Service and Maintenance Manual Models 1200SJP 1350SJP P/N - 3121142 July 22, 2014
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised A-2 - June 5, 2002 - January 15, 2003 - May 23, 2003 - August 30, 2004 - January 12, 2006 - July 12, 2006 - November 30, 2006 - January 18, 2007 - November 9, 2007 - April 9, 2008 - August 27, 2008 - January 22, 2009 - October 27, 2011 - March 28, 2012 - January 23, 2013 - July 22, 2014 – JLG Lift – 3121142
TABLE OF CONTENTS SECTION NO. SECTION A B C SECTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 SECTION 2.1 2.2 2.3 2.4 3121142 TITLE PAGE NO. A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. 2.5 2.6 SECTION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 ii TITLE PAGE NO. Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Do the Following When Welding on JLG Equipment . . . . .
TABLE OF CONTENTS SECTION NO. 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3121142 TITLE PAGE NO. Drive Hub - Reggiana Riduttori (S/N 134389 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. 3.27 3.28 3.29 iv TITLE PAGE NO. Deutz EMR 2 (S/N 87579 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 3121142 TITLE PAGE NO. 4 - BOOM & PLATFORM Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 5.1 5.2 5.3 5.4 5.5 5.6 5.7 vi TITLE PAGE NO. 5 - HYDRAULICS Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 3121142 TITLE PAGE NO. 6 - JLG CONTROL SYSTEM Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 7.1 7.2 7.3 7.4 7.5 viii TITLE PAGE NO. 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 2-1. 2-2. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41. 3-42. 3-43. 3-44. 3-45. 3-46. 3-47. 3-48. 3121142 TITLE PAGE NO. Lubrication and Operator Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 3-68. 3-69. 3-70. 3-71. 3-72. 3-73. 3-74. 3-75. 3-76. 3-77. 3-78. 3-79. 3-80. 3-81. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. viii TITLE PAGE NO. Swing Brake 12 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 4-32. 4-33. 4-34. 4-35. 4-36. 4-37. 4-38. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-27. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 3121142 TITLE PAGE NO. Powertrack Installation - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. 6-18. 6-19. 6-20. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. 6-30. 6-31. 6-32. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7-33. 7-34. x TITLE PAGE NO. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 7-35. 7-36. 7-37. 7-38. 7-39. 7-40. 7-41. 7-42. 7-43. 7-44. 7-45. 7-46. 7-47. 7-48. 7-49. 7-50. 3121142 TITLE PAGE NO. Electrical Schematic - Sheet 6 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Sheet 7 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 2-1 2-2 2-3 3-1 3-2 3-2 3-3 3-4 3-5 3-6 3-7 4-1 4-1 5-1 5-2 5-3 5-4 5-5 5-6 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 3121142 TITLE PAGE NO. Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Specifications. . . . . . . . . . . . . .
LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally.
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Deutz S/N 0300127698 to Present Table 1-4. Deutz TD2011L4 Specifications Table 1-1. Capacities Hydraulic Tank 55 gallons (208 liters) Type Fuel Tank 31 gallons (117 liters) Number of Cylinders 4 Hydraulic System 66 gallons (250 liters) Bore 3.7 in. (94 mm) Stroke 4.4 in. (112 mm) Total Displacement 190 cu. in. (3108 cm3) Compression Ratio 17.5 Firing Order 1-3-4-2 Output 75hp (56 kW) 5 Quarts (4.5 L) 11 Quarts (10.
SECTION 1 - SPECIFICATIONS 1.4 SPECIFICATIONS AND PERFORMANCE DATA Dimensional Data Table 1-7. Dimensional Data Reach Specifications Table 1-6. Reach Specifications Maximum Work Load (Capacity) Unrestricted Restricted Max.Vertical Platform Height (Unrestricted) 1200SJP 1350SJP Max.Vertical Platform Height (Restricted) 1200SJP 1350SJP 500 lb (230 kg) 1000 lb. (450 kg) 120 ft. (36.6 m) 135 ft. (41.2 m) 115 ft. (35.1 m) 125 ft. (38.1 m) Max.Horizontal Platform Reach (Unrestricted) 1200SJP 1350SJP 75 ft.
SECTION 1 - SPECIFICATIONS 1.5 TORQUE REQUIREMENTS 1.6 HYDRAULIC OIL Table 1-11. Hydraulic Oil Specifications Table 1-9. Torque Requirements Description Torque Value (Dry) Interval Hours Wheel Bolts 180 ft. lbs. (252 Nm) 150 Swing Bearing Bolts 190 ft. lbs. (258 Nm) Tele Cylinder Regen Valve Mounting Bolts Starter Solenoid Contacts Coil Hydraulic System Operating Temperature Range S.A.E.
SECTION 1 - SPECIFICATIONS Table 1-13. Mobil DTE 13M Specs Table 1-15. Mobil EAL H 46 Specs ISO Viscosity Grade #32 Type Synthetic Biodegradable Specific Gravity 0.877 ISO Viscosity Grade 46 Pour Point, Max -40°F (-40°C) Specific Gravity .910 330°F (166°C) Pour Point -44°F (-42°C) Flash Point 500°F (260°C) 0 to 180°F (-17 to 162°C) 7.64 lb. per gal. (0.9 kg per liter) Flash Point, Min. Viscosity at 40° C 33cSt Operating Temp. at 100° C 6.
SECTION 1 - SPECIFICATIONS 1.7 MAJOR COMPONENT WEIGHTS 1.8 PRESSURE SETTINGS Table 1-18. Pressure Settings Table 1-17. Component Weights Component Pounds Kilograms Tire & Wheel 867 393 Drive Hub & Motor 275.5 123 Swing Drive 290 Circuit PSI Bar Function Pump, High 3400 234.4 132 Function Pump, Low 300 20.6 Drive, Pre-Set 5000 344.7 Lift Up 2750 189.
SECTION 1 - SPECIFICATIONS 13 14 5 4 4 10,11 7 8 12 9 6 1 2,3 4 4 15 Figure 1-1.
SECTION 1 - SPECIFICATIONS 2. 1.9 LUBRICATION AND OPERATOR MAINTENANCE Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Lubrication and Operator Maintenance Diagram. Table 1-19. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 1 - SPECIFICATIONS NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. 4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128) Lube Point(s) - Level/Fill Plug Capacity - 0.5 liters (1/2 full) Lube - EPGL Interval - Change after first 150 hours then every 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position.
SECTION 1 - SPECIFICATIONS 7. Hydraulic Oil 9. Oil Change w/Filter - Deutz FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Fill Cap Capacity - 55 gallons (208 liters) Tank Lube - HO Interval - Check level daily. Change every 2 years or 1200 hours of operation. 8. Lube Point(s) - Fill Cap/Spin-on Element Capacity 5 Quarts (4.5 L) Cooling System 11 Quarts (10.
SECTION 1 - SPECIFICATIONS 10. Fuel Filter - Deutz 12. Oil Change w/Filter - CAT Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 11. Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10.5 Quarts (10 L) Lube - EO Interval - Check level daily; change every 150 hours or three months, whichever comes first. Adjust final oil level by mark on dipstick. Fuel Strainer 13.
SECTION 1 - SPECIFICATIONS 14. Air Filter 15.
Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue SECTION 1 - SPECIFICATIONS Figure 1-3.
Torq ue Tor que Torq ue Torqu e To rqu e SECTION 1 - SPECIFICATIONS Figure 1-4.
To rque To rqu e Torq ue Cl amp L oa d Torqu e Tor que Torq ue SECTION 1 - SPECIFICATIONS Figure 1-5.
To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue SECTION 1 - SPECIFICATIONS Figure 1-6.
Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue SECTION 1 - SPECIFICATIONS Figure 1-7.
SECTION 2 - GENERAL SECTION 2. GENERAL these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures. 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE Annual Machine Inspection General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
SECTION 2 - GENERAL Section 1. Always examine filters for evidence of metal particles. Changing Hydraulic Oil 3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil. 4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
SECTION 2 - GENERAL b. Flaking, pealing, scoring, or scratches on the pin surface. Cylinder Drift Table 2-2. Cylinder Drift Cylinder Bore Diameter c. Rusting of the pin in the bearing area. Max. Acceptable Drift in 10 Minutes inches mm inches mm 3 76.2 0.026 0.66 3.5 89 0.019 0.48 4 101.6 0.015 0.38 5 127 0.009 0.22 6 152.4 0.006 0.15 7 177.8 0.005 0.13 8 203.2 0.0038 0.10 9 228.6 0.0030 0.08 4. Re-assembly of pinned joints using filament wound bearings. a.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) ENGINE SPECIFICATIONS 80 F(27 C) SUMMER GRADE FUEL 70 F(21 C) 60 F(16 C) 50 F(10 C) 40 F(4 C) 30 F(-1 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE SPECIFICATIONS 60 F(16 C) 50 F(10 C) 40 F(4 C) 30 F(-1 C) 20 F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. ers. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque.
SECTION 3 - CHASSIS & TURNTABLE 3.2 EXTENDING AXLES The Axle Extension System allows each of the four axles to be extended and retracted together while maintaining full steering control as the machine is driven. The system allows the axles to extend or retract only while the boom is in the transport position and in order to minimize wheel scrubbing during axle movement, a minimum drive speed must be attained before axle extension/retraction will be permitted.
SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE SYSTEM The drive system utilizes 2 traction pumps so each side is powered individually. This produces maximum tractive effort to wheels by minimizing flow divider losses. The maximum drive speed is modulated with the steered angle of the wheels to eliminate the whiplash effect of driving at full speed and maximum steering lock. 3.
SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE/STEERING SPEED CONTROL 3.8 DRIVE ORIENTATION SYSTEM The Drive/Steering Speed Control system uses the steering sensors from the steering control system to increase operator control and comfort by reducing the effect of turning the chassis on the resulting lateral platform speed. The system proportionally varies the drive speed based on the predicted turning radius of the chassis for both coordinated and conventional two wheel steer modes.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-5.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. Axle Limit Switch (Right Front) Steer Angle Sensor (Right Front) Steer Valve (Front) Axle Lockout Valve Traction Valve Steer Valve (Rear) Steer Angle Sensor (Right Rear) Axle Limit Switch (Right Rear) 9. 10. 11. 12. 13. 14. 15. Axle Limit Switch (Left Rear) Steer Angle Sensor (Left Rear) Chassis Module Swivel/Collector Ring Axle Lockout Pressure Switch Steer Angle Sensor (Left Front) Axle Limit Switch (Left Front) Figure 3-6.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-7.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Platform Control Valve Jib Stow Switch Platform Level Sensor (Secondary - Left) Tail Lights Skypower Generator Alarm Main Control Valve Auxiliary Power Pump Auxiliary Power Relay Chassis Power Distribution Relay Headlight/Tail Light Relay Horn Lift Cylinder Pivot Pin Fuel Level Sensor B.L.A.M.
SECTION 3 - CHASSIS & TURNTABLE 3 1 DETAIL A 6 2 * AXLE STOP SHIMMING PROCEDURE: 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM. 5 DETAIL B 4 Figure 3-9.
SECTION 3 - CHASSIS & TURNTABLE 9 11,12,B,G 3 6 11,12,A,G 8 10 11,12,C,G DETAIL A 7 11,12,D,G 11,12,E,G 11,12,F,G 2 4 A - Assemble to Axle Box Mid Plate; Typical 8 Places DETAIL B B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 inches (12.7 ± 1.587 mm) thread engagement. C - Assemble to Side Plates of Axle Weldments; Typical 16 Places. D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-11.
SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes 1. 2. 3. Spindle Angle Sensor Assembly Steer Cylinder 4. 5. 6. A Apply Loctite #242 B Apply Loctite #271 C Apply Loctite #222 D Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut Steer Cylinder Pivot Pin King Pin Axle Figure 3-12.
SECTION 3 - CHASSIS & TURNTABLE 3.9 OSCILLATING AXLE SYSTEM The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground when traveling on rough terrain. The oscillating axle also incorporates two lockout cylinders connected between the frame and the axle. The lockout cylinders permit axle oscillation when the boom is in the transport position and drive is commanded.
SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position. The front axles will oscillate when the boom is in the transport position (i.e. when the boom is less than 15° above horizontal and not extended beyond 12" [30.4 cm] on the1350SJP or 24" [60.9 cm] on the 1200SJP) and drive is selected. 12. Drive machine off of block and ramp back onto the level surface. 13.
SECTION 3 - CHASSIS & TURNTABLE 3.11 DRIVE HUB (PRIOR TO S/N 100131) The final drive consists of two planetary stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load distribution. All torque transmitting components are made of forged quenched and tempered high-alloy steels. External gears are carburized. Precision roller bearings support the sprocket or wheel loads. A shaft seal protects the unit against contamination.
SECTION 3 - CHASSIS & TURNTABLE Assembly of First Stage Planetary Assembly (7) 1. Pre-freeze planet pins (5) and install into planet carrier (7). 2. Install planet carrier (7) together with planet pins (5) on sun gear (3), and install snap ring (16). 3. Put sun gear shaft (43) into sun gear (3). 4. Pre-heat stay rings (17) and install onto planet pins (5). 5. Pre-heat cylindrical roller bearings (10) and install onto planet pins (5) and fix bearings with snap rings (14).
Figure 3-13.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Planet Gear Planet Gear Sun Gear Shaft Nut Planet Pin Not Used Planet Carrier Cover Thrust Button Roller Bearing Roller Bearing Ball Bearing Hex Bolt Snap Ring Snap Ring 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 3121142 – JLG Lift – 31. 32. 33. 34. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. Not Used Not Used O-ring thru 40.
SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE HUB - BONFIGLIOLI (S/N 100128 TO PRESENT) Installation of the Wheel Drive on the Machine NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Section 3.13, Drive Hub - Reggiana Riduttori (S/N 134389 to Present). Do not use different hubs on the same machine. Product Identification 1. Clean the mating surfaces from oils or paint and fit the wheel drive on the machine frame. 2.
SECTION 3 - CHASSIS & TURNTABLE 5. Make sure that the oil temperature does not exceed values listed previously. After having finished running-in the gearbox, follow the steps given below. 6. Connecting the Brake The gearbox is fitted with a negative multi disk safety brake with hydraulic control release (parking brake). For information regarding the characteristics of the brake refer to the installation drawing. Check that there are no oil leaks. If leaks are present, fix them before proceeding.
SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5..........................Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..........Brake port Figure 3-16.
SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade Ambient temperature Oil viscosity -20°C / +30°C SAE 80W/90 Manufacturer Oil Brand SHELL SPIRAX HD SPIRAX HD AGIP ROTRA MP ROTRA MP ARAL GETRIEBEOL HYP GETRIEBEOL HYP BP-MACH HYPOGEAR EP HYPOGEAR EP CASTROL HYPOY HYPOY CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT ELF TRANSELF B TRANSELF B ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP I.P.
SECTION 3 - CHASSIS & TURNTABLE 3. Take out the cap nut (5). 4. Turn the cap nut (5) upside down. As result the pin (3) will be pushed inside in order to permit disengagement of the gearbox. 5. Rotate the cap nut (5). THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. Figure 3-17. Gearbox engaged 1. 2. 3-24 Unscrew the 2 socket head screws M8x16 (4), grade 8.8, of the end cover (7) with a male hex head wrench. Rotate the cap nut (5).
SECTION 3 - CHASSIS & TURNTABLE 6. Tighten the 2 socket head screws M8x16 (4) with a male hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. Should irregularities in function arise, it will be necessary to consult the troubleshooting checklist to find the most adequate solution. If unsuccessful, it may be necessary to partially or completely disassemble the gearbox. Table 3-4.
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting The following table is provided to help locate problems in the gearbox. Table 3-5.
SECTION 3 - CHASSIS & TURNTABLE 1. Install the special tool (6689960310) on the flanged hub (31) and turn the screw until it compresses the springs (45). 2. Remove the circlip (47) and remove the special tool. 3. Remove the spring retainer disc (46). 3121142 – JLG Lift – 4. Mark the position of the springs (45) as a reference for the reassembly. 5. Remove the springs (45) from their seats in the brake piston (44). 6.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Screw O-ring Pin Screw Cap Nut Oil Plug End Cover Pad O-ring 1st Stage Sun Gear 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Elastic Ring Washers Spring Splined Shaft Disengagement Shaft 1st Reduction Assembly 2nd Stage Sun Gear 2nd Reduction Assembly Circlip 3rd Reduction Assembly 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Spacer Ring Nut Gearbox Housing Bearing Spacer Spacer O-ring Spacer Half Seal Seal Ring 31. 32. 33. 34. 35. 36. 37. 38. 39.
SECTION 3 - CHASSIS & TURNTABLE 7. By using a puller remove, at the same time, the brake piston (44), the spacer (39) and the brake shaft (35). 8. Remove the spacer (39) from the brake piston (44). 9. Remove the internal O-Ring seal (41) and the backup ring (40) from their seat in the spacer (39). 3121142 – JLG Lift – 10. Remove the external O-Ring seal (38) and the backup ring (37) from their seat in the spacer (39). 11.
