Service Manual User guide

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Service and Maintenance Manual

Model

1500SJ

P/N - 3121262

May 22, 2013

Summary of content (628 pages)

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Service and Maintenance Manual Model 1500SJ P/N - 3121262 May 22, 2013
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE 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.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised A-2 - September 12, 2011 - November 9, 2011 - March 26, 2012 - May 16, 2012 - January 10, 2013 - February 20, 2013 - May 22, 2013 – JLG Lift – 3121262
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE 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 ii Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 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 3121262 TITLE PAGE NO. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75 Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.27 TITLE PAGE NO. DTC 604- Microprocessor Failure - RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170 DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172 DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174 DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 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 TITLE PAGE NO. Boom Lubrication Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59 Platform Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 5.3 5.4 5.5 5.6 5.7 5.8 TITLE PAGE NO. Jib Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56 Removal . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 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 3121262 TITLE PAGE NO. Control System Boom Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Sensor #1 - Moment Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Sensor #2 - Main Boom Angle Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 7.2 7.3 7.4 7.5 viii General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 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. 3121262 TITLE PAGE NO. Maintenance and Lubrication Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 3-47. 3-48. 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. 4-1. 4-2. 4-3. 4-3. 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. x TITLE PAGE NO. Swing Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 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. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 5-43. 5-44. 5-45. 5-46. 5-47. 5-48. 5-49. 5-50. 3121262 TITLE PAGE NO. Wire Rope Adjustment Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-51. 5-52. 5-53. 5-54. 5-55. 5-56. 5-57. 5-58. 5-59. 5-60. 5-61. 5-62. 5-63. 5-64. 5-65. 5-66. 5-67. 5-68. 5-69. 5-70. 5-71. 5-72. 5-73. 5-74. 5-75. 5-76. 5-77. 5-78. 5-79. 5-80. 5-81. 5-82. 5-83. 5-84. 5-85. 5-86. 5-87. 5-88. 5-89. 5-90. 5-91. 5-92. 5-93. 5-94. 5-95. 5-96. 5-97. 5-98. 5-99. 5-100. 5-101. 5-102. 5-103. 5-104. 5-105. 5-106. 5-107. xii TITLE PAGE NO. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-108. 5-109. 5-110. 5-111. 5-112. 5-113. 5-114. 5-115. 5-116. 5-117. 5-118. 5-119. 5-120. 5-121. 5-122. 5-123. 5-124. 5-125. 5-126. 5-127. 5-127. 5-128. 5-129. 5-130. 5-131. 5-132. 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. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. 6-30. 6-31. 3121262 TITLE PAGE NO. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 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. 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. xiv TITLE PAGE NO. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Resistance Measurement . . . . .
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LIST OF FIGURES FIGURE NO. TITLE PAGE NO. This page left blank intentionally.
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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 2-1 2-2 2-3 3-1 3-2 3-2 3-3 3-4 3-5 3-6 4-1 5-1 5-2 5-1 5-4 5-5 5-6 5-7 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 xvi TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-2. Dimensional Data Table 1-1. Operating Specifications Capacity - ANSI Unrestricted Restricted 500 lbs (227 kg) 1000 lbs (454 kg) Turning Radius (Axles Retracted) Outside Inside 22 ft. 6 in. (6.8 m) 14 ft. 5 in. (4.4 m) Capacity - CE & Australia Unrestricted Restricted 500 lbs (230 kg) 1000 lbs (450 kg) Turning Radius (Axles Extended) Inside Outside 8 ft. (2.4 m) 19 ft. 4 in. (5.
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SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES 1.5 ENGINE DATA Table 1-3. Capacities Deutz Hydraulic Oil Tank 55 gal. (208 L) Fuel Tank - Standard 31 gal. (117 L) Fuel Tank - Optional Table 1-5. Deutz TD2011L4 Specifications 52.8 gal. (200 L) Drive Hub Bonfiglioli Reggiana Riduttori 2.1 quarts (2 liters) ± 10% 0.5 quarts (0.5 liters) ± 10% 1.4 TIRES Table 1-4. Tire Specifications Liquid Cooled Number of Cylinders 4 Bore 3.7 in. (94 mm) Stroke 4.4 in. (112 mm) Total Displacement 190 cu. in.
