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Oshkosh JLG 1500SJ Telescopic Boom Lift Manuals
Manuals and User Guides for Oshkosh JLG 1500SJ Telescopic Boom Lift. We have
3
Oshkosh JLG 1500SJ Telescopic Boom Lift manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual
Oshkosh JLG 1500SJ Service And Maintenance Manual (706 pages)
Brand:
Oshkosh
| Category:
Boom Lifts
| Size: 50 MB
Table of Contents
General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
25
Operating Specifications
25
Dimensional Data
25
Capacities
26
Tires
26
Engine Data
26
Deutz
26
Caterpillar
26
Hydraulic Oil
27
Major Component Weights
28
Operator Maintenance
30
General
41
Machine Preparation, Inspection, and Maintenance
41
Preparation, Inspection, and Maintenance
41
Pre-Start Inspection
41
Pre-Delivery Inspection and Frequent Inspection
41
Annual Machine Inspection
41
Preventive Maintenance
41
Service and Guidelines
42
General
42
Safety and Workmanship
42
Cleanliness
42
Components Removal and Installation
42
Component Disassembly and Reassembly
43
Pressure-Fit Parts
43
Bearings
43
Gaskets
43
Bolt Usage and Torque Application
43
Hydraulic Lines and Electrical Wiring
43
Hydraulic System
43
Lubrication
43
Battery
43
Lubrication and Servicing
43
Hydraulic Oil
44
Changing Hydraulic Oil
44
Lubrication Specifications
44
Cylinder Drift Test
44
Platform Drift
44
Cylinder Drift
45
Pins and Composite Bearing Repair Guidelines
45
Welding on JLG Equipment
45
Do the Following When Welding on JLG Equipment
45
Do NOT Do the Following When Welding on JLG Equipment
45
Chassis & Turntable
51
Tires and Wheels
51
Tire Inflation
51
Tire Damage
51
Wheel and Tire Replacement
51
Wheel Installation
51
Extending Axles
52
Axle Limit Switch Adjustment Procedure
52
Drive System
53
Steering Control System
53
Drive/Steering Speed Control
54
Traction Control System
54
Drive Orientation System
54
Swing Envelope Service Mode
54
Oscillating Axle System
64
Oscillating Axle Bleeding Procedure and Lockout Test
64
Lockout Cylinder Bleeding
64
Oscillating Axle Lockout Test
65
Drive Hub - Bonfiglioli
66
Product Identification
66
Hydraulic Motor Installation
66
Installation of the Wheel Drive on the Machine
66
Start up and Running in
66
General Information
67
Connecting the Brake
67
Filling-Up the Gearbox with Lubricating Oil
67
Gearbox Disengagement
69
Maintenance Information
71
Changing the Lubricating Oil
71
Troubleshooting
72
Disassembly Information
72
Disassembly Procedure
72
Inspection of Parts
80
Assembly
81
Final Test and Reinstallation
91
Drive Hub - Reggiana Riduttori
96
Symbol Nomenclature
96
Tools
96
Disassembly
101
Assembly
105
Swing Drive
111
Roll and Leak Testing
111
Tightening and Torquing Bolts
111
Motor Control Valve Disassembly
112
Motor and Brake Disassembly
113
Main Disassembly
114
Hub-Shaft Disassembly
115
Carrier Disassembly
116
Hub-Shaft Sub-Assembly
117
Carrier Sub-Assembly
118
Main Assembly
121
Motor and Brake Assembly
123
Motor Control Valve Assembly
124
Swing Brake
125
Pre-Installation Checks
125
Installation
126
Maintenance
126
Disassembly
126
Examination
126
Assembly
126
Swing Motor
129
Disassembly and Inspection
129
Assembly
136
One Piece Stator Construction
143
Procedure for Setting Gear Backlash
144
Swing Drive Lubrication
145
Swing Bearing
146
Turntable Bearing Mounting Bolt Condition Check
146
Wear Tolerance
149
Turntable/Swing Bearing Removal
150
Turntable/Swing Bearing Installation