SECTION 3 - CHASSIS & TURNTABLE 13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the splined shaft (14). 14. Place the disengagement shaft kit (15) inside the special tool (6689960240). 17. Remove the special tool and remove the spring (13) and the washers (12). Tighten the 2 screws M5x16, grade 8.8, of the cover by a torque wrench to 18.4 ft.lbs. (25 Nm). 18. Turn the gearbox upside down and unscrew the 2 screws M8x16 (4), grade 8.
SECTION 3 - CHASSIS & TURNTABLE 19. Remove the cap nut (5). 20. Remove the pin (3). 21. 22. Unscrew the draining-filling-level oil plugs (6) by a male hex head wrench. 23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the end cover (7). 24. Remove the end cover (7). Remove the O-ring seal (2) from its seat in the end cover (7).
SECTION 3 - CHASSIS & TURNTABLE 25. Remove the O-ring seal (9) from its seat in the end cover (7). 26. Remove the 1st stage sun gear (10). 27. Remove the 1st reduction assembly (16). 3-32 28. Remove the 2nd stage sun gear (17). 29. Remove the 2nd reduction assembly (18). 30. By using pliers remove the circlips (19) from their seats in the flanged hub's pins (31).
SECTION 3 - CHASSIS & TURNTABLE 31. By using a puller remove the planet assemblies of the 3rd reduction (20). 34. By using a tackle place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 32. Remove the spacer (21) from their seats in the pins of the flanged hub (31). 35. By using the torque multiplier (ATZ.09.016.0) loosen the ring nut (22).
SECTION 3 - CHASSIS & TURNTABLE 37. By using a puller and a metal stopper, remove the flanged hub (31) from the gearbox housing (23). 40. By using a screwdriver, remove the 1st half-seal (29) from the flanged hub (31). 38. By using a tackle remove the gearbox housing (23) from the flanged hub (31). 41. By using a screwdriver, remove the 2nd half-seal (29) from the gearbox housing (23). 39. Remove the seal ring (30) from its seat in the flanged hub (31).
SECTION 3 - CHASSIS & TURNTABLE 4. When reassembling a part always replace all the seals involved. Add some grease on the seats and on the new seals to make reassembly easier. 5. Replace all the damaged parts with original spare parts. c. Carefully clean the lapped surface (D) of metal rings (E) and remove dust or fingerprints. Then lubricate them with a thin oil film, taking care not to oil the other components. 2. Assemble the half seal (29) on the tool (6689960300). 3.
SECTION 3 - CHASSIS & TURNTABLE 4. Using the same tool (6689960300), assemble the 2nd half seal (29) on the flanged hub (31). 5. Carefully clean the metallic faces of the lifetime seal (29) and lube the surfaces with oil. 7. Apply grease TECNOLUBE SEAL GS730 on the seal ring (30). AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29) 8. 6. 3-36 By using a hoist, place the gearbox housing (23) on the flanged hub (31). Insert the seal ring (30) in its seat in the flanged hub (31).
SECTION 3 - CHASSIS & TURNTABLE 9. By using a press and a metallic stopper, push the gearbox housing (23) against the shoulder on the flanged hub (31) until assembling of the unit is complete. 11. By using the mutiplier (ATZ.09.016.0), tighten the ring nut (22), using a torque wrench with an input multiplier torque of 71 ± 3 ft.lbs.(96,5 ± 4, 5 Nm) corresponding to an output multiplier torque of 3688 ± 184 ft.lbs. (5000 ± 250 Nm).
SECTION 3 - CHASSIS & TURNTABLE 13. Assemble correctly the spacers (21) on the pins of the flanged hub (31). 16. By using pliers, assemble the circlips (19) in the flanged hub pin seats (31). 14. Place the 5 planet assemblies of the 3rd reduction (20) in the flanged hub's pin (31). 17. Assemble the 2nd reduction assembly (18). 18. Insert the 2nd stage sun gear (17). 15.
SECTION 3 - CHASSIS & TURNTABLE 19. Assemble the 1st reduction assembly (16). 22. Place the end cover (7) on the gearbox housing (23). 20. Insert the 1st stage sun gear (10). 23. Tighten the 10 socket head screws M10x25 (1),grade 12,9, by a torque wrench at 62.7 ft.lbs. torque (85 Nm). 21. Assemble the O-ring seal (9) into its seat in the end cover (7). 24. Insert the plugs (6) into the oil draining-filling holes of the end cover (7). Torque the plugs to 52 ± 7 ft.lbs. (70±10 Nm).
SECTION 3 - CHASSIS & TURNTABLE 25. Assemble the O-ring seal (2) into its seat in the end cover (7). 28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. (25 Nm). 26. Protect the seat and the pin (3) with grease type MOLYKOTE G6000. Wait 15 minutes for it to completely dry. Insert the pin (3) in its seat in the end cover (7). 29. Insert the 1st washer (12) in the splined shaft (14). 30. Insert the spring (13) in the splined shaft (14). 27. 3-40 Assemble the cap nut (5).
SECTION 3 - CHASSIS & TURNTABLE 31. Insert the splined shaft (14) in the equipment (6689960240). 32. Insert the 2nd washer (12) correctly in the splined shaft (14). 33. 34. By using pliers, assemble the elastic ring (11) into its seat in the splined shaft (14). 35. Insert the disengagement shaft kit (15) in the flanged hub (31). Torque the 2 screws M5x16, grade 8.8, of the cover to 18.4 ft.lbs. (25 Nm).
SECTION 3 - CHASSIS & TURNTABLE 36. By using pliers assemble the circlip (36) into its seat in the brake shaft (35). 37. Turn the gearbox upside down and assemble the brake shaft (35) inside the flanged hub (31). 38. 3-42 Assemble the brake discs package according to the following order: first, insert one sintered bronze disc with external teeth (33). 39. Then insert an internally toothed steel disc (32). Repeat the operation until all 5 sintered bronze discs and 4 steel discs have been assembled.
SECTION 3 - CHASSIS & TURNTABLE 42. Insert the spacer (39) inside the flanged hub (31), paying attention not to damage the seals already fitted. 43. By using a rubber hammer and a metal stopper push the spacer (39) against the flanged hub (31), paying attention not to damage the seals already fitted. 3121142 44. Lube the seal seats into the flanged hub (31) and assemble the O-ring seal (42) and the backup ring (43).
SECTION 3 - CHASSIS & TURNTABLE 45. Insert the brake piston (44) inside the flanged hub (31), paying attention not to damage the seals already fitted. 47. Insert the springs (45) into the holes in the brake piston (44) marked previously. 46. By using a rubber hammer and a metal stopper push the brake piston (44) against the flanged hub (31), paying attention not to damage the seals already fitted. 48. Insert the spring retainer disc (46).
SECTION 3 - CHASSIS & TURNTABLE 49. Install the special tool (6689960310) on the flanged hub (31) and turn the screw until it compresses the springs (45). Final Test and Reinstallation Check the product by remounting it to the machine. Check the function of the drive hub following all the checks shown in Startup and Running In. If work on the brake was undertaken, it is important to check that there are no oil leaks. Follow the procedure below: 50. 1.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-20.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-21.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-22.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-23.
SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE HUB - REGGIANA RIDUTTORI (S/N 134389 TO PRESENT) 8. Wrench for M6, M8, M10 socket head screws and 1/4"G plug. 9. Socket wrench for M6 hexagonal screw. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Section 3.12, Drive Hub - Bonfiglioli (S/N 100128 to Present). Do not use different hubs on the same machine.
5x45° Ø210 Ø130 Ø30 25 SECTION 3 - CHASSIS & TURNTABLE M- 1321 LOCTITE 2701 110 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-26. Bearing Spacer Mountng CO16117 Figure 3-27.
SECTION 3 - CHASSIS & TURNTABLE M- 1316 35 Ø34 35 45° A 70 Ø11 20 Ø230 A 10 216.5 12 M- 1317 Ø 50 50 35 45° 70 M- 1317 10 45° 45° M- 1317 8 N° 4 R 35 10 10 30 M- 1020 10x45° 70 Ø17 11 38 55 Ø16 90 60 M- 1316 M- 1317 M- 1317 M- 1317 Figure 3-30. Anti-rotation Block 16 n° 8 Routing to 45° Ø205 Figure 3-28. Wrench For Ring Nut M- 1126 Ø20 Ø80 32 n° 12 Hole to 30° Ø6.5 20 10.5 Ø20 H7 (+0.021 ) n°12 Hole to 30° 0 30 T.U.
SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-32.
SECTION 3 - CHASSIS & TURNTABLE M- 1548 Ø93.5 Ø48 Ø46 +0.1 2.5x15° Ø40.5 Ø46 80 70 Ø13.5 5 Ø8.5 50 20 5 8.5 9 Ø20+0.2 5 M- 1546 Ø105 M- 1547 0 Ø20 -0.1 88.5 3.5 t.u. 12 Ø39.5 M8 VTCEI M8X16 n°1 Figure 3-33.
SECTION 3 - CHASSIS & TURNTABLE Disassembly 1. 2. 3. Release the screws from the release cover and pull the pin out. 4. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring. 5. Pull the reduction gears out. Remove the plugs and pour the lubricant in a container. Release the screws to disassemble the motor flange taking care not to damage the O-Ring.
Figure 3-34.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Screw Motor Support O-ring Inner Retention Ring Brake Spring Spacer Brake Spring Brake Piston Parbak O-ring O-ring Parbak Sintered Brake Disc 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 3121142 – JLG Lift – 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Tapered Roller Bearing Bearing Support Ring Nut Sphere Screw Pinion Reduction Gears Outer Retention Ring Pinion Reduction Gears Outer Retention Ring Pinion Figure 3-35.
SECTION 3 - CHASSIS & TURNTABLE 9. Loosen the M6x6 socket headless screws and also remove the 3/16" balls. 6. Loosen the M10x25 flathead socket screws and remove the planetary ring without damaging the O-Ring. 7. Remove the release joint together with the spring. 10. Loosen the ring nut using the special wrench. 8. Disassemble the Ø40 outer snap rings and using an extractor remove the planetary gears from the spindle pins. 11. Remove the hub support together with the roller bearing inner track.
SECTION 3 - CHASSIS & TURNTABLE 12. 13. 14. Disassemble the Ø160 inner snap ring and pull the spring holder spacer out. Remove the springs and using a compressed air jet in the brake control hole pull the piston out of the spindle. Assembly 1. Make sure all the component parts of the wheel gear are devoid of burrs, machining residues and that they are correctly washed. 2. Fit the ball bearing in the input shaft and lock with a Ø40 outer snap ring. 3.
SECTION 3 - CHASSIS & TURNTABLE 4. Fit the brake sealing rings O-Ring and PARBAK (lubricated with grease) in the respective spindle seats. Place the brake discs making sure to centre them on the spindle and on the input shaft. 5. Insert the brake piston and place the springs into the piston holes. Close the brake fitting the spring holder plate, then lock with the Ø160 inner snap ring. Check the brake leakage, if any, as well as the static torque and minimum opening pressure. 6.
SECTION 3 - CHASSIS & TURNTABLE 9. Now check the unit roll torque and proceed in the following order: 10. 7.) By keeping the spindle locked, apply a setting preload by tightening the ring nut at 40daNm, turn completely the hub support twice using the special wrench to recover any bearing cage misalignments. Release and tighten the ring nut at the final torque of 30daNm (alternate tightening and some setting turns). Check the roll torque with seal which must be within 1÷1,5 daNm. 11.
SECTION 3 - CHASSIS & TURNTABLE dle pins. Lock with a ÿ40 outer snap ring. Lubricate the bearings. 14. 3-62 15. Place the hub onto the support making the two holes coincide for tightening the M10x25 flathead socket screws at the torque of 5daNm. 16. Fit the reduction gears and the pinion in the unit. Using a marking pen, make a mark between the snap ring and the bearing. Fit the greased spring and the release joint. Use grease to fit the O-Ring 2-275 in the hub support seat.
SECTION 3 - CHASSIS & TURNTABLE 17. Prepare the closing cover fitting the O-ring 5-582 suitably greased and lock it with the shimming ring. Lubricate the bearings. 18. Fit the O-Ring 2-177 suitably greased, mount the cover locking it with the BR250 ring. 3121142 – JLG Lift – 19. Fit the O-Ring 2-163 suitably greased, onto the motor coupling flange S-D LC/KC. Mount the flange on the spindle with 6 M8x25 socket cap screws at the torque of 2.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. Swing Drive Inner Race Bearing Bolt Swing Bearing 4. 5. 6. Outer Race Bearing Bolt Turntable Lock Pin Remote Bearing Lubrication Fittings Figure 3-36.
SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING DRIVE Tightening and Torquing Bolts Roll and Leak Testing Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 1. Place unit on bench with the motor end up. 2. Remove O-ring Plug (1J) and drain the oil from the gearbox. 3. Remove Hydraulic Tubing Assembly (35) by loosening fittings on both ends of tube with a wrench. 1J. 10. 21. 24. 25. 26. O-Ring Plug Hydraulic Motor Plug ID Plate Drive Screw Hydraulic Brake 32. 33. 34. 35. 36. 4.
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 1. With unit resting on bench with Motor (10) end up, loosen Hex Bolts (29) and remove Lift Lugs (28) from the Motor (10). 2. Pull Motor (10) straight up and remove Motor (10) from Brake (26). 10. Hydraulic Motor 26. Hydraulic Brake 27. O-Ring 3. Remove Gasket (31) from between Brake (26) and Motor (10). 4. Remove Brake (26) from Main Torque-Hub Assembly and dump oil out of Brake (26). 5.
SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 1. 2. With the unit resting on the Output Shaft (Pinion) (1A), remove the eight Bolts (17), four Shoulder Bolts (18) and four Lock Washers (19) from the Input Cover (6). Thread either 1/2-13 UNC eye bolts or motor mounting Bolts (29) into threaded holes in Input Cover (6) and pull Input Cover (6) off on the main assembly. 3. Remove O-ring (5) from between Input Cover (6) and Ring Gear (4). 4. Remove Thrust Washer (8) from end of Sun Gear (13). 5.
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 1. Using retaining ring pliers, remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard. EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 2. Remove Thrust Washer (1H). 3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G). 4. Remove the Bearing Cone (1F) from the Housing (1G). 5.
SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which holds the Planet Shaft (3E) in the Carrier (3A) down into the Planet Shaft (3E) until it bottoms. NOTE: Make sure that the Roll Pin has bottomed. Otherwise, damage to the carrier could occur when the Planet Shaft is removed. 2. 3. Slide the Planet Gear (3F), two Ball-Indented Thrust Washers (3H) and the two Thrust Washers (3B) out of the Carrier (3A). 4.
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly 1. Press Bearing Cone (1D) onto Shaft (1A). 2. Press Bearing Cup (1C) into Housing (1G), take care to insure cup starts square with bore of Hub (1G). 3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing 1G). 4. Press or tap Seal (1B) into the counterbore of Housing (1G) to the point where it becomes flush with the Housing (1G) face. Care should be taken to insure Seal (1B) is being correctly installed (smooth face up). 5.
SECTION 3 - CHASSIS & TURNTABLE 8. Slide the second Thrust Washer (3E) between the Cluster Gear (3F) and the Carrier (3A) with the tang of the washer located in the cast slot of the Carrier (3A). Slide ball-indented Thrust Washer (3H) onto the end of the Planet Shaft with the indents against the second thrust Washer. Finish sliding the Planet Shaft (3E) through the Thrust Washers (3H) & (3B) and into the Carrier (3A). 9.
SECTION 3 - CHASSIS & TURNTABLE 3A. 3B. 3C. 3D. Carrier Tanged Thrust Washer Needle Bearing Thrust Washer 3E. 3F. 3G. 3H. Planet Shaft Cluster Gear Roll Pin Ball Indented Washer Figure 3-43.
SECTION 3 - CHASSIS & TURNTABLE 9. Main Assembly 1. With the Hub Shaft Sub-Assembly resting on the Shaft (1A) install Internal Gear (2). The spline of the Internal Gear (2) bore will mesh with the spline of the Output Shaft (1A). 2. Inspect the location of the Internal Gear (2) on the Output Shaft (1A). The portion of the Output Shaft (1A), which does not have full spline, should protrude through the Internal Gear (2) bore. 3. 4. 5.
SECTION 3 - CHASSIS & TURNTABLE 2. Internal Gear 4. Ring Gear 5. O-Ring 6. Input Cover 8. Hex Bolt 13. Sun Gear 15. 16. 17. 18. 19. 20. Thrust Bearing Thrust Washer Hex Bolt Shoulder Bolt Lockwasher Pipe Plug Figure 3-44.
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly 1. Place O-ring (27) onto end of Brake (26) and locate brake into pilot of cover. 2. Place Gasket (31) onto the brake face and line up the holes. 3. Place Motor (10) into Brake pilot against the Gasket (31). 10. Hydraulic Motor 26. Hydraulic Brake 27. O-Ring 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble Hex Bolts (29) with Lift Lugs through the Motor (10) and Brake (26) against the motor flange. Torque to 35 ft-lbs. 5.