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SECTION 1 - SPECIFICATIONS 1.6 HYDRAULIC OIL Table 1-9. Mobil DTE 13M Specs Table 1-7. Hydraulic Oil Hydraulic System Operating Temperature Range S.A.E. Viscosity Grade +0° to + 180° F (-18° to +83° C) 10W +0° to + 210° F (-18° to +99° C) 10W-20, 10W30 +50° to + 210° F (+10° to +99° C 20W-20 NOTE: Aside from JLG recommendations, 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.
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SECTION 1 - SPECIFICATIONS Table 1-11. Mobil EAL H 46 Specs Type Synthetic Biodegradable ISO Viscosity Grade 46 Specific Gravity .910 Pour Point -44°F (-42°C) Flash Point 500°F (260°C) Operating Temp. 0 to 180°F (-17 to 162°C) Weight 7.64 lb. per gal. (0.9 kg per liter) DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Table 1-13. Component Weights LBS.
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SECTION 1 - SPECIFICATIONS 13 16 14 5 4 4 10,11 7 8 9,12 6 15 2,3 1 4 4 16 Figure 1-1.
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SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE NOTE: 2. Swing Gearbox The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-14. 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.
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SECTION 1 - SPECIFICATIONS 4. A. Wheel Drive Hub - Bonfiglioli 5. Hydraulic Return Filter Lube Point(s) - Level/Fill Plug Capacity - 2.1 quarts (2 liters) ± 10% 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 8 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port.
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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. Suction Strainers (In Tank) Lube Point(s) - Fill Cap/Spin-on Element Capacity 5 Quarts (4.5 L) Cooling System 11 Quarts (10.
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SECTION 1 - SPECIFICATIONS 12. Oil Change w/Filter - CAT 10. Fuel Filter - Deutz Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 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. 11. Fuel Strainer - Deutz 13.
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SECTION 1 - SPECIFICATIONS 14. Air Filter 16. Boom Lube Point(s) - Apply to wear pad contact paths Lube - Super Lube® Interval - Every year or 600 hours of operation. Refer to the Section 4 - Boom for detailed procedures Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 15.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
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SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
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SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121262
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE 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. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operation 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.
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SECTION 2 - GENERAL Component Disassembly and Reassembly 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.
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SECTION 2 - GENERAL 2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage.
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SECTION 2 - GENERAL Cylinder Drift 4. Re-assembly of pinned joints using filament wound bearings. Table 2-2. Cylinder Drift Cylinder Bore Diameter a. Housing should be blown out to remove all dirt and debris...bearings and bearing housings must be free of all contamination. 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.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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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.
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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.
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND 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. Tire Damage Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners.
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SECTION 3 - CHASSIS & TURNTABLE 3.2 EXTENDING AXLES NOTE: The boom must be oriented between the rear wheels to extend or retract the 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.
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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.
PAGE 52
SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE/STEERING SPEED CONTROL 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.
PAGE 53
SECTION 3 - CHASSIS & TURNTABLE Press ENTER , the screen should read: Use the Left To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press ENTER or Right arrow key until you see: , the screen should read: Swing and drive functions can now be used to swing the turntable in the correct direction to return the boom between the rear wheels in the event the boom is beyond the swing envelope when the axles are retracted.
PAGE 54
SECTION 3 - CHASSIS & TURNTABLE 1 15 2 14 3 5 13 4 17 12 16 6 7 10 8 9 11 1001119385-C Figure 3-5.
PAGE 55
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 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) Axle Limit Switch (Left Rear) 10. 11. 12. 13. 14. 15. 16. 17.
PAGE 56
SECTION 3 - CHASSIS & TURNTABLE 2 1 3 28 27 4 5 26 25 6 7 10 11 12 13 23 22 24 21 8 9 14 20 15 16 19 18 17 1001119385-C Figure 3-7.