162
Swing Bearing Torque Values
169
Swing Speed Proportioning
170
Chassis Tilt Indicator System
170
Generator
171
Every 250 Hours
171
Every 500 Hours
171
Overload Protection
172
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
172
Auxiliary Power System
174
Engine
175
Glow Plugs
175
Checking Oil Level
175
Changing Engine Oil
176
Changing the Oil Filter
176
Replacing the Fuel Filter
177
Cleaning the Fuel Strainer
178
Deutz EMR 2
178
Bio Fuel in Deutz Engines
191
General
191
Bio Fuel
191
Biological Contamination in Fuels
192
List of Abbreviations in this Section
195
Diagnostic Trouble Codes
197
Can
197
MIL Output
197
DTC 116- ECT Higher than Expected Stage 1
198
DTC 117- ECT/CHT Low Voltage
199
DTC 118- ECT/CHT High Voltage
201
DTC 122- TPS1 Signal Voltage Low
203
DTC 123- TPS1 Signal Voltage High
205
DTC 217- ECT Higher than Expected 2
207
DTC 219- RPM Higher than Max Allowed Governed Speed
208
DTC 336- Crank Signal Input Noise
209
DTC 337- Loss of Crank Input Signal
211
DTC 521- Oil Pressure Sender/Switch High Pressure
212
DTC 524- Oil Pressure Low
213
DTC 562- Battery Voltage (Vbat) Low
215
DTC 563- Battery Voltage (Vbat) High
217
DTC 601- Microprocessor Failure - FLASH
219
DTC 604- Microprocessor Failure - RAM
221
DTC 606- Microprocessor Failure - COP
223
DTC 642- 5 Volt External Low Voltage
225
DTC 643- 5 Volt External High Voltage
226
DTC 1612- Microprocessor Failure - RTI 1
227
DTC 1613- Microprocessor Failure - RTI 2
228
DTC 1614- Microprocessor Failure - RTI 3
230
DTC 1615- Microprocessor Failure - A/D
232
DTC 1616- Microprocessor Failure - Interrupt
234
DTC 1625- CAN J1939 Shutdown Request
236
DTC 1626- CAN J1939 Transmit (Tx) Fault
237
DTC 1627- CAN J1939 Receive (Rx) Fault
238
DTC 1628- CAN Address Conflict Failure
239
DTC 1629- J1939 TSC1 Message Reciept Loss
241
DTC 1652- TPS1 Loss of Communications
242
DTC 2111- Unable to Reach Lower TPS
243
DTC 2112- Unable to Reach Higher TPS
245
DTC 9999- Throttle Actuator Failsafe Spring Failure
246
DTC to SPN/FMI Table
247
Counterweight
248
Boom & Platform
249
Boom Systems
249
Broken Cable Indicator System
249
Platform Control Enable System
249
Transport Position Sensing System
249
Beyond Transport - Drive Speed Cutback System
249
Drive/Steer - Boom Function Interlock System (CE ONLY)
252
Jib Stow System
252
Envelope Tracking System
252
Moment Control System
252
Boom Control System (BCS) Functional Check (Push to Test) System
253
Boom/Jib System Functionality
253
Main Lift/Jib Velocity Control
253
Jib Leveling During Automatic/Manual Envelope Control
253
Jib Lift Functionality
255
Jib Telescope Functionality
255
Jib Swing Functionality
255
Jib Swing Stow Sequence (Jib Pin Unlock)
255
Jib Swing Deploy Sequence (Jib Pin Lock)
257
Jib Lock Pin Lamp Operation
257
Swing/Axle Extend Retract Restrictions
258
Dual Capacity
258
Jib Control During Over/Under Moment
258
Boom Recovery Mode
258
Boom Removal and Installation
260
Removal
260
Installation
262
Boom Disassembly/Assembly & Cable Replacement
265
Disassembly
265
Assembly
283
Load Sensing Pin Removal and Installation
298
Jib
300
Removal
300
Installation
302
Boom Lubrication Application
307
Platform Leveling Cylinder
307
Removal
307
Installation
308
Jib Telescope Cylinder
309
Removal
309
Installation
311
Jib Lift Cylinder
312
Removal
312
Installation
313
Jib Straight Shimming Procedure
314
Boom Cleanliness Guidelines
316
Hose Routing
316
Powertrack Maintenance