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly 1. Lay assembly down with motor ports facing up. Remove the two plastic plugs in the motor ports, being careful not to loose the O-ring in each port. Assemble the Motor control Valve (32) onto the Motor (10) with Bolt (34) and Lock Washers (33). Torque Bolts (33) 23 to 27 ft-lbs. (32 to 38 Nm). 4. Assemble Tube (35) into Elbow Fittings (36) and torque 13 to 15 ft-lbs. (18 to 21 Nm). 5.
SECTION 3 - CHASSIS & TURNTABLE To check brake release, connect an appropriate hydraulic pressure supply set to the required level up to a maximum of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. 3.15 SWING BRAKE Pre-Installation Checks MECHANICAL Check, That in the handling prior to assembly, the mounting features and other parts of the brake are undamaged. Ensure that the shaft to which the brake is mounted are clean and free from burrs and swellings.
SECTION 3 - CHASSIS & TURNTABLE Installation 5. Remove 2-off dowel pins (19). Position 1-off gasket (5) over male pilot on brake housing (4). Locate brake shaft (1) and secure brake in position using 2-off 1/2” UNC mounting bolts in the through mounting (fixing) holes provided. Connect hydraulic pressure supply to brake pressure inlet port. Ensure that the hydraulic pressure is set to the required level up to a maximum of 3000 psi (200 bar) and check that the brake disengages and re-engages correctly.
SECTION 3 - CHASSIS & TURNTABLE 2. 3. Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing (2) bearing recess adjacent to shoulder. Apply complete coverage of Loctite 641 to outside diameter of bearing (10) and assemble fully in housing (2), retaining with internal retaining ring (11). Remove excess adhesive with clean cloth. Press shaft (1) through bearing (10), ensuring bearing inner ring is adequately supported.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Brake Shaft Housing Inner Friction Plate Pressure Plate Gasket Outer Plate Gasket 8. 9. 10. 11. 12. 13. 14. Cylinder Piston Deep Groove Ball Bearing Internal Retaining Ring Rotary Shaft Seal Socket Head Cap Screw Shakeproof Washer 15. O-Ring 16. Backing Ring 17. O-Ring 18. Backing Ring 19. Dowel Pin 20. Hexagon Plug 21. Plastic Plug 21A. Socket Pressure Plug Figure 3-50.
SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING MOTOR Disassembly and inspection 1. Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable. 3. Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head.
SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 2. End Cover 3. Seal Ring-Commutator 4. Seal Ring 5. Commutator Ring 6. Commutator Ring 7. Manifold 8. Rotor Set 8A. Rotor 5. 8B. Stator or Stator Vane 15. Thrust Bearing 8C. Vane 16. Seal 8D. Stator Half 17. Back-up Washer 9. Wear Plate 18. Housing 10. Drive Link 18A. O-Ring 11. Not Used 19. Bearing/Bushing, Outer 12. Coupling Shaft 20. Dirt & Water Seal 13. Bearing/Bushing, Inner 21. Plug 14. Thrust Washer Figure 3-51.
SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal.
SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set. 10. Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces.
SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing (18). 13. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 14.
SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required. 18. Remove seal (16) and back up washer (17) from Small Frame, housing (18). Discard both. 20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion.
SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the Torqlink™ is completed. NOTE: The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings. 22.
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most OEM parts distributors or Parker approved Torqlink™ distributors. (Contact your local dealer for availability).
SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19). 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.
SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 5. On the Torqlinks™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2. 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.
SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures.The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/ 16-24 UNF 2A bolts as required that are over 0.5 inch (12.
SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). NOTE: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down.
SECTION 3 - CHASSIS & TURNTABLE 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 17. Assemble the commutator ring (6) over alignment studs onto the manifold. 18. 3-94 19. If shuttle valve components items #21, were removed from the end cover (2) turn a plug (21), loosely into one end of the valve cavity in the end cover. A 3/16 inch Allen wrench is required. 20.
SECTION 3 - CHASSIS & TURNTABLE NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. lbs.
SECTION 3 - CHASSIS & TURNTABLE 4. One Piece Stator Construction A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures. 1. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqlink™ assembly procedures 1 through 13. Be sure the seal ring is in place.
SECTION 3 - CHASSIS & TURNTABLE 3.17 PROCEDURE FOR SETTING GEAR BACKLASH 1. Set backlash to 0.010 to 0.015" using the following procedure. 2. Place shim (JLG p/n 4071041) between pinion and bearing on the bearing high spot. The bearing high spot should be stamped with an "X" on the surface below the teeth and marked with yellow paint in the tooth space. 3. Torque the shoulder screw (shown below) to 660 footpounds (896 Nm) with Loctite #271. 4. Remove the turntable lock pin.
SECTION 3 - CHASSIS & TURNTABLE 8. Tighten the jam nut (shown below) with Loctite #271. The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API Service Classification GL-5 Extreme Pressure Gear Lube. Fill to cover the ring gear. 1.195 IN. (30.35 mm) TOP OF HOUSING TO TOP OF RING GEAR. TO BE FILLED TO COVER RING GEAR. 9. 10. Torque the capscrews shown in step 5 to 660 footpounds (896 Nm). Remove shim and discard. 3.18 SWING DRIVE LUBRICATION Figure 3-53.
SECTION 3 - CHASSIS & TURNTABLE c. Ensure that the 0.0015” feeler gauge will not penetrate under the bolt head to the bolt shank. 3.19 SWING BEARING d. Swing the turntable 90 degrees, and check some selected bolts at the new position. Turntable Bearing Mounting Bolt Condition Check e. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants. THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT.
SECTION 3 - CHASSIS & TURNTABLE BOOM FULLY ELEVATED DIAL INDICATOR MEASURING POINT FEELER GAUGE MEASURING POINT Figure 3-54.
3121142 – JLG Lift – Figure 3-55.
SECTION 3 - CHASSIS & TURNTABLE 3. If the measurement is greater than 0.094 in. (2.387 mm), the swing bearing should be replaced. 4. If the measurement is less than 0.094 in. (2.387 mm), and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following: a. Metal particles in the grease. b. Increased drive power required. c. Noise. d. Rough rotation. 5. Figure 3-56. Swing Bolt Feeler Gauge Check Swing Bearing Removal Wear Tolerance 1.
3121142 – JLG Lift – CENTER OF GRAVITY 18” (45 cm)-1200SJP C L ROTATION 13” (33 cm)-1350SJP Figure 3-57. Swing Bearing Removal 1350SJP Upperstructure - 30,250 lbs. (13,721 kg) 1200SJP Upperstructure - 26,150 lbs.
SECTION 3 - CHASSIS & TURNTABLE 5. At the rear of the main valve, remove the lift hose from port #4. Immediately cap the line and port. Swing Bearing Installation NOTE: The swing bearing weighs approximately 300 lbs. (136 kg). BACK OF VALVE 1. Using suitable lifting equipment, carefully lower the swing bearing into position on the frame. Ensure the scribed line of the outer race of the bearing aligns with the scribed line on the frame.
SECTION 3 - CHASSIS & TURNTABLE 3. Refer to the Torque Sequence diagram as shown in Figure 3-58., Swing Bearing Torque Sequence. Spray a light coat of Safety Solvent 13 on the new bearing bolts. Then apply a light coating of Loctite #271 to the new bearing bolts, and install the bolts and washers through the frame and outer race of the bearing. Tighten the bolts to an initial torque of 190 ft. lbs. (258 Nm) w/Loctite. 4. Remove the lifting equipment from the bearing. 5.
SECTION 3 - CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-58. Swing Bearing Torque Sequence Swing Speed Proportioning uses the boom length and angle sensors to improve the comfort, speed and control of the turntable swing function. Turntable swing speed is increased as the distance of the platform to the center of rotation is decreased. This results in approximately constant platform speeds regardless of boom position.
SECTION 3 - CHASSIS & TURNTABLE 3.22 ROTARY COUPLING Use the following procedure to for installing the seal kit. 1. Remove snap ring (7) from end. 2. Remove thrust ring (3) from same end. 3. Remove center body (1) from housing (3). 4. Cut off old seals (2,3,5). 5. Assemble lip seals (2) in direction shown in Figure 3-59., Rotary Coupling Seal Installation. 6. Reassemble O-ring (4). 7. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F (149° C). 8. Assemble cap seals over O-rings 9.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. Center Body Seal Housing O-ring 5. 6. 7. Seal Thrust Ring Snap Ring Figure 3-60.
SECTION 3 - CHASSIS & TURNTABLE 5 1,2 6 8 8 4 1,9 8 3 5A 5B 1. 2. 3. 4. 5. 5A. Loctite #242 Bolt Bolt Swivel Bracket Rotary Coupling & Collector Ring Assembly Rotary Coupling 5B. 6. 7. 8. 9. Rotary Circuit Contactor Locknut Not Used Flatwasher Nut Figure 3-61.
SECTION 3 - CHASSIS & TURNTABLE 6 2 1 6 4 7 1 5 4 5 3 1 1 4 2 3 2 1 2 3 3 2 5 7 6 7 7 Figure 3-62.
SECTION 3 - CHASSIS & TURNTABLE Every 500 hours Table 3-6. Coupling Port Information Table Port Outlets No.
SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER. The circuit breaker protects the generator windings from overload. If the circuit breaker opens, generator output stops. If the circuit breaker continues to open, check for faulty equipment connected to the platform receptacles. Refer to Figure 3-63.
SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings 2 3 Acceptable Unacceptable Brushes must ride completely on slip rings 1 1/4 in (6 mm) Or Less - Replace 2 7/16 in - 1/2 in (11 - 12 mm) New 3 1. 2. 3. Brush Holder Assembly Brushes Slip Rings Figure 3-63.
SECTION 3 - CHASSIS & TURNTABLE 3.24 AUXILIARY POWER SYSTEM The auxiliary power system is intended as a secondary means of moving the boom in the event of primary power loss. This system uses an electric motor/pump unit powered by a 12V battery capable of operating all functions except drive, controlled arc, controlled boom angle, and envelope tracking. During lift up or down functions, no other functions are permitted and during lift up functions, automatic platform leveling is not active.
SECTION 3 - CHASSIS & TURNTABLE HYDRAULIC OIL TANK HEATER CABLE BATTERY HEATER CABLE BATTERY HEATER CABLE BATTERY REF AUX PUMP BATTERY HEATER BATTERY HEATER VIEW A-A A B A B TANK HEATER VIEW B-B Figure 3-65.
SECTION 3 - CHASSIS & TURNTABLE Check the oil level, and if necessary, top the oil level up to the MAX mark with an approved grade and type of oil as outlined in the engine manufacturer’s operator’s manual. Refer to Figure 3-66., Deutz Engine Dipstick. 3.25 COLD WEATHER PACKAGE As an option, a cold weather package is available to allow the machine to be operated in lower temperatures. The package consists of battery heaters, a hydraulic tank heater, Exxon Univis hydraulic oil, and diesel fuel conditioner.
SECTION 3 - CHASSIS & TURNTABLE 5. Open the oil drain valve. Changing the Oil Filter WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING. 1. Wipe the area around the filter to clean any dirt from the area. 2. Using a suitable oil filter removal tool, loosen the lube oil filter cartridge and spin off. 3. Catch any escaping oil. 4. Clean any dirt from the filter carrier sealing surface. 5. Lightly oil the rubber gasket on the new oil filter.
SECTION 3 - CHASSIS & TURNTABLE 6. Manually screw in the new filter until the gasket is flush. 8. Open the fuel shut-off valve. 9. Check for leaks. Cleaning the Fuel Strainer 7. Tighten the filter another half-turn. 8. Check the oil level. 9. Check the oil pressure. 10. Check the oil filter cartridge and make sure there are no leaks. Replacing the Fuel Filter WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN FLAMES OR SPARKS IN THE AREA.
SECTION 3 - CHASSIS & TURNTABLE 3.27 DEUTZ EMR 2 (S/N 87579 TO PRESENT) NOTE: S/N 87532 also incorporates EMR2. S/N 87765 incorporates old Engine controls. The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are connected by means of separate cable harnesses to the EMR control unit.
SECTION 3 - CHASSIS & TURNTABLE CONTROL ROD POSITION SENSOR/ACTUATOR COOLANT TEMPERATURE SENSOR POWER SUPPLY FLYWHEEL SPEED SENSOR JLG SYSTEM HANDLES ENGINE START/STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE & FAULT REPORTING. OIL PRESSURE SENSOR Figure 3-68.
3121142 – JLG Lift – Connect Laptop to use Deutz Diagnostic Software Contact Deutz Service Department NO Does the engine operate correctly? NO Are there any faults listed since the power was cycled? Connect JLG Analyzer YES Does the machine have fuel and a charged battery? Deutz EMR2; Fails to Start/ Runs Abnormally NO YES YES NO Does the diagnostic software indicate a problem? Does the fault indicate a Deutz fault code number? NO Does the fault indicate the engine module is not detected?
Figure 3-70.
Figure 3-71.
Figure 3-72.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-73.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-74.
Figure 3-75.
Figure 3-76.
Figure 3-77.
Figure 3-78.
Figure 3-79.
SECTION 3 - CHASSIS & TURNTABLE The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20 weight-%. The US bio-diesel used for the mixture must comply with the ASTM D6751-07a (B100) standard. 3.28 BIO FUEL IN DEUTZ ENGINES General Use of bio fuels is permitted for the compact engines made by DEUTZ. Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ compact engines.
SECTION 3 - CHASSIS & TURNTABLE PREVENTIVE MEASURES PLANT OIL • Keep the storage tank clean, regular cleaning of the tank by specialist companies PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPERATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH VISCOSITY, POOR EVAPORATION BEHAVIOR.
SECTION 3 - CHASSIS & TURNTABLE 3.29 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS This section defines the diagnostics and recommended troubleshooting procedures associated with the engine control module (ECM) on the CAT 3.4 engine. This section is organized in the following manner: 1st page of Diagnostic Information for a Given Fault (See Figure 3-80.) then: 2nd Page of Diagnostic Information for a Given Fault (See Figure 3-81.
SECTION 3 - CHASSIS & TURNTABLE DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Yes Troubleshooting flow chart No Figure 3-81.
SECTION 3 - CHASSIS & TURNTABLE List of Abbreviations in this Section AL Adaptive Learn LED Light Emitting Diode BP Barometric Pressure LPG Liquefied Propane Gas CAN Controller Area Network MAP Manifold Absolute Pressure CCP CAN Calibration Protocol MGCP Marine Global Control Platform CHT Cylinder Head Temperature μP Microprocessor CL Closed Loop Mfg Manufacture CNG Compressed Natural Gas MIL Malfunction Indicator Lamp DBW Drive-By-Wire NG Natural Gas DGC Diesel Governor Co
SECTION 3 - CHASSIS & TURNTABLE FP Fuel Pressure UEGO Universal Exhaust Gas Oxygen Sensor (also called wide-range EGO) FPP Foot Pedal Position VDC Voltage, Direct Current FRP Fuel Rail Pressure VR Variable Reluctance FRT Fuel Rail Temperature Vsw Switched, Ignition Voltage FSS Fault Snapshot WGP Waste-Gate Pressure FT Fuel Temperature GCP Global Control Platform HDGCP Heavy-Duty Global Control Platform (On-Road Heavy-Duty) HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S) HO2
SECTION 3 - CHASSIS & TURNTABLE Diagnostic Trouble Codes The numeric diagnostic trouble codes assigned to the faults in this section are cross-referenced to SAE’s "Recommended Practice for Diagnostic Trouble Code Definitions" (SAE J2012). While these codes are recommended, the manufacturer may define their own codes by assigning a new number to the flash code in the diagnostic calibration. This will assign both the DTC as displayed in EDIS as well as the flash code output on the MIL output pin.
SECTION 3 - CHASSIS & TURNTABLE DTC 116- ECT Higher Than Expected Stage 1 TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor Diagnostic Aids • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have caused "ECT Higher Than Expected 1.
SECTION 3 - CHASSIS & TURNTABLE DTC 117- ECT/CHT Low Voltage TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor • Check Condition-Engine Running • Fault Condition-CHT/ECT sensor voltage less than the limit defined in the diagnostic calibration This fault will set if the signal voltage is less than the limit defined in the diagnostic calibration anytime the engine is running. The limit is generally set to 0.10 VDC.
SECTION 3 - CHASSIS & TURNTABLE · Key On, Engine Running · System Mode = “Running” Does DST display an ECT voltage less the limit defined in calibration? Yes · · · · Key Off Disconnect ECT sensor from harness Key On, Engine Off System Mode = “Stopped” No · Intermittent Problem Yes Does DST display ECT voltage of 4.