PAGE 57
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Ground Control Box Headlight Deutz EMR2 Module & Diagnostic Connector 110V / 220V Generator 110V / 220V Generator Control Box Alternator Throttle Actuator Oil Temperature Switch Oil Pressure Switch Intake Heaters In-Head Glow Plugs Engine Speed Sensor Starter Drive Pumps 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
PAGE 58
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.
PAGE 59
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 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. DETAIL B C - Assemble to Side Plates of Axle Weldments; Typical 16 Places. D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
PAGE 60
SECTION 3 - CHASSIS & TURNTABLE Figure 3-11.
PAGE 61
SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes 1. 2. 3. Spindle Angle Sensor Assembly Steer Cylinder 4. 5. 6. A Apply JLG Threadlocker P/N 0100011 B Apply JLG Threadlocker P/N 0100019 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.
PAGE 62
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.
PAGE 63
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 6° above horizontal and not extended beyond 12" [30.4 cm] and drive is selected. 12. Drive machine off of block and ramp back onto the level surface.
PAGE 64
SECTION 3 - CHASSIS & TURNTABLE 3.11 DRIVE HUB - BONFIGLIOLI NOTE: Machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Section 3.12, Drive Hub - Reggiana Riduttori. Do not use different hubs on the same machine. Installation of the Wheel Drive on the Machine 1. Clean the mating surfaces from oils or paint and fit the wheel drive on the machine frame. 2. Attach the gearbox to the machine frame with the mounting bolts and torque to 178 ft.lbs. (241 Nm).
PAGE 65
SECTION 3 - CHASSIS & TURNTABLE 4. Make sure that the functioning is regular and without any excessive noises and vibrations. 5. Make sure that the oil temperature does not exceed values listed previously. 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. After having finished running-in the gearbox, follow the steps given below.
PAGE 66
SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5..........................Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..........Brake port Figure 3-14.
PAGE 67
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.
PAGE 68
SECTION 3 - CHASSIS & TURNTABLE 3. Take out the cap nut (5). THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. 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. Figure 3-15. Gearbox engaged 1. Unscrew the 2 socket head screws M8x16 (4), grade 8.8, of the end cover (7) with a male hex head wrench. 5. Rotate the cap nut (5). 2. Rotate the cap nut (5).
PAGE 69
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. Good maintenance will ensure an ongoing functioning in time as well as maximum reliability. 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.
PAGE 70
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting The following table is provided to help locate problems in the gearbox. Table 3-5.
PAGE 71
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. 5. Remove the springs (45) from their seats in the brake piston (44). 6. By using pliers remove the circlip (36) from its seat in the brake shaft (35). 3. Remove the spring retainer disc (46). 3121262 4. Mark the position of the springs (45) as a reference for the reassembly.
PAGE 72
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.
PAGE 73
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). 10. Remove the external O-Ring seal (38) and the backup ring (37) from their seat in the spacer (39). 11. Remove the O-ring seal (42) and the backup ring (43) from their seats in the flanged hub (31). 8. Remove the spacer (39) from the brake piston (44). 12. Remove brake discs pack (32-33). 9.
PAGE 74
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). 15. Tighten the 2 screws M5x16, grade 8.8, of the cover by a torque wrench to 18.4 ft.lbs. (25 Nm). 3-26 17. Remove the special tool and remove the spring (13) and the washers (12). 18. Turn the gearbox upside down and unscrew the 2 screws M8x16 (4), grade 8.
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SECTION 3 - CHASSIS & TURNTABLE 22. Unscrew the draining-filling-level oil plugs (6) by a male hex head wrench. 19. Remove the cap nut (5). 20. Remove the pin (3). 23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the end cover (7). 21. Remove the O-ring seal (2) from its seat in the end cover (7). 3121262 24. Remove the end cover (7).