320
One Piece Bracket Maintenance
320
Two Piece Bracket Maintenance
322
Snap Rings and Screws
323
Wire Rope
325
Inspection
325
Three Month Inspection
325
Eight Year Inspection
325
Replacement Criteria
325
Wire Rope Tensioning Adjustment
326
Boom Section Re-Positioning
326
Wire Rope Tensioning Procedure
328
Broken Boom Cable Proximity Switch
335
Adjusting the Proximity Switch
335
Electronic Platform Leveling
335
Description
335
Normal Operation
336
Rotary Actuator
337
Theory of Operation
337
Tools Required
338
Disassembly
339
Inspection
344
Assembly
345
Greasing Thrust Washers
349
Installing Counterbalance Valve
349
Testing the Actuator
349
Installation and Bleeding
351
Troubleshooting
352
Jib Rotator Torquing Procedure
353
Basic Hydraulic Information & Hydraulic Schematics
355
Lubricating O-Rings in the Hydraulic System
355
Cup and Brush
355
Dip Method
356
Spray Method
356
Brush-On Method
356
Hydraulic Connection Assembly and Torque Specification
357
Tapered Thread Types
357
Straight Thread Types, Tube and Hose Connections
357
Straight Thread Types, Port Connections
358
Flange Connection Types
358
Tightening Methods
358
Assembly and Torque Specifications
359
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
360
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
361
Assembly Instructions for 37° (JIC) Flare Fittings
362
Assembly Instructions for 45° SAE Flare Fittings
365
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
367
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
369
Assembly Instructions for Bulkhead (BH) Fittings
371
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
381
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
388
Assembly Instructions for Adjustable Port End (BSPP) Fittings
391
Assembly Instructions for Flange Connections: (FL61 and FL62)
398
Double Wrench Method
401
FFWR and TFFT Methods
402
Adjustable Stud End Assembly
402
O-Ring Installation (Replacement)
403
Hydraulic Cylinders
404
Axle Extension Cylinder
404
Axle Lockout Cylinder
410
Jib Level Cylinder
416
Platform Level Cylinder
422
Boom Lift Cylinder
428
Jib Lift Cylinder
434
Jib Lock Cylinder
440
Steer Cylinder
443
Jib Telescope Cylinder
447
Main Boom Telescope Cylinder
451
Cylinder Length Sensor
457
Removal
457
Installation
459
Oil Sampling
470
Procedure
470
Pressure Setting Procedure
471
Set up of the Function Pump
471
Adjustments Made at the Main Valve Bank
472
Adjustments Made at the Frame Valve Bank
472
Adjustments Made at the Platform Valve Bank
477
Adjustments Made at the Jib Valve
478
Drive Pumps
484
Troubleshooting Procedure
484
Charge Pressure Relief Valve Adjustment
487
Mechanical Centering of Pump
488
Hydraulic Centering of Control Modules
488
High Pressure Relief Valve Adjustments
489
Removal and Inspection of Charge Pump
489
Routine Maintenance
490
Removal and Installation of Shaft Seal
492
Function Pump
493
Spare Parts
493
Sealing the Drive Shaft
494
Disassembly and Assembly of the Complete Unit
495
Assembly
498
Adjustments
499
Tightening Torques
499
Pump Control Disassembly for Cleaning
501
Start-Up Procedure
503
Jlg Control System
517
Introduction
517
To Connect the JLG Control System Analyzer
518
Using the Analyzer
518
Changing the Access Level of the Hand Held Analyzer
519
Adjusting Parameters Using the Hand Held Analyzer
520
Machine Setup
521
Level Vehicle Description
521
Test Notes
534
Canbus Communications
535