SECTION 3 - CHASSIS & TURNTABLE DTC 118- ECT/CHT High Voltage TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor • Check Condition-Engine Running • Fault Condition-CHT/ECT sensor voltage higher than the limit defined in the diagnostic calibration • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp, disable adaptive learn fueling correction during active fault, or any combination thereof as defined in calibration.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-143
SECTION 3 - CHASSIS & TURNTABLE DTC 122- TPS1 Signal Voltage Low 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN • Throttle Position Sensor 1 • Check Condition-Key On, Engine Off • Fault Condition-TPS1 sensor voltage lower than the limit defined in the diagnostic calibration • Corrective Action(s): Sound audible warning or illuminate secondary warning lamp, shutdown engine condition while the engine is cranking or running. The limit is generally set to 4.90 VDC.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-145
SECTION 3 - CHASSIS & TURNTABLE DTC 123- TPS1 Signal Voltage High 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN • Throttle Position Sensor 1 • Check Condition-Key On, Engine Off • Fault Condition-TPS1 sensor voltage higher than the limit defined in the diagnostic calibration • Corrective Action(s): Sound audible warning or illuminate secondary warning lamp, shutdown engine • Non-emissions related fault In the case of a diesel engine, an actuator controls a fuel injection pump,
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-147
SECTION 3 - CHASSIS & TURNTABLE DTC 217- ECT Higher Than Expected 2 TAN/WHITE BLACK/GREEN Diagnostic Aids • Engine Coolant Temperature Sensor • Check Condition-Engine Running • Fault Condition-Engine Coolant Temperature reading or estimate greater than the stage 2 limit when operating at a speed greater than defined in the diagnostic calibration • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp, disable adaptive learn fueling correction during active fault.
SECTION 3 - CHASSIS & TURNTABLE DTC 219- RPM Higher Than Max Allowed Governed Speed 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN • Max Govern Speed Override- Crankshaft Position Sensor Diagnostic Aids • Check Condition-Engine Running NOTE: If any other DTCs are present, diagnose those first.
SECTION 3 - CHASSIS & TURNTABLE DTC 336- Crank Signal Input Noise 2 WHITE/PURPLE PURPLE/WHITE WHITE/PURPLE 1 PURPLE/WHITE • Crankshaft Position sensor • Check Condition- Key On, Engine On • Fault Condition- Electrical noise or irregular crank pattern detected causing x number of crank resynchronization events as defined in the diagnostic calibration • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp and disable adaptive fueling correction for remain
SECTION 3 - CHASSIS & TURNTABLE • Key On, Engine Running • System Mode= “Running” Operate engine at condition that set fault based on fault snapshot Yes No Is crank sensor a VR/ magnetic pick-up? Does DTC 336 reset ? No Check wiring and electrical connections between crankshaft position sensor and ECM Yes Is the wiring OK? Intermittent fault No Repair wireharness Yes Faulty wireharness (twist circuit) No Is wiring between sensor and ECM properly twisted? • Poor system ground • Bad crankshaft p
SECTION 3 - CHASSIS & TURNTABLE DTC 337- Loss of Crank Input Signal 2 WHITE/PURPLE PURPLE/WHITE WHITE/PURPLE 1 PURPLE/WHITE • Crankshaft Position sensor • Check Condition- Key On, Engine On • Fault Condition- Loss of crankshaft position signal while valid camshaft position signals continue for x number of cam pulses as defined in the diagnostic calibration • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp The ECM must see a valid crankshaft positio
SECTION 3 - CHASSIS & TURNTABLE The ECM can be configured to monitor oil pressure through a proportional transducer or through a switch. Oil pressure monitoring is important to prevent engine damage due to low oil pressure resulting in higher friction and lack of lubrication. In addition, high oil pressure can be undesirable because it can cause oil to leak past seals and rings, can be a result of a restriction in the oil flow path, or can be a sign of a malfunctioning oiling system.
SECTION 3 - CHASSIS & TURNTABLE DTC 524- Oil Pressure Low 19 BLACK/GREEN 2 1 BLUE • Engine Oil Pressure • Check Condition- Key on, Engine on • Fault Condition- Engine oil pressure lower than expected while engine has been running for a minimum amount of time while engine speed is above some limit as defined in the diagnostic calibration For systems that use a transducer, this fault sets if the engine oil pressure is less than x psia and engine speed is greater than y RPM after the engine has been runni
SECTION 3 - CHASSIS & TURNTABLE Normally Closed Switch • Key-On, Engine On • System Mode= “Running” • Warm engine at idle to normal operating temperature • Increase RPM above limit set in diagnostic calibration Does DTC 524 reset ? • Key Off • Disconnect harness from Oil Pressure switch • Jumper Oil Pressure signal wire to ground • Clear DTC 524 • Key On, Engine On • System Mode= “Running” • Operate engine et idle for at least one minute • Increase RPM above limit set in diagnostic calibration Yes Does
SECTION 3 - CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low BLACK RED/TAN • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle actuator, power supplies, and other powered devices that the ECM controls.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-157
SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High BLACK RED/TAN • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle acutator, power supplies, and other powered devices that the ECM controls.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-159
SECTION 3 - CHASSIS & TURNTABLE DTC 601- Microprocessor Failure - FLASH ECM Microprocessor RAM • Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-161
SECTION 3 - CHASSIS & TURNTABLE DTC 604- Microprocessor Failure - RAM ECM Microprocessor RAM • Engine Control Module- Random Access Memory • Check Condition- Key on • Fault Condition- Internal ECM microprocessor memory access failure • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle, recommend power derate 2 and low rev limit to reduce possible engine damage and/or overspeed condition
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-163
SECTION 3 - CHASSIS & TURNTABLE DTC 606- Microprocessor Failure - COP ECM Microprocessor RAM • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-165
SECTION 3 - CHASSIS & TURNTABLE DTC 642- 5 Volt External Low Voltage 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN Diagnostic Aids • Engine Control Module • Check Condition- Key on • Fault Condition- ECM 5-volt output is below the acceptable limit • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp • Non-emissions related fault The ECM supplies 5-volt power to sensors, switches, and actuators external to the ECM.
SECTION 3 - CHASSIS & TURNTABLE DTC 643- 5 Volt External High Voltage 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN Diagnostic Aids • Engine Control Module • Check Condition- Key on • Fault Condition- ECM 5-volt output is above the acceptable limit • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp • Non-emissions related fault The ECM supplies 5-volt power to sensors, switches, and actuators external to the ECM.
SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 ECM Microprocessor RAM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
SECTION 3 - CHASSIS & TURNTABLE DTC 1613- Microprocessor Failure - RTI 2 ECM Microprocessor RAM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
SECTION 3 - CHASSIS & TURNTABLE SFC 555- RTI 2 Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Does SFC 555 reset with engine idling? Yes Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-170 – JLG Lift – 3121142
SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 ECM Microprocessor RAM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
SECTION 3 - CHASSIS & TURNTABLE SFC 556- RTI 3 Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 556 reset with engine idling? Are all circuits ok? Yes Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-172 – JLG Lift – 3121142
SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D ECM Microprocessor RAM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
SECTION 3 - CHASSIS & TURNTABLE SFC 513- A/D Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 513 reset with engine idling? Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-174 – JLG Lift – 3121142
SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure - interrupt ECM Microprocessor RAM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
SECTION 3 - CHASSIS & TURNTABLE SFC 512- Invalid Interrupt Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 512 reset with engine idling? Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-176 – JLG Lift – 3121142
SECTION 3 - CHASSIS & TURNTABLE DTC 1625- CAN J1939 Shutdown Request BLUE/RED or PINK BLUE/WHITE Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Fault Condition- ECM has received shutdown message from another CAN device and is shutdown on request. • The ECM has shutdown the engine upon command by a external controller. This is the requested and expected behavior.
SECTION 3 - CHASSIS & TURNTABLE DTC 1626- CAN J1939 Transmit (Tx) Fault BLUE/RED or PINK BLUE/WHITE Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Fault Condition- ECM CAN transceiver transmit error counts greater than the limit defined in the diagnostic calibration (must be < 125 failures) • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp • Non-emissions related fault • Verify that all CAN devices are p
SECTION 3 - CHASSIS & TURNTABLE DTC 1627- CAN J1939 Receive (Rx) Fault BLUE/RED or PINK BLUE/WHITE Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Fault Condition- ECM CAN transceiver receive error counts greater than the limit defined in the diagnostic calibration (must be < 125 failures) • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp • Non-emissions related fault • Verify that all CAN devices are pow
SECTION 3 - CHASSIS & TURNTABLE DTC 1628- CAN Address Conflict Failure BLUE/RED or PINK BLUE/WHITE • CAN device(s) • Check Condition- Key On, Engine on • Fault Condition- two or more devices on the network that contain the same SA • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp • Non-emissions related fault The Controller Area Network serves as a communication portal between intelligent devices.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-181
SECTION 3 - CHASSIS & TURNTABLE DTC 1629- J1939 TSC1 Message Reciept Loss BLUE/RED or PINK BLUE/WHITE Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Running • Fault Condition- ECM is expecting to receive J1939 TSC1 messages and has not received a message for more than n seconds (as defined in the diagnostic calibration). • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp. Govern engine speed at a forced idle.
SECTION 3 - CHASSIS & TURNTABLE DTC 1652- TPS1 Loss of Communications 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN Diagnostic Aids • Throttle Actuator (with serial/digital position feedback) • Check Condition- Key On, Engine Running and/or Stopped • Fault Condition- ECM is expecting to receive throttle position information from the throttle actuator and is not. • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp.
SECTION 3 - CHASSIS & TURNTABLE DTC 2111- Unable to Reach Lower TPS 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN • Throttle Position Sensor • Check Condition-Cranking or Running • Fault Condition-Throttle command is 20% less than throttle position for 200ms or longer • MIL-On during active fault • Engine Shut Down In the case of a diesel engine, an actuator controls a fuel injection pump, directly affecting the fueling level into the cylinders.
SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-185
SECTION 3 - CHASSIS & TURNTABLE DTC 2112- Unable to Reach Higher TPS 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN • Throttle Position Sensor • Check Condition-Cranking or Running • Fault Condition-Throttle command is 20% more than actual throttle position • MIL-On during active fault • Engine Shut Down In the case of a diesel engine, an actuator controls a fuel injection pump, directly affecting the fueling level into the cylinders.
SECTION 3 - CHASSIS & TURNTABLE DTC 9999- Throttle Actuator Failsafe Spring Failure 4 PINK/WHITE 3 TAN/ORANGE 5 GREEN/RED 1 PURPLE/BLUE 2 BLACK/GREEN Diagnostic Aids • Throttle Actuator • Check Condition- Key Off, Engine Stopped • Fault Condition- When the key is off (or the actuator is unpowered), the ECM is expecting the failsafe spring in the actuator to return the throttle position to near 0%. If the throttle does not reach this position when the actuator is powered, a fault is generated.
SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT INDEX 3-188 DESCRIPTION SPN FMI 2 DTC 118: ECT voltage high 110 3 3 DTC 117: ECT voltage low 110 4 4 DTC 116: ECT higher than expected stage 1 110 15 9 DTC 563: Vbat voltage high 168 15 10 DTC 562: Vbat voltage low 168 17 11 DTC 643: Sensor supply voltage 1 high 1079 3 12 DTC 642: Sensor supply voltage 1 low 1079 4 13 DTC 123: TPS1 voltage high 51 3 14 DTC 122: TPS1 voltage low 51 4 29 DTC 524: Oil
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM SYSTEMS Transport Position Sensing System Broken Cable Indicator System The boom on this model is a 4 section proportionally driven telescopic boom. The inner mid boom is driven directly by the telescope cylinder. The outer mid and fly booms are each driven by separate wire rope systems. Each rope system contains redundant ropes that are capable of allowing the operator to unknowingly continue use of the machine with a single rope failure.
SECTION 4 - BOOM & PLATFORM Drive/Steer – Boom Function Interlock System (CE ONLY) The Drive/Steer – Boom Function Interlock System uses the Transport Position Sensing System to sense when the boom is out of the transport position. All controls are simultaneously functional when the booms are within the transport position as on the standard machine. When the boom is beyond the transport position, the control functions are interlocked to prevent simultaneous operation of any boom function with drive/steer.
SECTION 4 - BOOM & PLATFORM Moment Control System The Moment Control System is the secondary means of controlling the stability of the machine. This system uses a load moment pin to attach the lift cylinder of the boom to the turntable. This pin is instrumented with gauges allowing the forces in the pin to be monitored. These forces are used to compare the actual boom moment (force at a distance) to a predetermined allowable boom moment.
SECTION 4 - BOOM & PLATFORM position of the boom control select switch. Refer to Boom Control Select. Envelope Tracking The Envelope Tracking System uses the envelope control sensors to enhance the control of the boom within the working envelope. Due to the shape of the working envelope, the maximum boom angle varies with telescope length.
SECTION 4 - BOOM & PLATFORM Dual Capacity System Electronic Platform Leveling The Dual Capacity System on this machine is a multiple envelope control system as opposed to an indication system. The control system changes the working envelope and moment limits to match the capacity select mode to either the 500 lb. (230 kg) mode or the 1000 lb. (450 kg) mode.
SECTION 4 - BOOM & PLATFORM Boom Control Select The boom control select switch is mounted on the platform control panel and allows the operator the ability to select between two different modes of boom control functionality: automatic and manual. While in either mode, the Envelope Control System and Moment Control System remains active.
SECTION 4 - BOOM & PLATFORM 4.2 BOOM REMOVAL, DISASSEMBLY/ASSEMBLY, & CABLE REPLACEMENT 6. Tag and disconnect the telescope, tank, and pressure hoses as indicated below from the main valve and cap ends. Removal 1. Place machine on firm, level ground. 2. Slightly elevate the boom and support the fly boom with a crane or an adequate lifting device capable of handling 6 - 7 tons. 3. Place blocking under lift cylinder to hold it in place. 4.
1. 2. 3. 4. 4-8 – JLG Lift – 5. 6. 7. Jib Rotator Jib Assembly Platform Rotator Figure 4-1.
3121142 3 2 4 1 1. 2. 3. Outer Mid Extend Block Outer Mid Retract Sheave Rope Retainer Block 9 5 – JLG Lift – Retract Rope Retainer Plate Rope Retainer Block Fly Retract Sheave 7. 8. 9. 8 Retract Rope Retainer Plate Lock Plate Tele Cylinder Wear Pad SECTION A-A Figure 4-2. Boom Assembly - Sheet 2 of 7 4. 5. 6.
1. 2. 3. 4. 5. 4-10 – JLG Lift – 6. 7. 8. 9. Shim Tele Cylinder Pulley Assembly Bottom Rear Wear Pad Shim Figure 4-3.
1. 2. 3. 4. 5. 3121142 – JLG Lift – 6. 7. 8. 9. Rope Retainer Block Level Cylinder Front Lower Wear Pad Lock Plate Figure 4-4.
1. 2. 3. 4. 5. 6. 4-12 – JLG Lift – 7. 8. 9. 10. 11. 12. Jib Rotator Jib Rotator Cam Front Side Wear Pad Shim Shim Lock Plate Figure 4-5.
1. 2. 3. 3121142 – JLG Lift – 4. 5. 6. Outer Mid Retract Rope Proximity Switch Spring Switch Adjustment Block Figure 4-6.
Figure 4-7.
SECTION 4 - BOOM & PLATFORM 7. Tag and disconnect the three electrical wires that run to the power track and the wire that goes to the proximity switch. 8. Unbolt the power track. 9. Remove the bolt securing the keeper pin and remove the keeper pin from boom pivot pin. 3121142 – JLG Lift – 10. Using the lifting device, support the rear of the boom to remove the load from the pivot pin. 11. Remove the boom pivot pin. 12.
SECTION 4 - BOOM & PLATFORM 13. Using the lifting device, remove boom from chassis. 14. Place boom on saw horses or other adequate supports. 6. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin. 7. Remove the jib and platform assembly from the boom. Disassembly It is not necessary to completely remove the entire boom assembly from the machine to replace the cables. In the following procedure, the base boom section will remain on the machine.
SECTION 4 - BOOM & PLATFORM 8. Attach a lifting device to the powertrack for support and unbolt the upper powertrack tube from the fly boom. Pull the disconnected tube back to allow room to disconnect the lower tube. 3121142 – JLG Lift – 9. Unbolt the lower powertrack tube from the outer mid boom section and the mounting bracket from the inner mid boom section.. 10.
SECTION 4 - BOOM & PLATFORM 11. Remove the bolts securing the side wear pads to the front of the base boom and remove the pads and shims. 12. Remove the boom length plate. 4-18 13. Remove the cover over the boom length limit switch at the front of the boom base section. Remove the switch. 14. Remove the rear boom cover.
SECTION 4 - BOOM & PLATFORM 15. Tag and disconnect the wiring harness running to the boom length sensor. Remove all the bolts and washers securing the sensor, including those that secure the measuring cable to the telescope cylinder, and remove the length sensor. 16. Tag and disconnect the hydraulic hoses from the telescope cylinder. Cap or plug all openings. 17. Remove the front side, top, and lower wear pads from the boom base section. 3121142 – JLG Lift – 18.
SECTION 4 - BOOM & PLATFORM 21. Remove the adjustment nuts for the for the outer mid extend cables along with the Broken Cable proximity switch, spring, and adjustment plate. 22. Remove the cable mounting plate. 4-20 23. Remove the cover plate from the bottom of the boom and remove the sheave blocks. 24. Remove the trunnion blocks that secure the telescope cylinder rod to the boom base section.
