 Calibrating Tilt Sensor​

4.3.4 Boom Sensor Calibration​

4.3.5 Jib Sensor Calibrations​

4.3.6 Resetting The MSSO System​

4.3.7 Setting Crackpoints​

Special Procedures​

4.4.1 Fuel Tank Cleaning and Drying​

4.4.2 Cylinder Drift​

4.4.3 Drive Cutout Override Service Mode​

4.4.4 Boom Unlock Procedure​

4.4.5 Boom Recovery Mode​

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Diagnostic Menu​

JLG Analyzer​

5.2.1 Introduction​

5.2.2 To Connect the JLG Control System Analyzer​

5.2.3 Using the Analyzer​

5.2.4 Changing the Access Level of the Hand Held Analyzer​

5.2.5 Adjusting Parameters Using the Hand Held Analyzer​

5.2.6 Machine Setup​

5.2.7 Level Vehicle Description​

5.2.8 Ground Control Console Display Gauge - Machines using Diesel Exhaust Fluid (DEF)​

5.2.9 Analyzer Software​

Analyzer Software Accessibility​

5.3.1 Machine Configuration Programming Information​

5.3.2 Machine Configuration Programming Settings​

5.3.3 Machine Personality Settings and Function Speeds​

Function Test​

CANBUS Communications​

Electronic Platform Leveling​

5.6.1 Platform Leveling Fault Warning​

5.6.2 Fault Response​

ClearSky (CS550) Configuration and Troubleshooting​

5.7.1 ClearSky Smart FleetTM CS550 Configuration​

5.7.2 Troubleshooting​

Fault Codes

Fault Codes Introduction​

Engine Diagnostic​

Machine Fault Codes​

6.3.1 Diagnostic Fault Code​

6.3.2 Diagnostic Trouble Code​

6.3.3 ClearSky CSV3 Smart Fleet DTC Fault Codes​

6.3.4 LSS Troubleshooting​

6.3.5 System Test Messages​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components​

7.3.1 Hydraulic Oil Tank​

7.3.2 Oil Sampling Procedure​

7.3.3 Pressure setting Procedure​

7.3.4 Drive and Function Pump Start Up Procedures​

Torque Values​

Standard Hydraulic Diagram - Boom And Turntable​

Hydraulic Diagram - Chassis​

Hydraulic System​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Harness Layouts​

Board Layouts​

AMP Connector​

8.5.1 Assembly​

8.5.2 Disassembly​

8.5.3 Wedge Lock​

8.5.4 Service - Voltage Reading​

Wiring Harness and Connector Label Diagrams​

8.6.1 Connector Labels​

8.6.2 Component Labels​

Telematics Gateway​

8.7.1 Telematics-Ready (TCU) Plug​

Electrical Installation​

Removal and Installation

Wheel and Tire​

9.1.1 Tire Replacement​

9.1.2 Wheel Replacement​

9.1.3 Wheel Installation​

Chassis/Frame Assembly​

9.2.1 Axle​

9.2.2 Drive Hub and Motor​

9.2.3 Spindle Assembly​

Boom​

9.3.1 Boom Components Terminology​

9.3.2 Load Sensing Pin Removal and Installation​

9.3.3 Cylinder Length Sensor​

9.3.4 Powertrack​

9.3.5 Hose Adjustment Procedure​

9.3.6 Boom Removal and Installation​

9.3.7 Jib​

9.3.8 Jib Straight Shimming Procedure​

9.3.9 Stowed Jib Shimming Procedure​

9.3.10 Rotator​

Platform​

9.4.1 Platform/Support​

9.4.2 Bolt-on External Fall Arrest​

Engine​

9.5.1 Component Terminology​

9.5.2 Engine Serial Number​

9.5.3 Engine Replacement​

9.5.4 Surge Tank​

9.5.5 Pump Coupling Kit​

9.5.6 Air Filter Assembly​

9.5.7 Radiator Assembly​

9.5.8 Relay Assembly​

9.5.9 Starter​

9.5.10 Alternator​

9.5.11 Fuel Tank​

9.5.12 Pre-Fuel Filter and Fuel Pump​

Transmission​

Hydraulic Cylinders​

9.7.1 Upper Lift Cylinder​

9.7.2 Platform Level Cylinder​

9.7.3 Jib Lift Cylinder​

9.7.4 Telescope Cylinder​

9.7.5 Axle Deploy Cylinder​

9.7.6 Steer Cylinder​

Hydraulic Valves​

9.8.1 Main Control Valve​

9.8.2 Platform Valve​

9.8.3 Traction valve​

Hydraulic Pumps​

9.9.1 Gear Pump​

9.9.2 Piston Pump Assembly​

9.9.3 Tandem Pump​

Electrical Components​

9.10.1 Battery​

Turntable​

9.11.1 Swing Drive Hub​

9.11.2 Setting Swing Gear Backlash​

9.11.3 Swing Bearing Torque Values​

9.11.4 Swing Bearing​

9.11.5 Rotary Coupling​

Generator Pulley​

9.12.1 Removal​

9.12.2 Installation​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.13.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 Drive Motor​

10.1.2 Drive Hub​

10.1.3 Free Wheeling Option​

10.1.4 Gear Hub Oil Service​

Boom and Jib Assembly​

10.2.1 Boom Assembly​

10.2.2 Boom Shimming Procedure​

10.2.3 Boom Lubrication Application​

Platform​

Engine Components​

10.4.1 Engine Disassembly, Inspection and Service​

10.4.2 Fuel Tank​

Pumps​

10.5.1 Drive Pumps​

10.5.2 Function Pump​

10.5.3 Gear Pump​

Hydraulic Cylinders​

10.6.1 Axle Extend Cylinder​

10.6.2 Jib Level (Slave) Cylinder​

10.6.3 Platform Level Cylinder​

10.6.4 Boom Lift Cylinder​

10.6.5 Jib Lift Cylinder​

10.6.6 Jib Lock Cylinder​

10.6.7 Steer Cylinder​

10.6.8 Jib Telescope Cylinder​

10.6.9 Boom Telescope Cylinder​

Hydraulic Valves​

Hydraulic Components​

10.8.1 Hydraulic Oil Tank​

Turntable​

10.9.1 Swing Drive​

10.9.2 Swing Brake​

10.9.3 Rotary Coupling​

Generator Disassembly and Assembly​

10.10.1 Generator Disassembly and Assembly​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​

Generator Schematics​

12.3.1 Generator Troubleshooting Circuit Diagram​

12.3.2 Generator Electrical Circuit Diagram​

12.3.3 Power Board Electrical Circuit Diagram​

12.3.4 Lead Connection List for Generator​