Calibration Instructions
537
Control System Boom Sensors
553
Sensor #1 - Moment Pin
553
Sensor #2 - Main Boom Angle Sensors
553
Sensor #3 - Main Boom Length Sensor
555
Sensor #4 - Main Boom Cylinder Angle Sensor
555
Sensor #5 - Main Boom Transport Length Switch
555
Sensor #6 - Jib Level Angle Sensor
556
Sensor #7 - Jib Lock Pin Switch
556
Sensor #8 - Jib Stow Angle Sensor
556
Sensor #9 - Jib Lift Cylinder Angle Sensor
556
Sensor #10 - Dual Capacity / Jib Transport Length Switches
557
Sensor #11 - Platform Level Cylinder Angle Sensor
557
Sensor #12 - Platform Level Sensors
557
Sensor #13 - Rotary Turntable Angle Sensor
557
Jib Control Module
558
CAN Gateway
558
System Test
559
Test from the Platform
559
Test from the Ground Station
562
Calibrating Steer
577
Calibrating Drive
580
Electronic Platform Leveling
583
Platform Leveling Fault Warning
583
Fault Response
583
Calibrating Platform Level
584
Step 1: Setting the Platform Valve Minimums
584
Step 2: Bleeding the Platform Valves
585
Calibrating Lift Crack Point
587
Calibrating Telescope Crack Point
590
Calibrating Tilt Sensor
594
Jib Sensor Calibrations
596
Calibrating the Jib Level up and down Valve Crackpoints
605
Calibrating the Boom Sensors
607
Boom Control System Check Procedure
623
Basic Electrical Information & Electrical Schematics
645
General
645
Multimeter Basics
645
Grounding
645
Backprobing
645
Min/Max
645
Polarity
645
Scale
645
Voltage Measurement
645
Resistance Measurement
646
Continuity Measurement
646
Current Measurement
647
Applying Silicone Dielectric Compound to Electrical Connections
647
Installation of Dielectric Grease
648
Deutsch HD, DT, DTM, DRC Series
648
AMP Seal
648
AMP Mate-N-Lok
649
DIN Connectors
649
Exclusions
649
AMP Connector
651
Assembly
651
Disassembly
653
Wedge Lock
653
Service - Voltage Reading
653
Deutsch Connectors
655
DT/DTP Series Assembly
655
DT/DTP Series Disassembly
655
HD30/HDP20 Series Assembly
656
HD30/HDP20 Series Disassembly
656
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Oshkosh JLG 1500SJ Operation And Safety Manual (215 pages)
Brand:
Oshkosh
| Category:
Boom Lifts
| Size: 22 MB
Table of Contents
Foreword Revision Log
8
Table of Contents
8
List of Figures Figure Number - Title Page
14
Section 1. Safety Precautions
18
General
18
Pre-Operation
18
Operator Training and Knowledge
18
Workplace Inspection
19
Machine Inspection
20
Operation
20
General
20
Trip and Fall Hazards
21
Electrocution Hazards
22
Tipping Hazards
24
Crushing and Collision Hazards
27
Towing, Lifting, and Hauling
28
Maintenance
28
Maintenance Hazards
28
Battery Hazards
29
Section 2 - User Responsibilities, Machine Preparation, and Inspection
30
2.1 Personnel Training
30
Operator Training
30
Training Supervision
30
2.2 Preparation, Inspection, and Maintenance
31
Machine Familiarization
31
Operator Responsibility
31
Pre-Start Inspection
36
Walk-Around Inspection
38
Function Check
42
Skyguard Function Test
44
Boom Control System Check Procedure
45
Section 3 - Machine Controls and Indicators
46
General
46
Controls and Indicators
46
Ground Control Station
47
Override (MSSO) (CE Only)
50
Ground Control Indicator Panel
53
Platform Station
56
Platform Control Indicator Panel
63
Section 4 - Machine Operation
68
Description
68
Boom Operating Characteristics and Limitations
68
Capacities
68
Controlled Arc
69
Controlled Angle
70
Envelope Tracking
70
Swing Speed Proportioning
70
Platform Load Sensing System (LSS)