SECTION 4 - BOOM & PLATFORM 25. Remove the outer mid retract cables from the attachment fixtures at the front of the boom base section. 26. Attach an auxiliary hydraulic power source to the telescope cylinder and extend the cylinder rod enough to turn the trunnion in a vertical position. 3121142 – JLG Lift – 27. Pull the inner mid, outer mid, and fly boom sections out of the base boom section.
SECTION 4 - BOOM & PLATFORM 28. Remove the trunnion blocks that secure the telescope cylinder barrel to the inner mid boom section. 29. Attach a lifting device to the telescope cylinder and pull the cylinder, along with the outer mid extend cables out of the inner mid boom section. Reposition the lifting device as necessary to balance the cylinder. 4-22 30. Remove the hardware attaching the outer mid extend block and remove the block and outer mid extend cables. 31.
SECTION 4 - BOOM & PLATFORM 32. Remove the rear bottom wear pad. 33. Remove the lock plates from the fly boom retract cable adjustment nuts and remove the adjustment nuts from the fly boom retract cables and from the fly boom extend cables at the front of the inner mid boom section. 3121142 – JLG Lift – 34. Pull the fly boom extend cables from their mounting receptacles. 35. Remove the top, side, and bottom wear pads from the front of the inner mid boom sections.
SECTION 4 - BOOM & PLATFORM 36. 37. 4-24 Attach a strap to pull the outer mid and fly boom sections out of the inner mid boom section. Secure the rear of the inner mid boom section so it doesn’t move as the other sections are withdrawn. NOTE: When pulling the outer mid and fly boom sections out of the inner mid boom section, make sure the outer mid retract cables do not catch at the rear of the boom section. 38.
SECTION 4 - BOOM & PLATFORM 40. 41. Remove the cable retract retainer plates, cable retainer blocks, sheaves, and bushings from the rear of the outer mid boom section. 42. Remove the upper rear wear pads from the fly boom section. 43. Remove the cable retainer blocks and shims. Remove the front wear pads from the outer mid boom section.
SECTION 4 - BOOM & PLATFORM 44. Pull the fly boom extend cables out enough to have clearance to remove the sheave, and remove the retaining bolt, keeper pin, pin, bushings, and sheave from the front of the outer mid boom section. NOTE: When pulling the fly boom section out of the outer mid boom section, make sure the fly boom retract cables do not catch at the rear of the boom section. 45.
SECTION 4 - BOOM & PLATFORM 46. Remove the tape from the fly boom section and remove the fly boom retract cables. Assembly NEVER HANDLE WIRE ROPE WITH BARE HANDS. NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all four inner surfaces of both ends of each boom section to a minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom section only needs Super Lube applied to the insertion end.
SECTION 4 - BOOM & PLATFORM wire rope and place them into the fly boom, tape the slots to keep the rope from jumping out. TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY PROCEDURE. 1. Install the fly extend wire rope button ends into the slots on the bottom of the fly boom section. Place tape over the wire ends to keep them in place during assembly. 2. Fabricate a special fixture as shown below to keep four extend wire ropes from crossing over each other. 3.
SECTION 4 - BOOM & PLATFORM A B C Ft-Lbs. Nm A 165 224 B 165 224 C 35 49 D 50 70 D Figure 4-8.
SECTION 4 - BOOM & PLATFORM F E NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Check torque on the bolts every 150 hours of operation. G Ft-Lbs. Nm E 340 460 F 480 672 G 190 260 Figure 4-9.
SECTION 4 - BOOM & PLATFORM 4. Install the fly boom section partially into the outer mid boom section. 7. Install the sheave, bushings, pin, keeper pin, and retaining bolt to the front of the outer mid boom section. DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES WHILE INSERTING IT INTO THE OUTER MID BOOM. 8. Install the cable retainer blocks and shims. 9.
SECTION 4 - BOOM & PLATFORM 10. Apply JLG Threadlocker P/N 0100011 to the bolts and install the rear upper and side wear pads on the outer mid boom section as marked during disassembly. Torque the bolts to 50 ft.lbs. (68 Nm). 11. Uncoil the fly retract wire ropes from the fly boom. Route the threaded ends of the wire ropes through the holes in the outer mid boom plates at the retract sheave locations. 4-32 12.
SECTION 4 - BOOM & PLATFORM 16. 17. Feed the fly boom retract cable into the inner mid boom section from the front. 18. Attach the fly boom retract cables in the inner mid boom section to the receptacles at the rear of the outer mid boom section. 19. Put tape over the holes to keep the cable ends from jumping out. 20. Push the outer mid assembly part way into the inner mid boom section.
SECTION 4 - BOOM & PLATFORM 21. 22. 4-34 Push the outer mid assembly into the inner mid while pulling the boom cables out the back fo the inner mid section at the same time. Leave 3 to 4 feet of the outer mid section sticking out of the inner mid section. 23. Push the outer mid assembly almost completely into the inner mid boom section. 24. Install the cable retainer blocks over the fly boom retract cables and insert the fly boom extend cable into the mounting receptacles.
SECTION 4 - BOOM & PLATFORM 25. Apply JLG Threadlocker P/N 0100011 to the bolts and install the side and top wear pads into the inner mid boom section. Torque the bolts to 50 ft.lbs. (68 Nm). 26. Put moly paste on the sheave mounts at the rear of the inner mid boom section and install the sheaves. 3121142 – JLG Lift – 27. Apply a thin coat of moly paste lubricant to the inside diameter of the sheave composite bearings.
SECTION 4 - BOOM & PLATFORM 29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and install the cable retainer block. 30. Install the outer mid extend cables into the cable pulley at the rod end of the telescope cylinder. 33. Using an adequate lifting device, insert the cylinder and cables part way into the inner mid boom. 31. 4-36 Install the other end of the outer mid extend cables into the cable guide block.
SECTION 4 - BOOM & PLATFORM 34. Apply JLG Threadlocker P/N 0100019 to the bolts and attach the cable guide to the inner mid boom section with the mounting hardware. Torque the bolts to 165 ft.lbs. (224 Nm). 35. Push the cylinder the rest of the way into the inner mid boom assembly. 36. Install the cylinder trunnion blocks and shims. 3121142 – JLG Lift – 37. Using Super Lube®, lubricate all wear surfaces on the inside of the boom base section and the outside of the inner mid boom section. 38.
SECTION 4 - BOOM & PLATFORM 41. Apply JLG Threadlocker P/N 0100011 to the bolts and install the side and upper wear pads into the boom base section. Torque the bolts to 50 ft.lbs. (68 Nm). 42. Install the boom transport length sensor on the side of the boom base section. 43. Attach the powertrack tubes. 44.
SECTION 4 - BOOM & PLATFORM #271 #0100011 #0100011 #0100019 #0100019 #0100011 A A #0100011 SECTION A-A Figure 4-10.
SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-11.
SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-12.
SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100019 #0100011 #0100011 #0100011 #0100011 Figure 4-13.
SECTION 4 - BOOM & PLATFORM 4.3 BOOM LUBRICATION APPLICATION 4.4 BOOM SHIMMING PROCEDURE This procedure applies to booms after assembly or during annual application using Super Lube® lubricant (JLG p/n 3020042). 1. Position the boom on the boom rest using the 500lb capacity setting. 2. Telescope main boom section as far as it will extend at this position, approximately 3 ft. (0.9 m). 3.
SECTION 4 - BOOM & PLATFORM 4. Install the top wear pad(s) on the fly boom and shim as necessary to obtain 0 - 1/16” (0 - 1.6 mm) less than the corresponding dimension recorded in step 2. 5. Slide the fly into the outer mid boom leaving 2 - 6 feet (0.6-1.8 m) exposed. 6. Install the bottom wear pad(s) and shims if necessary into the end of the outer mid boom. 7. Temporarily insert the side pads on one side and slide the fly boom to that side.
SECTION 4 - BOOM & PLATFORM 3. Run a nylon strap capable of supporting the weight of the lift cylinder around the bottom of the cylinder. Lift up on the strap to relieve the weight of the lift cylinder on the load sensing pin. 4. Loosen and remove the bolt that secures the retaining pin and remove the retaining pin. 5. Disconnect the wiring harness from the strain relief connector at the opposite side of the load sensing pin. 6.
SECTION 4 - BOOM & PLATFORM Figure 4-16.
SECTION 4 - BOOM & PLATFORM Figure 4-17.
SECTION 4 - BOOM & PLATFORM Figure 4-18.
SECTION 4 - BOOM & PLATFORM Figure 4-19.
SECTION 4 - BOOM & PLATFORM Figure 4-20.
SECTION 4 - BOOM & PLATFORM 0271875 D 1. 2. 3. A B C Bar Blade Mount Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate Apply Loctite #242 & torque to 50 ft.lbs. (70 Nm) Figure 4-21.
SECTION 4 - BOOM & PLATFORM 1 Pivot Pin 2 Bolt 3 Keeper Rod 4 Load Sensing Pin 5 Pin Orientation Bar * Position the Load Sensing Pin with the strain relief connector opposite the pin orientation bar as shown CAUTION: Pounding on the Load Sensing Pin for removal can destroy the internal strain gauge. Use care when removing the pin. Figure 4-22.
SECTION 4 - BOOM & PLATFORM 4.8 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of the powertrack. 4. Pull up on the loose side of the round bar to allow the poly roller to slide off. One Piece Bracket Maintenance 1. 2. Place the powertrack on a workbench. Remove the screws from the bars on one side of the powertrack on the first link.
SECTION 4 - BOOM & PLATFORM 5. Slide the poly roller off of the round bar. 7. Slide the flat bar out. 6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket. 9. Remove the snap ring from the other side of the bracket.
SECTION 4 - BOOM & PLATFORM 10. 11. 12. Push down with slight pressure on the link and slide the bracket side up and over the extrusion on the link. Two Piece Bracket Maintenance 1. Loosen the screw. 2. Slide the roller off the bar. 3. Hold the bar tightly and remove the other screw. Repeat the previous step on the other side. Slide the bracket off of the powertrack.
SECTION 4 - BOOM & PLATFORM 4. Hold the flat bar and remove the screws. 5. Remove the snap rings and pins. 7. Slide the link out. Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO DISCARD AND REPLACE ALL OLD SCREWS. Make sure screws are tight and installed properly. 6. 4-56 Remove the screws from the bar. Remove the snap ring and pin.
SECTION 4 - BOOM & PLATFORM Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below. CLOSED OPEN 10-24 x 0.812 button torx socket head with blue locking patch: • Tighten to 45-50 in.lbs. (5-5.6 Nm). An open snap ring is shown below. • Use T-25 torx bit. • Do not reuse this screw. After removing replace with a new one. A snap ring that is not seated is shown below.
Figure 4-23.
Figure 4-24.
Figure 4-25.
Figure 4-26.
4-62 – JLG Lift – DESCRIPTION Table 4-1. Hose/Cable Pull Chart Figure 4-27.
Figure 4-28.
SECTION 4 - BOOM & PLATFORM 6. 4.9 HOSE ROUTING PROCEDURE Inspect sheaves with a groove wearout gauge for excessive wear. For proper hose routing and cable wrap placement and clamping, refer to Figure 4-23., Figure 4-24., Figure 4-25., Figure 4-26., Figure 4-27., and Figure 4-28. It is important to periodically inspect hoses, wraps and clamps for proper slack adjustments and clamping integrity (pull check).
SECTION 4 - BOOM & PLATFORM INNER MID BOOM SECTION REPOSITIONING 4.11 WIRE ROPE TENSIONING ADJUSTMENT ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALIBRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD. The inner mid section of the boom is positioned by the hydraulic cylinder. No adjustments can be made to this section. The wire ropes within the assembly only control the movement of the Outer Mid Boom and Fly Boom sections.
SECTION 4 - BOOM & PLATFORM 3. Remove the lock plates and nylon collar locknuts from the wire rope adjustment nuts. a. If the Outer Mid Boom still does not fall within the dimension and tolerance of Figure 4-30., repeat the Outer Mid Boom positioning procedure. b. If the Outer Mid Boom falls within the dimension and tolerance of Figure 4-30., proceed to the Fly Boom Section Positioning procedure in this section.
SECTION 4 - BOOM & PLATFORM 4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope adjustment nuts. 2. If not already done, remove the lock plates and nylon collar locknuts from the wire rope adjustment nuts. 3. Position the boom so that it is horizontal within ±5°. If the boom is below horizontal, ensure that the boom is not on the boom rest. 4. Extend the boom so the platform moves 5 to 6 feet (1.51.8 m) from the fully retracted position.
SECTION 4 - BOOM & PLATFORM 6. Using tool JLG p/n 4120043, torque the Outer Mid Boom Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternating between the two ropes until both maintain the required torque. 9. Using tool JLG p/n 4120043, torque the Outer Mid Boom Extend Adjustment Nuts to 80 ft-lb (108 Newton meters), alternating between the two ropes until both maintain the required torque. Outer Mid Extend Adjusting Nuts and Lock Plates Outer Mid Retract Adjusting Nuts and Lock Plates 7. 10.
SECTION 4 - BOOM & PLATFORM 11. Repeat the following boom movement steps three times. This is to ensure that the wire rope tension has equalized on both sides of the sheaves and the ropes are seated properly in the sheave grooves. 18. Install all covers. a. Fully retract the boom. b. Extend the boom such that the platform moves 5 to 6 feet (1.5-1.8 m) from fully retracted position. 12. Verify the Fly Boom and Outer Mid Boom Retract wire rope torques. a.
SECTION 4 - BOOM & PLATFORM 9.5 ± 0.5” 241 ± 13 mm 3.5 ± 0.5” 90.5 ± 13 mm BASE BOOM OUTER MID BOOM FLY BOOM INNER MID BOOM NOTE: Boom shown in fully retracted position. Figure 4-30.
Figure 4-31.
Figure 4-32.
SECTION 4 - BOOM & PLATFORM 1. 2. 3. 2" Socket 3/4” Socket Retaining Bolt Figure 4-33.
SECTION 4 - BOOM & PLATFORM 4.12 BROKEN BOOM CABLE PROXIMITY SWITCH This system uses a proximity switch to detect excessive movement of the cable block. If movement is detected the Cable Break indicator will illuminate in the platform control panel. No restrictions are made to the functionality of the control system. It is the responsibility of the operator to take immediate action.
SECTION 4 - BOOM & PLATFORM PLATFORM VALVES The platform specific valves are located in a manifold at the platform. There are individual proportional control valves that control each of the four platform functions; Platform Level, Platform Rotate, Jib Lift, and Jib Swing. In order to obtain acceptable performance while performing all hydraulic functions, five sets of parameters are used. These “zones” allow compensation for differences in how the basket level changes when doing different functions.
SECTION 4 - BOOM & PLATFORM 4.14 ROTARY ACTUATOR Required Tools Theory of Operation The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03).
SECTION 4 - BOOM & PLATFORM PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1. Screw 103.2 . Washer 106.1. Port Plug 106.2. Port Plug 109 . Lock Pin 113. Capscrew SEALS 200. T-Seal 202. T-Seal 204. O-ring 205. Cup Seal 207. Backup Ring 304.1. Wiper Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 420.1 Bushing 420.2 Bushing 421.1 Bushing Figure 4-35.
SECTION 4 - BOOM & PLATFORM PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1. Screw 103.2 . Washer 106.1. Port Plug 106.2. Port Plug 109 . Lock Pin 113. Capscrew SEALS 200. T-Seal 202. T-Seal 204. O-ring 205. Cup Seal 207. Backup Ring 304.1. Wiper Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 420.1 Bushing 420.2 Bushing 421.1 Bushing Figure 4-36.
SECTION 4 - BOOM & PLATFORM 6” drill bit to a depth of 1/2” (12.7mm) to drill out the entire pin. Disassembly 1. Remove the cap screws (113) over end cap lock pins (109). 4. Install the end cap (4) removal tools provided with the Helac seal kit. 2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16” (4.76mm). 5. Using a metal bar, or something similar, unscrew the end cap (4) by turning it counter clockwise. 3.
SECTION 4 - BOOM & PLATFORM 6. Remove the end cap (4) and set aside for later inspection. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. 4-80 – JLG Lift – 8. Every actuator has timing marks for proper engagement. 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assembly.
SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet. 11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O.D. gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2). 12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged. 3121142 – JLG Lift – 13.
SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove. 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 4-82 19. Remove the piston O.D. seal (202). 20. Remove the piston I.D. seal (200). You may now proceed to the inspection process.
SECTION 4 - BOOM & PLATFORM 3. Inspection 1. Inspect the wear guide condition and measure thickness (not less than 0.123” or 3.12 mm). Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth. Assembly 1. 2. Inspect the thrust washers (304) for rough or worn edges and surfaces.
SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end cap (4). 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion. 3. Install the wiper seal (304.1/green 0-ring) into it’s groove on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304). 5. Install the wear guide (302) on the end cap (4) and shaft (2). 6.