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SECTION 3 - CHASSIS & TURNTABLE 25. Remove the O-ring seal (9) from its seat in the end cover (7). 28. Remove the 2nd stage sun gear (17). 29. Remove the 2nd reduction assembly (18). 26. Remove the 1st stage sun gear (10). 27. Remove the 1st reduction assembly (16). 3-28 30. By using pliers remove the circlips (19) from their seats in the flanged hub's pins (31).
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SECTION 3 - CHASSIS & TURNTABLE 31. By using a puller remove the planet assemblies of the 3rd reduction (20). 32. Remove the spacer (21) from their seats in the pins of the flanged hub (31). 34. By using a tackle place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 35. By using the torque multiplier (ATZ.09.016.0) loosen the ring nut (22). 36. Take out the ring nut (22).
PAGE 78
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).
PAGE 79
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. Assembly Apply grease TECNOLUBE SEAL GS730 on the gearbox housing (23). metallic rings in volatile solvent or industrial degreasing alcohol. c. Carefully clean the lapped surface (D) of metal rings (E) and remove dust or fingerprints.
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SECTION 3 - CHASSIS & TURNTABLE 7. Apply grease TECNOLUBE SEAL GS730 on the seal ring (30). 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. AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29) 8. By using a hoist, place the gearbox housing (23) on the flanged hub (31). 6. Insert the seal ring (30) in its seat in the flanged hub (31). 9.
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SECTION 3 - CHASSIS & TURNTABLE flanged hub (31) until assembling of the unit is complete. SCREW THE NUT (22) ON PARTIALLY IN ORDER TO PREVENT THE FLANGED HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE FOLLOWING STEPS. 10. By using a hoist place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 3121262 11. By using the multiplier (ATZ.09.016.0), tighten the ring nut (22), using a torque wrench with an input multiplier torque of 71 ± 3 ft.lbs.
PAGE 82
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.
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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).
PAGE 84
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. Assemble the cap nut (5).
PAGE 85
SECTION 3 - CHASSIS & TURNTABLE 31. Insert the splined shaft (14) in the equipment (6689960240). 34. By using pliers, assemble the elastic ring (11) into its seat in the splined shaft (14). 32. Insert the 2nd washer (12) correctly in the splined shaft (14). 35. Insert the disengagement shaft kit (15) in the flanged hub (31). 33. Torque the 2 screws M5x16, grade 8.8, of the cover to 18.4 ft.lbs. (25 Nm).
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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. Assemble the brake discs package according to the following order: first, insert one sintered bronze disc with external teeth (33). 3-38 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. 40.
PAGE 87
SECTION 3 - CHASSIS & TURNTABLE 42. Insert the spacer (39) inside the flanged hub (31), paying attention not to damage the seals already fitted. 44. Lube the seal seats into the flanged hub (31) and assemble the O-ring seal (42) and the backup ring (43). 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.
PAGE 88
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. 48. Insert the spring retainer disc (46). 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.
PAGE 89
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: 1.
PAGE 90
SECTION 3 - CHASSIS & TURNTABLE Figure 3-18.
PAGE 91
SECTION 3 - CHASSIS & TURNTABLE Figure 3-19.
PAGE 92
SECTION 3 - CHASSIS & TURNTABLE Figure 3-20.
PAGE 93
SECTION 3 - CHASSIS & TURNTABLE Figure 3-21.
PAGE 94
SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE HUB - REGGIANA RIDUTTORI 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 3.11, Drive Hub - Bonfiglioli. Do not use different hubs on the same machine. M- 1326 Ø240 Symbol Nomenclature Ø130 5x45° 10 = ADHESIVE ° 15 5 R5 35 Ø30 Ø224 Ø233 Ø240 60° ° 60 60 ° = LUBRICANT A A = GREASE N° 6 Hole to 120° Ø30 Figure 3-22.
PAGE 95
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 3-24. Bearing Spacer Mounting CO16117 Figure 3-25.
PAGE 96
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 Figure 3-28. Anti-rotation Block M- 1317 M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-26. 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.
PAGE 97
SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-30.