71
Stability
71
Capacity Select
71
Position of Least Forward Stability
72
Engine Operation
74
Starting Procedure
74
Shutdown Procedure
75
Air Shutoff Valve (ASOV) (if Equipped)
76
ASOV Reset (Open to Closed Position)
76
Fuel Reserve / Shut-Off System
77
Selective Catalytic Reduction (Scr) - Machines Using Diesel Exhaust Fluid (Def)
78
Standstill Cleaning
78
Cancelling Maintenance Standstill
80
Initiation Methods
80
Maintenance Standstill Cleaning
80
Unsuccessful Cleaning Event
81
Traveling (Driving)
84
Grade and Side Slopes
85
Traveling Forward and Reverse
86
Traveling on a Grade
87
Steering
87
Extending the Axles
87
Platform
88
Platform Level Adjustment
88
Platform Rotation
88
Boom
88
Raising and Lowering the Boom
89
Swinging the Boom
89
Function Speed Control
90
Machine Safety System Override
90
Stowing/Swinging the Jib
90
Telescoping the Boom
90
Telescoping the Jib
90
Skyguard
91
Skyguard - Skyline
91
Skyguard Operation
91
Skyguard - Skyeye
92
Skyguard Function Table
92
4.13 Emergency Towing
93
Drive Disconnect Hub
93
4.14 Shut down and Park
94
4.15 Lifting and Tie down
94
Lifting
94
4.16 Stowing the Jib for Transport
95
Tie down
95
Lifting and Tie down Chart
96
Section 5 - Lcd Display Panel - Generation 1 & 2
108
Lcd Display Panel
108
Description
108
LCD Panel
108
Generation 1 Lcd Display Panel Screens
109
Boot up Splash Screen
109
Default Screen
111
Conditional Icons
113
CAN Communication Error Screen
115
Serviceable Fault Indication Screen
117
Keyswitch in Ground Control Mode Screen
119
Keyswitch in Ground Control Mode Screen with Operational Faults
121
Operational Faults
121
Operational Fault - no Graphics Screen
123
Operational Fault - with Graphics Screen
125
Operational Fault - Footswitch Open Screen
127
Out of Transport - Axles Retracted
129
Operational Fault - Transport Swing Fault Screen
131
Transport Swing Fault Screen
132
Envelope Speed Reduction Screen
133
Backward Envelope Speed Reduction Fault Screen
134
Forward Envelope Violation Fault Screen
136
Operational Fault - Over/Under Moment Fault (DTC 0017/0018)
137
Generation 2 Lcd Display Panel Screens
139
Boot up Splash Screen
139
Machine Operating Screen
141
Keyswitch in Ground Mode
143
Function Speed
144
CAN Bus Lost
145
Take Foot out
146
Put Foot in
147
BCS Lamp on
148
Broken Cable
150
Platform Level
151
Platform Overload
152
Capacity Mode Error
153
Swing Dtcs
154
Jib Unlocked
156
Jib Locked
157
Chassis Status
158
Machine Tilted Mode
161
Envelope Status
162
Machine Model Unknown
166
Operational Fault Code Listing
167
Section 6 - Emergency Procedures
169
General
169
Incident Notification
169
Emergency Operation
169
Operator Unable to Control Machine
169
Emergency Towing Procedures
170
Machine Safety System Override
171
Section 7 - Accessories
172
Fall Arrest Platform
174
Safety Precautions
174
Pipe Racks
174
Capacity Specifications (Australia Only)
175
Operation
175
Preparation and Inspection
175
Safety Precautions
175
Skycutter
176
Safety Precautions
176
Accessory Ratings
177
Generator Output
177
Operation
177
Preparation and Inspection
177
Skyglazier
178
Capacity Specifications
178
Operation
179
Preparation and Inspection
179
Safety Precautions
179
Skypower
180
Accessory Ratings
180
Generator Output
180
Operation
181
Preparation and Inspection
181
Safety Precautions
181
Skywelder
181
Accessory Ratings
182
Generator Output
182
Welding Accessories
182
Operation
183
Preparation and Inspection