SECTION 4 - BOOM & PLATFORM Each T-seal has 2 back-up rings (see drawing for orientation). Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion. Make sure the wedged ends overlap correctly. Repeat this step for the outer seal (202). 3121142 – JLG Lift – 7. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore. 8.
SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) you can see if your timing marks are lining up. When they do, tap the piston (3) in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out. 11. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (2) with the gear teeth on the inside of the piston (3).
SECTION 4 - BOOM & PLATFORM 14. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. Install the 0-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4). 16. Thread the end cap (4) onto the shaft (2) end. Make sure the wear guide stays in place on the end cap as it is threaded into the housing (1). 3121142 – JLG Lift – 17. Tighten the end cap (4). In most cases the original holes for the lock pins will line up. 18.
SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Bleeding After Installation Refer to Figure 4-37., Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Loctite. 2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing. 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve.
SECTION 4 - BOOM & PLATFORM Figure 4-37.
SECTION 4 - BOOM & PLATFORM A,B,D E C,D A B C D E Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque to 480 ft. lbs. (650 Nm) Check torque every 150 hours of operation Torque to 75 ft. lbs. (102 Nm) Figure 4-38.
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated. 3. Turn the o-ring on the other side of the fitting and repeat the previous step, ensuring the entire o-ring is coated with hydraulic oil.
SECTION 5 - HYDRAULICS Dip Method Spray Method NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. This method requires a pump or trigger spray bottle. The following is needed to correctly oil the o-ring in this manner: 1. Fill the spray bottle with hydraulic oil. 2. Hold the fitting over a suitable catch can. 3. Spray the entire o-ring surface with a medium coat of oil.
SECTION 5 - HYDRAULICS 5.2 CYLINDER REPAIR NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting. Figure 5-2. Cap Screw Removal DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Loctite #242 (Not Shown) Locking Primer (Not Shown) Loctite #RC 609 (Not Shown) Capscrew Tapered Bushing Head 7. 8. 9. 10. 11. 12. Barrel Rod Piston Not Used Wear Ring Back-Up Ring 13. 14. 15. 16. 17. 18. Back-Up Ring O-Ring O-Ring Rod Wiper Seal Wear Ring 19. 20. 21. 22. 23. T-Seal Washer Ring Bolt Holding Valve O-Ring Plug Figure 5-3.
SECTION 5 - HYDRAULICS 11 6 24 24 11 1 12 10 4 3 19 10 20 16 5 18 15 17 23 22 21 17 25 13 2 11 11 1684081-C 1. 2. 3. 4. 5. 6. 7. Barrel Rod Piston Bushing Head Counterbalance Valve Loctite #242 (Not Shown) 8. 9. 10. 11. 12. 13. Locking Primer (Not Shown) Loctite #RC 609 (Not Shown) Bolt Bearing O-ring Plug Socket Head Bolt 14. 15. 16. 17. 18. 19. Not Used Wear Ring Backup Ring Lock Ring Backup Ring O-ring 20. 21. 22. 23. 24. 25.
SECTION 5 - HYDRAULICS 8 1A 1 11 7 12 4 10 17 22 3 15 5 23 21, 25 15 16 20 6 18 19 18 17 22 2 9 13, 24 2A 1684149-D 1. Barrel 1A. Bushing 2. Rod 2A. Bushing 3. Piston 4. Tapered Bushing 5. Head 6. Spacer 7. Holding Valve 8. 9. 10. 11. 12. 13. 14. 15. 16. Cartridge, Holding Valve Washer Ring Capscrew O-Ring Plug O-Ring Plug Capscrew Not Used Wear Ring Back-Up Ring 17. 18. 19. 20. 21. 22. 23. 24. 25.
SECTION 5 - HYDRAULICS 30 28 9 29 27 5 10 4 13 1,2,24 12 22 16 12 26 21 19 14 15 14 13 20 7 18 23 2,3,17 8 25 30 1684162-D 1. 2. 3. 4. 5. 6. Loctite #242 Locking Primer Not Used Capscrew Tapered Bushing Not Used 7. 8. 9. 10. 11. 12. Head Rod Barrel O-ring Plug Not Used Guide Ring 13. 14. 15. 16. 17. 18. Lock Ring Back Up Ring O-Ring Wear Ring Rod Wiper Rod Seal 19. 20. 21. 22. 23. 24. Backup Ring O-ring Wear Ring Piston Washer Ring Not Used 25. 26. 27. 28. 29. 30.
SECTION 5 - HYDRAULICS 7 13 13 1A 1A 1 13 11 8** 13 14 3 11 104 6 105 12* 106 109 101 110 101 103 102 5 4 107 16*,108 2 9 10 2A 2A * Prior to S/N 79667 ** Torque to 20 ft.lbs. (27 Nm) Max 1684173-D 1. 1A. 2. 2A. 3. 4. Barrel Bushing Rod Bushing Piston Head 5. 6. 7. 8. 9. 10. Spacer Tapered Bushing Counterbalance Cartridge Check Valve Cartridge Washer Ring Capscrew 11. 12. 13. 14. 15. 16. Capscrew Not Used O-ring Plug O-ring Plug Loctite #242 Not Used 101. Wear Ring 102.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Rod Head Piston Nut Loctite #222 (not shown) 7. 8. 9. 10. 11. 12. Not Used Rod End Bushing Barrel End Bushing Not Used Wiper Rod Seal 13. 14. 15. 16. 17. 18. Wear Ring Piston Seal Wear Ring O-ring Back Up Ring O-ring Figure 5-8.
SECTION 5 - HYDRAULICS 4 14 6 9 5* 12 10 8 3 11 7 13 1 2 * Torque to 400 ft.lbs. (542 Nm) Max 1. 2. 3. 4. 5. Cylinder Cap Rod Head Barrel Nut 1684314-D 6. 7. 8. 9. 10. Piston Backup Ring Wear Ring Wear Ring O-ring 11. 12. 13. 14. O-ring Wiper Piston Seal Loctite #222 (not shown) Figure 5-9.
SECTION 5 - HYDRAULICS 21 5 28 28 5 30 21 7 8 22 4 14 24 26 11 16 18 11 13 30 31 15 6 12 25** 19 17 20 29 9 27 23* * Torque to 13 ft.lbs. (17.5 Nm) ** Torque to 120 ft.lbs. (163 Nm) 1. 2. 3. 4. 5. 6. 7. Loctite #242 Locking Primer Not Used Capscrew Bolt Bracket Tapered Bushing 1684108 J 8. 9. 10. 11. 12. 13. 14. Barrel Rod Not Used Wear Ring Backup Ring Wear Ring O-Ring 15. 16. 17. 18. 19. 20. 21. O-Ring Backup Ring Rod Wiper T-Seal Rod Seal Retaining Ring Wear Pad 22. 23. 24.
SECTION 5 - HYDRAULICS EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 5-12. Tapered Bushing Removal 13. Screw the piston CCW, by hand, and remove the piston from cylinder rod. 14.
SECTION 5 - HYDRAULICS 4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary. 5. Inspect threaded portion of barrel for damage. Dress threads as necessary. 6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 8.
SECTION 5 - HYDRAULICS 2. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove. Figure 5-15.
SECTION 5 - HYDRAULICS 3. Place a new “O-ring and back-up seal in the applicable outside diameter groove of the cylinder head. NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(See magnified insert in Figure 5-18.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other. Figure 5-17. Installation of Head Seal Kit 4.
SECTION 5 - HYDRAULICS 10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing. b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-1) 11.
SECTION 5 - HYDRAULICS 20. Secure the cylinder head gland using the washer ring and socket head bolts. (See Table 5-1, Cylinder Head and Tapered Bushing Torque Specifications and Table 5-2, Holding Valve Torque Specifications) Table 5-1. Cylinder Head and Tapered Bushing Torque Specifications Head Torque Value (Wet) Tapered Bushing Torque Value (Wet) Tele Cylinder (1200SJP) 120 ft. lbs. (163 Nm) 30 ft. lbs. (40.5 Nm) Tele Cylinder (1350SJP) 120 ft. lbs. (163 Nm) 45 ft. lbs.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Return Filter Vented Fill Cap Sight/Temperature Gauge Suction Strainer Magnetic Drain Plug Figure 5-22.
SECTION 5 - HYDRAULICS A. B. C. D. E. F. Front Steer Valve/Axle Extend Traction Valve Rear Steer Valve/Axle Extend Chassis Module Controller Junction Manifold Valve Axle Oscillation Valve Figure 5-23.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Level Up Rotate Right Level Down Rotate Left Jib Down 6. 7. 8. 9. Jib Swing Left Jib Up Jib Swing Right Platform Dump 10. Level Up Relief 11. Jib Up/Down Relief 12. Level Down Relief 13. Filter or Plug 14. Main Pressure Check Port 15. Level Up Test Port 16. Level Down Test Port 17. Jib Up/Down Test Port Figure 5-24.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Level Up Rotate Right Level Down Rotate Left 5. 6. 7. 8. Jib Down Jib Swing Left Jib Up Jib Swing Right 9. 10. 11. 12. Platform Dump Level Up Relief Jib Up/Down Relief Level Down Relief 13. 14. 15. 16. Main Pressure Check Port Level Up Test Port Level Down Test Port Jib Up/Down Test Port Figure 5-25.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Aux Lift Down Tele Out Lift Up Swing Right 5. 6. 7. 8. Dump Swing Relief Swing Left Lift Down 9. 10. 11. 12. Lift Up Relief Lift Down Relief Lift Flow Tele In 13. 14. 15. 16. Tele Out Relief Tele In Relief Tele Flow Lift Down/Aux Select Figure 5-26.
SECTION 5 - HYDRAULICS Table 5-3. Cartridge Torque Values Ft-Lbs. Nm Ft-Lbs. Nm 1 25-30 33.9-40.6 9 30-35 40.6-47.4 2 25-30 3 30-35 33.9-40.6 10 30-35 40.6-47.4 40.6-47.4 11 30 40.6 4 30-35 5 30-35 40.6-47.4 12 30-35 40.6-47.4 40.6-47.4 13 30-35 40.6-47.4 6 7 30-35 40.6-47.4 14 30-35 40.6-47.5 30-35 40.6-47.4 15 30-35 40.6-47.5 8 30 40.6 Figure 5-27.
SECTION 5 - HYDRAULICS 4 3 2 4 1 Table 5-4. Plug Torque Values Ft-Lbs. Nm 1 115 156 2 100 135.5 3 40 54 4 13 17.5 Figure 5-27.
SECTION 5 - HYDRAULICS 5.3 HYDRAULIC TANK 5.4 PRESSURE SETTING PROCEDURE The hydraulic tank has a capacity of 55 gallons (208 liters) and includes the hydraulic return filter and two suction strainers. It is normal for the oil level to appear low when the boom is raised and should only be checked with the machine on level ground and with the boom fully retracted and lowered.
SECTION 5 - HYDRAULICS 4. To make an adjustment to this pressure, go back to the engine compartment to the function pump which is the back pump. The high pressure relief adjustment is the adjustment closest to the pump. Using a 17 mm wrench, remove the cover nut. Be careful not to lose the O-ring washer inside the cover nut. 5. Loosen the jam nut at the setscrew with the 17 mm wrench. Using a 3 mm allen wrench, adjust clockwise to increase, or counterclockwise to decrease. 3.
SECTION 5 - HYDRAULICS SWING - 1500 PSI (103.4 BAR) STEERING, FRONT AND REAR NOTE: Left and right are done with one adjustment. NOTE: The following procedure requires 2 people to perform. One is needed for verifying / adjusting pressure readings and wheel spindle alignment the other for operating the steer functions and using the Analyzer from the platform. 1. Install a high pressure gauge at port MS. 2. Lock the turntable pin. 3. Activate swing, the gauge should read 1500 psi (103.4 Bar).
SECTION 5 - HYDRAULICS Figure 5-28.
SECTION 5 - HYDRAULICS 4. 5. Remove the front circular steer/axle access covers at the front of the chassis, and the rear square cover at the top rear of the chassis to gain access to the axle/steer valves. mounted next to the MS2 port, CW to increase or CCW to decrease. 6. Remove the pressure gauge from MS2 port and install on the MS1 port, which is on the right side of the front axle/steer valve, closest to the right front wheel spindle.
SECTION 5 - HYDRAULICS 8. 9. 5-30 Checking the left rear steer cylinder is identical to the procedure for left front steer cylinder, except now we are checking pressures at the rear axle/steer valve location. Install pressure gauge at MS1 port. This should be located on the left side of the valve closest to the left rear wheel spindle. MS1 port should read 2600 psi (179 Bar) when the left rear steer cylinder is activated with the rod in the fully retracted position.
SECTION 5 - HYDRAULICS 12. 13. 14. 15. Remove the gauge from MS3 port and install on MS4 port, which is on the left side of the front axle/steer valve, closest to the left front wheel spindle. Position the steer switch to activate the right front steer cylinder until the rod is in the fully extended position and hold the steer switch for a few seconds after the rod has stopped extending. The MS4 port should read 2000 psi (138 Bar).
SECTION 5 - HYDRAULICS 2. 5.5 DRIVE PUMPS a. Is there any charge pressure at port G or indicated by measuring pressure at Ma and Mb? No - Proceed to step 2.d Yes - Proceed to step 2.b Troubleshooting Procedure To aid in troubleshooting, refer also to the pressure measuring port connections for test gauge installation information as shown on the hydraulic circuit diagram. Procedure assumes proper gauges are installed.
SECTION 5 - HYDRAULICS h. Remove charge pressure relief valve from the middle pump and inspect. Is it damaged? No - Refit cartridge and proceed to step 2.i Yes - Clean & inspect cartridge, poppet, springs, seals to determine cause of damage. Repair or fit a new cartridge and return to step 2.a to step 3.a Yes - Proceed to step 3.g g.
SECTION 5 - HYDRAULICS 5. 7. Transmission Drives in one direction only Transmission Does Not Find or Hold Neutral a. Are electrical connections to pump control proportional solenoids correct, intact and without defects? Yes - Proceed to step 5.b No - Rectify the problem a. Does pump remain in neutral with electrical connectors removed? No - proceed to step 7.b Yes - Check electrical system for signal problem b. Check hot oil flushing valve cartridge #120 located in the Traction Control Manifold.
SECTION 5 - HYDRAULICS f. Is a wheel drive hydraulic motor operating at excessive speed? Yes - Check minimum displacement stop screw adjustments on the motors. Should be 0.433" or 11mm above the stop screw lock nut. Is one or more motors "stuck" at minimum displacement, check for plugged/blocked two-speed stroking orifice(s). 9. 11. a. Does the charge pump pressure meet specification? No - Return to step 2.a Yes - Proceed to step 11.b b.
SECTION 5 - HYDRAULICS NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are available in 0.3, 0.5, and 1.0 mm thickness. Hydraulic Centering of Control Modules PREPARATION FOR ADJUSTMENT When control modules are exchanged or replaced, it is generally necessary to center the new module. This is done by running the pump with gauges installed at ports X1, X2, MA, and MB Release the jam nut and turn the adjustment screw on top of the control module valve body.
SECTION 5 - HYDRAULICS trol spring are correctly located in the grooves near the end of the feedback lever arms. Removal and inspection of charge pump Before removing cap screws, mark the position of the charge pump housing and separator plate in relation to the port block. High Pressure Relief Valve Adjustments 1. Remove relief valve cover from pump (ref. item 1). Loosen screws with metric allen wrench. 2. Loosen jam screw (ref. item 2). 3. Holding spring loading nut (ref.
SECTION 5 - HYDRAULICS sembly. Make sure 0-rings are completely seated in their grooves. Routine Maintenance The Variable Displacement Hydrostatic Transmission Pumps are relatively maintenance free. Maintenance work is confined to the system, by way of maintaining hydraulic fluid condition, the "life blood" of the machine. Oil monitoring, changes and filter renewal promote system cleanliness. This will prevent premature breakdown and repairs.
SECTION 5 - HYDRAULICS g. Under application conditions with a heavy occurrence of dust or severe temperature fluctuations, the intervals between fluid maintenance should be shortened accordingly. PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAINTENANCE ERRORS OCCUR DURING AN OIL CHANGE DUE TO: b. The air/oil cooler surfaces and engine radiator should be cleaned at the same time. c.
SECTION 5 - HYDRAULICS Press in shaft seal with bushing to the stop. Then replace snap ring. Removal and Installation of Shaft Seal Remove the retaining ring with snap ring pliers. Screw in sheet metal screw into the holes fitted with rubber. Pull out shaft seal with pliers.
SECTION 5 - HYDRAULICS 5.6 FUNCTION PUMP Figure 5-29. Function Pump - Sectional View Spare Parts 1. 2. Drive Shaft 3. Bearing set, miscellaneous parts. Sealing kit, existing spare parts: shaft sealing ring, orings, and a circlip.
SECTION 5 - HYDRAULICS 4. Rotary Group complete: 9 pistons, cylinder subassembly, valve plate, retaining plate, and retaining ball. Sealing the Drive Shaft BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE REMOVAL OF THE SHAFT SEALING RING. 5. 6. 7. 5-42 1. Remove the snap ring. 2. Change the shaft seal and check its’ sliding surface (drive shaft) and housing. Grease the sealing ring. 3. Be careful while you seal the drive shaft.