PAGE 98
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 3-31.
PAGE 99
SECTION 3 - CHASSIS & TURNTABLE Disassembly 3. Release the screws from the release cover and pull the pin out. 1. Remove the plugs and pour the lubricant in a container. 4. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring. 2. Release the screws to disassemble the motor flange taking care not to damage the O-Ring. 5. Pull the reduction gears out.
PAGE 100
Figure 3-32.
PAGE 101
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 3121262 – JLG Lift – Iron Brake Disc Plastic Plug Spindle Planet Wheel Bearing Outer Retention Ring Input Shaft Input Shaft Bearing Ring Disengagement Spring Disengagement Shaft Spindle Oil Seal 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
PAGE 102
SECTION 3 - CHASSIS & TURNTABLE 6. Loosen the M10x25 flathead socket screws and remove the planetary ring without damaging the ORing. 9. Loosen the M6x6 socket headless screws and also remove the 3/16" balls. 10. Loosen the ring nut using the special wrench. 7. Remove the release joint together with the spring. 8. Disassemble the Ø40 outer snap rings and using an extractor remove the planetary gears from the spindle pins. 3-54 11. Remove the hub support together with the roller bearing inner track.
PAGE 103
SECTION 3 - CHASSIS & TURNTABLE 12. 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. 13. Remove the brake discs and seals. 3.
PAGE 104
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.
PAGE 105
SECTION 3 - CHASSIS & TURNTABLE 9. Now check the unit roll torque and proceed in the following order: 10. 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.
PAGE 106
SECTION 3 - CHASSIS & TURNTABLE the spindle pins. Lock with a ÿ40 outer snap ring. Lubricate the bearings. 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. 14. 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 2275 in the hub support seat.
PAGE 107
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. 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 2.4daNm with LOCTITE 243 Insert the pin and carry out the rotation test according to PGQ22 standard. 18.
PAGE 108
SECTION 3 - CHASSIS & TURNTABLE 1. Swing Drive 2. Inner Race Bearing Bolt 3. Swing Bearing 4. Outer Race Bearing Bolt 5. Turntable Lock Pin 6. Remote Bearing Lubrication Fittings Figure 3-34.
PAGE 109
SECTION 3 - CHASSIS & TURNTABLE 3.13 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.
PAGE 110
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36) and remove fittings from Brake (26) and Motor Control Valve (32). 1. Place unit on bench with the motor end up. 5. Remove O-ring Plugs (21) from Motor Control Valve (32). 2. Remove O-ring Plug (1J) and drain the oil from the gearbox. 6. Remove Motor Control Valve (32) from Motor (10) by removing the four Bolts (34) and washers (33). 3.
PAGE 111
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor (10). 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 4. Remove Brake (26) from Main Torque-Hub Assembly and dump oil out of Brake (26). 5.
PAGE 112
SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15) from between Input Cover (6) and Carrier (3A) Subassembly. 1. 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). 7. Remove Ring Gear (4) from Housing (1G). 8. Remove O-ring (5) from between Ring Gear (4) and Housing (1G). 2.
PAGE 113
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G). 1. Using retaining ring pliers, remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard. 5. Invert the Housing (1G) and remove the Lip Seal (1B) if not already removed when Output Shaft (1A) was pressed out of Housing (1G). 6. Remove the Bearing Cone (1D). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Bearing Cups (1C & 1E) will remain in Housing (1G). 2.
PAGE 114
SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust Washers (3H) and the two Thrust Washers (3B) out of the Carrier (3A). 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. 4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F). NOTE: Make sure that the Roll Pin has bottomed.
PAGE 115
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly 8. Press or tap the Bearing Cone (1F) onto the Output Shaft (1A) until it is seated in the Bearing Cup (1E). 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.
PAGE 116
SECTION 3 - CHASSIS & TURNTABLE Carrier Sub-Assembly 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). 1.
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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 3-41.
PAGE 118
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 3-42.