183
Safety Precautions
183
Bolt-On External Fall Arrest
184
Soft Touch
184
Inspection before Use
185
Section 8 - General Specifications & Operator Maintenance
188
Introduction
188
Operating Specifications and Performance Data
188
Operating Specifications
188
Dimensional Data
189
Capacities
190
Tires
190
Engine Data
191
Hydraulic Oil
192
Operator Maintenance
200
Tires & Wheels
211
Tire Damage
211
Tire Replacement
211
Wheel Replacement
211
Wheel Installation
212
Oshkosh JLG 1500SJ Service And Maintenance Manual (163 pages)
Brand:
Oshkosh
| Category:
Boom Lifts
| Size: 54 MB
Table of Contents
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
4
Specifications
21
Operating Specifications
21
Machine Specifications
21
Dimensional Data
21
Machine Dimensional Data
21
Capacities
21
Tires
22
Engine Data
22
Hydraulic Oil
23
Major Component Weights
24
Operator Maintenance
26
Threadlocking Compound
32
Torque Charts
33
SAE Fastener Torque Chart
33
Metric Fastener Torque Chart
39
General
44
Machine Preparation, Inspection, and Maintenance
44
Preparation, Inspection, and Maintenance
44
Pre-Start Inspection
44
Pre-Delivery Inspection and Frequent Inspection
44
Annual Machine Inspection
44
Preventive Maintenance
44
Service and Guidelines
45
General
45
Safety and Workmanship
45
Cleanliness
45
Components Removal and Installation
45
Component Disassembly and Reassembly
46
Pressure-Fit Parts
46
Bearings
46
Gaskets
46
Bolt Usage and Torque Application
46
Hydraulic Lines and Electrical Wiring
46
Hydraulic System
46
Lubrication
46
Battery
46
Lubrication and Servicing
46
Lubrication and Information
47
Hydraulic System
47
Hydraulic Oil
47
Changing Hydraulic Oil
47
Lubrication Specifications
47
Cylinder Drift
48
Theory
48
Cylinder Leakage Test
48
Cylinder Thermal Drift
48
Pins and Composite Bearing Repair Guidelines
49
Welding on JLG Equipment
49
Do the Following When Welding on JLG Equipment
49
DO NOT Do the Following When Welding on JLG Equipment
49
Chassis & Turntable
55
Tires and Wheels
55
Tire Damage
55
Tire Replacement
55
Wheel Replacement
55
Wheel Installation
55
Axle Extension System
56
Axle Limit Switch Adjustment Procedure
56
Drive System
57
Steering Control System
57
Drive/Steering Speed Control
58
Traction Control System
58
Drive Orientation System
58
Swing Envelope Service Mode
58
Oscillating Axle System
70
Oscillating Axle Bleeding Procedure and Lockout Test
70
Lockout Cylinder Bleeding
70
Oscillating Axle Lockout Test
71
Wheel Drive Assembly
72
Removal
72
Installation
72
Drive Motor
73
Removal
73
Installation
73
Drive Hub - if Equipped with Bonfiglioli
75
Product Identification
75
Hydraulic Motor Installation
75
Installation of the Wheel Drive on the Machine
75
Start up and Running in
75
General Information
76
Connecting the Brake
76
Filling-Up the Gearbox with Lubricating Oil
76
Gearbox Disengagement
78
Maintenance Information
80
Changing the Lubricating Oil
80
Troubleshooting
81
Disassembly Information
81
Disassembly Procedure
81
Inspection of Parts
89
Assembly
90
Final Test and Reinstallation
100
Drive Hub - if Equipped with Reggiana Riduttori
105
Symbol Nomenclature
105
Tools
105
Disassembly
110
Assembly
114
Swing Drive
120
Roll and Leak Testing
120
Tightening and Torquing Bolts
120
Swing Brake
123
Pre-Installation Checks
123
Installation
124
Maintenance
124
Disassembly
124
Examination
124
Assembly
125
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