SECTION 5 - HYDRAULICS 4. Assemble the sealing ring, fitting tool holds the correct position of the sealing ring in the pump housing. 2. Mark the position of the port plate and remove the socket screw of the port plate. 5. Assemble the snap ring. 3. Remove the port plate together with the valve plate (hold the valve plate so the plate can’t fall down). 6. Assemble the snap ring in the correct position. 4. Remove the o-ring. 5. Disassemble the taper roller bearing (nearby port plate).
SECTION 5 - HYDRAULICS 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow. 8. Loosen the fixing nut of the stopper max flow and disassemble it. 12. Remove the threaded pin. 9. Turn in the stopper max flow to get swivel angle zero. 13. Disassemble the plug.
SECTION 5 - HYDRAULICS 14. Disassemble the control piston while moving the swash plate. 15. The swash plate must be lifted a little bit to disassemble the piston rod. 16. 17. 18. Remove both bearing shells. 19. Remove the drive shaft. 20. Disassemble the snap ring. 21. Disassemble the sealing ring. Remove the swash plate. Remove the spring.
SECTION 5 - HYDRAULICS 22. The external front bearing ring is pulled out of the pump housing. 25. 23. Remove the o-ring. Lifting of the valve plate isn’t shown. Assembly 24. 5-46 A bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care of the surface of the port plate. – JLG Lift – The spring has additional pretension while you disassemble the three pressure pins inside the cylinder. 1.
SECTION 5 - HYDRAULICS 3. Pumps clockwise driven must have a position of the valve plate 4 degrees out of center in the same direction decentered like drive direction. Adjustments TAPER ROLLER BEARING INITIAL TENSION Cast Iron pump housing must have initial tension of the bearings: 0 to 0.05 mm. 4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees decentered in the ccw position.
SECTION 5 - HYDRAULICS Figure 5-30. Function Pump, Pressure and Flow Control - Sheet 1 Figure 5-31.
SECTION 5 - HYDRAULICS Figure 5-32. Function Pump, Pressure and Flow Control - Sheet 3 Pump Control Disassembly For Cleaning NOTE: If the Function Pump does not perform correctly after following the pre-start start-up procedures, it is possible that a contaminate particle has lodged in the pump control preventing proper operation. The pump control’s internal parts are not provided as spare parts due to the close tolerances required between the mating parts.
SECTION 5 - HYDRAULICS 9. Remove the spring cover hex cap for the ”outer” flow regulation adjustment this requires a 19-mm wrench. 10. Remove the spring disc. 11. Remove the adjusting springs (two springs, one ”nested” inside the other) and spring follower. 12. The flow regulation spool should slide from the control housing, (a magnet should aid in removal).
SECTION 5 - HYDRAULICS 5.7 DRIVE & FUNCTION PUMP START UP PROCEDURES Start-Up Procedure The 1200/1350 Boom Lift utilizes a Triple Combination Pump coupled to the Deutz diesel engine. The pumps are connected in-line to each other as follows: 1. The front hydrostatic transmission pump, or drive pump, is coupled directly to the diesel engine and provides oil flow to operate the machine's right side wheels. 2.
SECTION 5 - HYDRAULICS 10. Operate the drive system in the "turtle mode", forward and reverse. 17. Check oil level & temperature. 18. Remove and inspect charge pressure oil filter, replace with new element. 11. De-aerate the system by bleeding fluid from the Ma & Mb ports. 19. 12. Switch the drive mode speed control from "turtle" to "rabbit". Gradually increase drive speed forward & reverse, still with no load - wheels off the ground.
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION smooth control of: acceleration, deceleration, creep, min speed, and max.-speed for all boom, drive, and steering functions. WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATE THE TILT SENSOR.
SECTION 6 - JLG CONTROL SYSTEM Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc;) 6.2 CANBUS COMMUNICATIONS CANbus: CAN (Control Area Network) is a two wire differential serial link between the Platform Module, Ground Module, Boom Length Angle Module and the Chassis Module providing bi-directional communications. Two-wire: One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal; both wires ”float” (2.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-2.
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Calibration Instructions 6.3 CALIBRATION INSTRUCTIONS This machine incorporates a variety of sensors and a high degree of function interaction. For safety and proper machine functionality, the calibration procedures must be repeated for any control module replacement, system calibration related fault, or removal or replacement of any sensors, valves, coils, motors, or pumps. The chart below lists the calibrations required and potential reasons for re-calibration.
3121142 (See Figure 6-5.) (See Figure 6-6.) (See Figure 6-7.) or (See Figure 6-8.) or (See Figure 6-9.) – JLG Lift – Figure 6-3. Analyzer Flow Chart NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration. (See Figure 6-4.
6-6 – JLG Lift – Figure 6-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
3121142 Figure 6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
6-8 – JLG Lift – CALIBRATIONS: DRIVE CALIBRATE DRIVE? CALIBRATIONS: BOOM SENSORS POSITION 1: CHECK SYSTEM? CALIBRATIONS: STEER CALIBRATE STEER? CALIBRATIONS: TILT SENSOR POSITION 1: CHECK SYSTEM? DEUTZ SETUP: SETUP 4 DEUTZ SETUP: SETUP 3 DEUTZ SETUP: SETUP 2 DEUTZ SETUP: SETUP 1 CALIBRATIONS: DEUTZ SETUP: CALIBRATE BOOM VALVES? CALIBRATIONS: BOOM VALVES CALIBRATIONS: NONE AVAILABLE CALIBRATIONS: UNLOCK BOOM CALIBRATE UNLOCK BOOM? CALIBRATE LEVEL DOWN CRACKPOINT? CALIBRATIONS: LEVEL DOWN CR
3121142 – JLG Lift – Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
6-10 – JLG Lift – Figure 6-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
3121142 – JLG Lift – Figure 6-9. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 3 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
Figure 6-10.
SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-11.
SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: 6.4 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 1. Connect the cable supplied with the analyzer, to the controller module located in the platform box or at the controller module in the ground control box and connect the remaining end of the cable to the analyzer. NOTE: The cable has a four pin connector at each end of the cable; the cable cannot be connected backwards. 2.
SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password. Use the UP or DOWN arrow key to enter the second digit of the password which is 33271. Continue using the arrow keys until all the remaining digits of the password is shown.
SECTION 6 - JLG CONTROL SYSTEM 6.7 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER 6.8 MACHINE SETUP Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2 = LIFT DOWN PERSONALITIES: DRIVE ACCEL 1.0s There will be a minimum and maximum for the value to ensure efficient operation.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Configuration Digit Number Default Number Description NOTE: The machine configuration must be completed before any personality settings can be changed.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Configuration Digit GLOW PLUG: 5 STARTER LOCKOUT: 6 ENGINE SHUTDOWN: 7 TILT: 8 Number Default Number Description 0 NO GLOW PLUGS: No glow plugs installed. 1 AIR INTAKE: Glow plugs installed in the air intake on the manifold. 2 IN-CYLINDER: Glow plugs installed in each cylinder.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Configuration Digit GEN SET/WELDER: 10 GEN SET CUTOUT: 11* Number Default Number Description 1 0 NO: No generator installed. 1 BELT DRIVE: Belt driven setup. 2 HYDRAULIC DRIVE: Hydraulic driven setup. 0 MOTION ENABLED: Motion enabled when generator is ON. 1 MOTION CUTOUT: Motion cutout in platform mode only. 0 * Only visible if Gen Set / Welder Menu selection is not 0.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Configuration Digit FUNCTION CUTOUT: 14* Number Default Number Description 0 0 NO: No drive cutout. 1 BOOM CUTOUT: Boom function cutout while driving above elevation. 2 DRIVE CUTOUT: Drive cutout above elevation. 3 DRIVE CUT E&T: Drive cutout above elevation and tilted. * Only visible under certain market selections.
SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. 6.9 MACHINE PERSONALITY SETTINGS/FUNCTION SPEEDS Table 6-3. Personality Ranges/Defaults SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE TIME RANGE (SEC) (SEE SECTION 6.10 FOR DEFAULT VALUES MACHINE ORIENTATION WHEN SETTING SPEEDS) 1200 DRIVE: 1350 1350S 44-48 44-48 ACCEL X.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) SWING: MAIN TELESCOPE: BASKET LEVEL: 6-24 PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE TIME RANGE (SEC) (SEE SECTION 6.10 FOR DEFAULT VALUES MACHINE ORIENTATION WHEN SETTING SPEEDS) 1200 1350 ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0 DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) BASKET ROTATE: JIB LIFT: JIB SWING: 3121142 PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE TIME RANGE (SEC) (SEE SECTION 6.10 FOR DEFAULT VALUES MACHINE ORIENTATION WHEN SETTING SPEEDS) 1200 1350 ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1.0 1.0 DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5 0.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) GROUND MODE: GEN SET/WELDER: PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE 0 to 100% TIME RANGE (SEC) (SEE SECTION 6.10 FOR DEFAULT VALUES MACHINE ORIENTATION WHEN SETTING SPEEDS) 1200 1350 60 60 U. LIFT UP XXX% Displays/adjusts fixed main lift up speed U.
SECTION 6 - JLG CONTROL SYSTEM 6.10 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDS Test Notes 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance. 2. Stop watch should be started when the function is activated. 3. Unless noted, all speed tests are run from the platform. These speeds do not reflect the ground control operation.
SECTION 6 - JLG CONTROL SYSTEM 3. 6.11 SYSTEM TEST The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Before proceeding, ensure that the switches on the platform console are in the following positions: a. Drive speed switch is in the Middle position. (Turtle Icon) b. 4WS switch is in the Middle position. (2WS mode) Test from the Platform 1. c. Capacity select switch in the 1000 lb. (450 kg) mode.
SECTION 6 - JLG CONTROL SYSTEM 4. 5. Pull out the Emergency Stop switch and Start the engine. 6. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate. 7. Follow the flow path in Figure 6-12., System Test Flow Chart - Platform Tests and go through the component tests.
Figure 6-12.
SECTION 6 - JLG CONTROL SYSTEM Test from the Ground Station 1. 2. 3. Pull out the Emergency Stop switch. and Start the engine. 4. The analyzer screen should read: 5. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate. 6. Follow the flow path in Figure 6-13., System Test Flow Chart - Ground Station Tests and go through the component tests.
Figure 6-13.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer RUNNING 3121142 Description Initial display when system test is run; certain “critical” checks are made. Problems that can be reported include below messages. ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TESTING VALVES Description Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils. NOTE: In platform mode, the footswitch must be closed. NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if TOWER TELE=NO.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TEST ALL INPUTS? TESTS COMPLETE 3121142 Description Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends. If ENTER is pressed or clicked, each operator input is prompted for in turn. In platform mode every platform switch and joystick is tested. In ground mode every ground switch is tested.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description ENGINE: START ACTIVE/NOT ACTIVE Displays status of the engine start circuit AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL NUMBER = 7 or 8) BATTERY XX.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description SYSTEM: 3121142 GM BATTERY XX.XV Ground module battery voltage PM BATTERY XX.XV Platform module battery voltage AMB. TEMP XXXC Ambient temperature FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) 6-40 Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description HI TILTED - NO/YES Displays status of hi tilt input.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING AXLE = 1) SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) MOMENT: 6-42 Description Displayed if MODEL NUMBER = 7 or 8 (LB-IN) ACTUAL XXXXXXXX Displays current moment value (LB-IN) OVER XXXXXXXX Displays current over moment setpoint. (LB-IN) UNDER XXXXXXXX Displays current under moment setpoint.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) ENVELOPE: Displayed if MODEL NUMBER = 7 or 8 LENGTH XXXX.X Displays the current indicated boom length in inches. ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees. ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM 6.12 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Platform position. 2. Plug the analyzer into the connector at the base of the platform control box. When calibrating steering, each individual wheel must be calibrated in order to make the tire and wheel parallel with the frame.
SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the engine. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 3121142 – JLG Lift – 8. Use the arrow keys to reach Steer. The screen will read: 9. Hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer. 15. Left Rear Steer Calibration will be followed by Right Forward Steer Calibration which will be followed by Right Rear Steer Calibration. 16. After completing all the Steer Calibrations, hit ESC twice to go back to CALIBRATIONS. 12.
SECTION 6 - JLG CONTROL SYSTEM 6.13 CALIBRATING DRIVE 1. 2. 3. Pull out the Emergency Stop switch and Start the engine. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. Position the Platform/Ground select switch to the Platform position. Plug the analyzer into the connector at the base of the platform control box.
SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read: 9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate the Drive Joystick forward full stroke until the machine just begins to move, then leave off the joystick immediately. The display will read CRK PT = and show the numeric crack point value.
SECTION 6 - JLG CONTROL SYSTEM 13. Hit Enter. The number displayed will be the value that the crack point is set to. The screen will show: 3121142 – JLG Lift – 14. Hit Enter. The screen will read: 15. Repeat steps 10 thru 12 for left reverse drive. 16. Left Reverse Drive Calibration will be followed by Right Forward Drive Calibration which will be followed by Right Reverse Calibration. 17. After completing all the Drive Calibrations, hit ESC twice to go back to CALIBRATIONS.
SECTION 6 - JLG CONTROL SYSTEM allow the operator to operate the machine as a new level setpoint is taken. 6.14 ELECTRONIC PLATFORM LEVELING Platform Leveling Fault Warning VALVE DRIVER ERRORS The JLG Control System takes a snapshot of the two sensor values and records the difference once on each power up. The Control system allows a ±5 degree difference from those values.
SECTION 6 - JLG CONTROL SYSTEM TILT SENSOR ERRORS CAN Errors If the secondary tilt sensor is faulty, the control system will continue to utilize information from the primary sensor. The Ground Module has two direct outputs dedicated to overriding the Platform Module’s control of the leveling valves. The Ground Module “Platform Level Up/Down” outputs are used to control the platform level up and down valves.
SECTION 6 - JLG CONTROL SYSTEM STEP 3: BLEEDING THE PLATFORM VALVES Platform Leveling Calibration Procedure STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 1. Put machine into “Ground Mode”. 1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer. 2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen. 3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode. 4. Enter “33271” to get into Access Level 1 mode. 5.
SECTION 6 - JLG CONTROL SYSTEM 10. Hit ENTER again. “Cal. Complete” message should appear 11. Engine should again return to idle. 12. Hit ESC should return to “Basket U Crkpt” screen. 13. Hit RIGHT ARROW to get to the “Basket D Crkpt” screen. Hit ENTER. 14. “Calibrate?” prompt should appear. Hit ENTER again. 15. You will hear engine go to 1800 rpm. 2. Plug the analyzer into the connector inside the Ground control box. 3. Pull out the Emergency Stop switch and start the engine. 4.
SECTION 6 - JLG CONTROL SYSTEM 7. Use the arrow button to reach PERSONALITIES adjust the following personalities. Refer to the Personality Ranges/Defaults table for proper setting values. 4. Manually level the platform with the switch on the Main Terminal Box. 5. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the arrow button to reach CALIBRATIONS menu and hit ENTER. 9. Use right arrow go to PLAT.
SECTION 6 - JLG CONTROL SYSTEM 10. Hit ENTER. The screen should read: STEP 3: BLEEDING THE PLATFORM VALVES 11. Hit ENTER again to calibrate level sensors. 12. When calibration has been successful CAL. COMPLETE should appear. 13. Cycle power to the machine. 3121142 – JLG Lift – 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3. Pull out the Emergency Stop switch and start the engine.
SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Go to the PERSONALITIES menu. 8. Using the left arrow button, go to the GROUND MODE menu. 9. Hit ENTER. 10. 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3.
SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: 11. Using UP ARROW, increase the value until you see the basket up movement. 12. Hit ENTER again. CAL. COMPLETE message should appear 13. Engine should again return to idle. 14. Hit ESC should return to BASKET U CRKPT screen. 15. Hit RIGHT ARROW to get to the “BASKET D CRKPT” screen. Hit ENTER. 16. CALIBRATE? prompt should appear. Hit ENTER again. 17. You will hear engine go to 1800 rpm.
SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector at the base of the platform control box. 3. Pull out the Emergency Stop switch and Start the engine. 6-60 – JLG Lift – 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach Upper Lift Crack Point (UPPER LIFT CRKPT). The screen will read: 9. Hit enter. The screen will read: 3121142 – JLG Lift – 10. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate the Lift Up function by fully stroking the joystick until the boom starts to move, then leave off immediately. The display will read CRK PT = and show the numeric crack point value.
SECTION 6 - JLG CONTROL SYSTEM 13. Hit enter. The number displayed will be the value that the crack point is set to. The screen will show: 14. Hit Enter. The screen will read: 15. Repeat steps 10 thru 12 for the Lift Down function. 16. After completing all the Tele Calibrations, hit ESC twice to go back to CALIBRATIONS. 6-62 6.17 CALIBRATING TELESCOPE CRACK POINT – JLG Lift – 1. Position the Platform/Ground select switch to the Platform position. 2.
SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the engine. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 3121142 – JLG Lift – 8. Use the arrow keys to reach Upper Telescope Crack Point (UPPER TELE CRKPT). The screen will read: 9. Hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 11. Hit enter again. The screen will read: 12. 6-64 13. Hit enter. The number displayed will be the value that the crack point is set to. The screen will show: 14. Hit Enter. The screen will read: Activate the Tele Out function until the boom starts to move, then leave off immediately. The display will read CRK PT = and show the numeric crack point value.
SECTION 6 - JLG CONTROL SYSTEM 15. Hit Enter. The screen will read: 6.18 CALIBRATING TILT SENSOR A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE. 1. Use the following procedure to calibrate the tilt sensor. Before the tilt sensor can be calibrated, the following conditions must be met: a. Steering previously calibrated. b. Axles extended. c. Wheels straight. d. Turntable centered. e.
SECTION 6 - JLG CONTROL SYSTEM 3. Plug the analyzer into the connector inside the Ground control box. 4. Pull out the Emergency Stop switch and start the engine. 5. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 6-66 9. Use the arrow keys to reach the TILT SENSOR. The screen should read: 10. Press ENTER. 11.
SECTION 6 - JLG CONTROL SYSTEM 6.19 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the Ground position. 3. Plug the analyzer into the connector inside the Ground control box. 4. Pull out the Emergency Stop switch and start the engine. DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR THE REAR WHEEL TO LIFT FROM THE GROUND APPROXIMATELY 1 INCH (2.5 CM). IF THE WHEEL RAISES APPRECIABLY MORE THAN THIS (I.E.
SECTION 6 - JLG CONTROL SYSTEM 5. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 6-68 9. 10. – JLG Lift – Use the arrow keys to reach BOOM SENSORS. The screen should read: Hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 11. After verifying all the conditions listed in step 1 are met, hit Enter. The screen will read: 13. After visually verifying that the jib is horizontal, hit Enter. The screen will read: 12. After verifying all load (personnel or material) is removed from the platform, hit Enter. The screen will read: 14. After visually verifying the platform is level, hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 15. After visually verifying the platform is centered, hit Enter. The screen will read: 16. After operating telescope in to verify the boom is fully retracted, hit Enter. The screen will read: 6-70 17. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen will read: 18. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
SECTION 6 - JLG CONTROL SYSTEM 19. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen will read: 21. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen will read: 20. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen will read: 22.
SECTION 6 - JLG CONTROL SYSTEM 23. After making sure the machine is in Calibration Position 1, hit Enter. The screen will read: 24. Lift up to stop (full stroke of cylinder) for Calibration Position 2. When the machine is in that position, hit Enter. The screen will read: Figure 6-15.
SECTION 6 - JLG CONTROL SYSTEM 25. Swing 180 degrees (centered over opposite end of chassis) for Calibration Position 3. When Position 3 calibrating is complete the screen will read: Figure 6-16. Boom Sensor Calibration Position 3 When the machine is in the proper position, hit Enter.
SECTION 6 - JLG CONTROL SYSTEM 26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: Swing the machine back 180 degrees (centered over original end of chassis) for Calibration Position 4. When Position 4 calibrating is complete, the screen will read: Figure 6-17.
SECTION 6 - JLG CONTROL SYSTEM 27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: Telescope out to stop (boom must be fully extended) for Calibration Position 5. Figure 6-18.
SECTION 6 - JLG CONTROL SYSTEM 28. Retract to stop (boom must be fully retracted) for Calibration Position 6. 29. Lift down to stop (boom must be on boom rest) for Calibration Position 7. Figure 6-20. Boom Sensor Calibration Position 7 When the machine is in the proper position, hit Enter. The screen will read as follows: Figure 6-19. Boom Sensor Calibration Position 6 When the machine is in the proper position, hit Enter.
SECTION 6 - JLG CONTROL SYSTEM When Position 7 Calibrating is complete, the screen will read: 30. Lift until the function stops (controller will stop at 5 degrees above horizontal) for Calibration Position 8. Figure 6-21. Boom Sensor Calibration Position 8 When the machine is in the proper position, hit Enter. The screen will read: Press Enter.
SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: 31. When the boom is in the proper position, hit Enter. The screen will read: Telescope to the yellow witness mark (controller will be close - operator must position the pointer to center line on decal within 0.25" [6 mm]) for Calibration Position 9. When Position 9 calibrating is complete, the screen will read: Figure 6-22.
SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: 32. When the boom is in the proper position, the screen will read: Telescope in to green witness mark (controller will find the position - operator must visually verify the position). Press Enter. The screen will read: Figure 6-23. Boom Sensor Calibration Position 10 3121142 – JLG Lift – 33. After completing all the Boom Sensors Calibrations, hit ESC twice to go back to Calibrations. 34. Cycle the emergency stop switch.
SECTION 6 - JLG CONTROL SYSTEM 5. Boom Control System Check Procedure Perform the following check with no load (personnel or material) in the platform from the ground control station. 1. With the boom fully retracted, raise the boom off the boom rest to horizontal. 2. Position the jib horizontal, jib straight, and platform level. 3. Extend the boom until it stops. 4. Boom must stop on colored stripe matching the capacity indicator.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-24.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 001 00 1 EVERYTHING OK The normal help message in Platform Mode. 002 00 2 GROUND MODE OK The normal help message in Ground Mode. 0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" while the vehicle is out of transport position.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for more then seven seconds. - Can be reported during powerup. 2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Footswitch open. - Can be reported during powerup. 2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with Footswitch open. 2215 22 15 D/S JOY.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected before engine start. 237 23 7 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed during power-up. 250 25 0 <<< FUNCTION PREVENTED >>> 259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been changed.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 330 33 0 <<< GROUND OUTPUT DRIVER >>> 331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake Valve. 332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the Brake Valve. 3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles Ground Alarm. only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the Alternator 3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the Auxiliary Power Pump Relay. 3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the Auxiliary Power Pump Relay. 3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the Auxiliary Power Pump Relay.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground Alarm. 3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped Generator Relay. vehicles only. 3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator Relay.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Rotate Right Valve. 3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the Platform Rotate Right Valve. 3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Rotate Right Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33135 33 135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system Platform Control Valve. equipped vehicles only. 33136 33 136 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only. Main Lift APU Valve. 33137 33 137 MAIN LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Lift APU Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Down Auxiliary Valve. 33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehiLift Down Auxiliary Valve. cles only. 33156 33 156 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only. Tower Lift APU Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33175 33 175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Left Valve. 33176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Left Valve. 33177 33 177 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Left Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing Left Valve. 33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the Main Telescope Flow Control Valve. 33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Telescope Flow Control Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 434 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only. is < 0.1V for more then 5 sec- Not reported during engine onds. start. 435 43 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sensor reading is < 0.1V. Fault Message Fault Description Check - Deutz engine only. 437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 454 45 4 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply voltage is high. 455 45 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only. voltage is high. 456 45 6 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG Valve supply voltage is high. - 1250AJP only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 4524 45 24 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve command is improper. - 1250AJP only. 4525 45 25 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has timed out. - 1250AJP only. 4526 45 26 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has timed out. - 1250AJP only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 660 66 0 <<< COMMUNICATION >>> 662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost. 666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN communication lost. 667 66 7 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communica- - 1250AJP only. tion lost. 668 66 8 CANBUS FAILURE - TOWER LIFT PVG Tower Lift PVG CAN communica- - 1250AJP only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load Sensing System indicates the Platform is overloaded AND is configured to warn only while the Platform is overloaded.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system ence voltage is outside accept- equipped vehicles only. able range (4.9 to 5.1 volts). 8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system ence voltage is outside accept- equipped vehicles only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehinications lost. cles only. 8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 commu- - Envelope Control equipped vehinications lost. cles only. 8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of range.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8426 84 26 TOWER LENGTH SENSOR #2 - OUT OF RANGE HIGH Tower Boom Angle Sensor #2 out of range high. - Envelope Control equipped vehicles only. -1250 8427 84 27 TOWER LENGTH SENSOR #2 - OUT OF RANGE LOW Tower Boom Angle Sensor #2 out of range low. - Envelope Control equipped vehicles only. -1250 8428 84 28 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 out of range.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8441 84 41 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor - Envelope Control equipped vehiis changing without a tower lift cles only. command. -1250 8442 84 42 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is - Envelope Control equipped vehibad. cles only.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8484 84 84 BCS VIOLATION - BOOM LOCKED X 8485 84 85 BCS - HYDRAULIC RETRIEVAL ACTIVE X 8486 84 86 BCS - ELECTRICAL RETRIEVAL ACTIVE X 8487 84 87 BCS - MULTIPLE FAILURES ACTIVE X 850 85 0 <<< MOMENT / LOAD PINS >>> 851 85 1 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal force is out of range.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 864 86 4 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open Circuit to the Axle Retract Valve. 865 86 5 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the Axle Retract Valve. 866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open Circuit to the Right Front Steer Right Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8618 86 18 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open Circuit to the Left Rear Steer Right Valve. 8619 86 19 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Left Rear Steer Right Valve.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8634 86 34 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an Open Circuit to the Rear Right Steer Sensor. 8635 86 35 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the Rear Right Steer Sensor.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 9921 99 21 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has reported that its high side driver cutout failed. 9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has reported that the V(Low) FET has failed. 9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported that the V(Low) FET has failed.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 9941 99 41 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply voltage is low. 9942 99 42 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communica- - BLAM equipped vehicles only. tions link test was activated at -1250 startup, but no communication connection established/maintained.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-25. CANbus Connections Diagram 6.20 CANBUS TROUBLESHOOTING The PLATFORM MODULE and the CHASSIS MODULE have ”Terminator Resistors” located inside the modules, these resistors squelch high speed signal reflections in the CANbus transmission lines. The value of the terminators is determined by wire properties, this includes the type of insulation and geometry, combined to determine the perfect value for bus termination.
SECTION 6 - JLG CONTROL SYSTEM B A PLATFORM MODULE CANbus Link C Figure 6-26.
SECTION 6 - JLG CONTROL SYSTEM 1. Chassis Module CANbus Link 2. Ground Module CANbus Link 3. Boom Length & Angle Module 4. BLAM J1 (Gray) Plug * Remove BLAM J1 Plug and measure the A & B pin of the T fitting. This should measure approximately 60 Ohms for a complete CANbus Circuit. Figure 6-27.
SECTION 6 - JLG CONTROL SYSTEM Remove Ground Module J7 plug and measure the A & B pin of the T fitting. This should measure approximately 60 Ohms for a complete CANbus Circuit. Boom Length & Angle Module CANbus Link Ground Module J7 (Black) plug Platform Module J7 (Black) plug Figure 6-28.
SECTION 6 - JLG CONTROL SYSTEM "BEFORE" Slip Ring Connection "AFTER" Slip Ring Connection Figure 6-29.
SECTION 6 - JLG CONTROL SYSTEM Chassis Module J1 (Gray) Plug Chassis Module CANbus Link Figure 6-30.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-31.
SECTION 6 - JLG CONTROL SYSTEM CANbus Communication Failure 4. The analyzer screen should read: 5. Press enter twice to reach Logged Help. The screen will read: 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter. If a problem in the CANbus system is suspected, use the following step-by-step procedure to verify which part of the CANbus communication system has failed. CANBUS LINK FROM THE PLATFORM MODULE LOST 1.
SECTION 6 - JLG CONTROL SYSTEM 7. 8. 6-116 If the CANbus link from the platform module is lost, you will see the Ground Module SW version, Ground Module HW version, Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version or the Platform Module HW version.
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED 10 Disconnect the Chassis Module connection at the right side of the battery at the turntable lock pin. Perform an ohms check at the #1 and #2 connections of the plug. Inspect shield wire #3 for possible short. Approximately 120 ohms Reconnect plug and go to step 11 Inspect the harness from the slip ring connections at the top and bottom plug connections of the swivel.
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE GROUND MODULE LOST 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3. 4. The analyzer screen should read: 5. Press enter twice to reach Logged Help. The screen will read: 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter. Pull out the Emergency Stop switch.
SECTION 6 - JLG CONTROL SYSTEM 7. 6-120 If the CANbus link from the ground module is lost, you will see the Ground Module SW version, Ground Module HW version, Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version or the Platform Module HW version. The Analyzer screen will read: – JLG Lift – 8. Hit the right arrow button once.
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE BOOM LENGTH & ANGLE MODULE (BLAM) LOST 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3. 4. The analyzer screen should read: 5. Press enter twice to reach Logged Help. The screen will read: 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter. Pull out the Emergency Stop switch.
SECTION 6 - JLG CONTROL SYSTEM 7. 6-122 If the CANbus link from the Boom Length & Angle Module is lost, you will see the Platform Module SW version, Platform Module HW Rev, Platform Module SN, Ground Module SW version, Ground Module HW Revision, Ground Module SN, Chassis SW version, but you will not see the Boom Length & Angle Module SW revision.
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Troubleshooting: BLAM Can Communications Lost STEP ACTION REQUIRED 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE CHASSIS MODULE LOST 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3. 6-124 4. The analyzer screen should read: 5. Press enter twice to reach Logged Help. The screen will read: 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter. Pull out the Emergency Stop switch.
SECTION 6 - JLG CONTROL SYSTEM 7. 8. If the CANbus link from the Chassis Module is lost, you will NOT see the Platform Module SW version, Platform Module HW rev, Platform Module SN, Chassis SW version, Boom Length & Angle Module SW version, but you WILL see the Ground Module SW version, Ground Module HW rev, and the Ground Module SN. The analyzer screen will read: 9. Hit the right arrow button once. The screen will read: 10. Hit the right arrow button once.
SECTION 6 - JLG CONTROL SYSTEM 11. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS LOST NOTE: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault Code 6-6) basically means all communication linked from the Ground Module to the Chassis Module is lost.
SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Troubleshooting: Chassis Can Communications Lost STEP ACTION REQUIRED 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
SECTION 6 - JLG CONTROL SYSTEM refer to Section 4 for information concerning replacement of the Load Moment Pin. Load Moment Pin Troubleshooting The following Troubleshooting Charts outline diagnostic measures to be taken to diagnose problems within the Load Moment Pin portion of the JLG Control System. If necessary, Table 6-10.
SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range STEP 1 FAULT CODE/SYMPTOM 8/6 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE The horizontal force is out of allowed range. REPAIR YES NO Check to see if the platform is overloaded in the vertical position. Check the rated capacity requirement. Remove excess weight 2 Check to see if any additional accessories have been added to the platform without proper calibration.
SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range STEP FAULT CODE/SYMPTOM 1 8/6 MOMENT PIN VERTICAL FORCE OUT OF RANGE The vertical force is out of allowed range. REPAIR YES NO Check to see if the platform is overloaded in the vertical position. Check the rated capacity requirement. Remove excess weight Go to step 2 2 Check to see if any additional accessories have been added to the platform without proper calibration.
SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Load Moment Pin Troubleshooting: Moment Pin Sensor Fault STEP 1 FAULT CODE/SYMPTOM 8/6 MOMENT PIN SENSOR FAULT The moment pin has reported a fault flag REPAIR Use the Analyzer, scroll to the DIAGNOSTICS menu, press ENTER, then scroll to the MOMENT menu, and press ENTER, check to see if PIN E FLAGS has any numbers on the screen display. YES Replace load moment pin & Perform the Boom Sensor calibration process NO Contact JLG Service Dept. Table 6-14.
Figure 6-32.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 7.1 or negative side of the signal and the lead on the other port goes to the positive side of the signal. GENERAL This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS NOTE: Over a period of time, oxidation increases electrical resistance at the connection, eventually causing circuit failure. Current Measurement 2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing. Also, silicone grease must be applied at the joint where the male and female connectors come together. Any other joints (around strain reliefs, etc.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 7.4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-11.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly A A B B C C D Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4. 1.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A C B C Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. 1.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-18.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0274660 D Figure 7-19.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-20.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0272445-E Figure 7-21.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-22.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0274660-D Figure 7-23.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-24.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-25.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-26.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-27.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-28.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-29.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS This page left blank intentionally.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Page 1: TABLE OF CONTENTS Page 2: GROUND CONTROL & BLAM (Boom Length Angle Module) Page 3: PLATFORM Page 4: CHASSIS Page 5: CAT ENGINE Page 6: DEUTZ ENGINE Page 7: DEUTZ TIER 4 FINAL ENGINE 1001119860-G Figure 7-30.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 2 Figure 7-31.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 2 1001119860-G Figure 7-32.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 3 Figure 7-33.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001119860-G SHEET 3 Figure 7-34.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 4 Figure 7-35.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 4 1001119860-G Figure 7-36.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 5 Figure 7-37.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 5 1001119860-G Figure 7-38.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 6 Figure 7-39.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 6 1001119860-G Figure 7-40.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 7 Figure 7-41.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 7 1001119860-G Figure 7-42.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-43.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-44.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-45.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-46.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-47.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-48.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-49.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-50.
SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS NOTES: 7-44 – JLG Lift – 3121142
3121142 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65813058 JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG Latino Americana Ltda. Rua Eng.