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SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh with the Internal Gear (2) and Input Gear (13). On the Ring Gear (4) locate the hole marked "X", or punch marked, over one of the marked counterbored holes (Step 5) in Hub (1G). Check timing through the slots in the carrier. Rotate carrier in assembly to check for freedom of rotation. 1.
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SECTION 3 - CHASSIS & TURNTABLE 2. 4. 5. 6. 8. 13. Internal Gear Ring Gear O-Ring Input Cover Hex Bolt Sun Gear 15. 16. 17. 18. 19. 20. Thrust Bearing Thrust Washer Hex Bolt Shoulder Bolt Lockwasher Pipe Plug Figure 3-43.
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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.
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SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque 13 to 15 ft-lbs. (18 to 21 Nm). 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).
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SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BRAKE of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. 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. HYDRAULIC/MECHANICAL To check brake release, connect an appropriate hydraulic pressure supply set to the required level up to a maximum 1. 2.
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SECTION 3 - CHASSIS & TURNTABLE Installation 8. Remove internal retaining ring (11). 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.
PAGE 125
SECTION 3 - CHASSIS & TURNTABLE To ensure correct brake operation, it is important that the backing rings are assembled opposite ti the pressurized side of piston (9). 5. Correctly orientate piston (9) aligning spaces with the two dowel pin holes and, assemble into cylinder housing (8) taking care not to damage seals and carefully lay aside. 6. Loctite 2-off pins (19) in housing (2) followed by pressure plate (4) and friction plates i.e. an inner (3) followed by an outer (6) in correct sequence. 1. 2. 3.
PAGE 126
SECTION 3 - CHASSIS & TURNTABLE 3.15 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.
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SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing 2. End Cover 8C. Vane 16. Seal 3. Seal Ring-Commutator 8D. Stator Half 17. Back-up Washer 4. Seal Ring 9. Wear Plate 18. Housing 5. Commutator Ring 10. Drive Link 18A. O-Ring 6. Commutator Ring 11. Not Used 19. Bearing/Bushing, Outer 7. Manifold 12. Coupling Shaft 20. Dirt & Water Seal 8. Rotor Set 13. Bearing/Bushing, Inner 21. Plug 8A. Rotor 14. Thrust Washer Figure 3-48. Swing Drive Motor 5.
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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. 8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring.
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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.
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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). 15. Remove coupling shaft (12), by pushing on the output end of shaft.
PAGE 131
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. 20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics.
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SECTION 3 - CHASSIS & TURNTABLE replaced. If the housing has passed 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.
PAGE 133
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).
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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.
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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. 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™. 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.
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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. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-70M. NOTE: Mobil Mobilith SHC ® 460 NOTE: A 102Tube (P/N 406010) is included in each seal kit.
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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.
PAGE 138
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. 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.
PAGE 139
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.
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SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures. 1. 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.
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SECTION 3 - CHASSIS & TURNTABLE 3.16 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 footpounds (122 Nm) with Loctite #271. 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.
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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. Torque the capscrews shown in step 5 to 660 footpounds (896 Nm). 10. Remove shim and discard. 3.17 SWING DRIVE LUBRICATION Figure 3-50.
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SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not penetrate under the bolt head to the bolt shank. Turntable Bearing Mounting Bolt Condition Check THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-51.
PAGE 145
Figure 3-52.
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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. If bearing inspection shows no defects, reassemble and return to service. Figure 3-53.
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SECTION 3 - CHASSIS & TURNTABLE Turntable/Swing Bearing Removal The following procedure was accomplished using two overhead cranes with the jib assembly and the boom removed prior to un-decking the turntable. For un-decking information concerning lifting the entire upperstructure as a unit, or removing the boom and jib assembly together refer to Section 4 - Boom & Platform. additional lines to gain access to certain fittings. Cap or plug all openings. 1.
PAGE 148
Figure 3-54.
PAGE 149
3121262 Main Boom Pivot – JLG Lift – Boom & Jib Assembly - 20,650 lbs. (9,370 kg) Figure 3-55.
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3-102 Main Boom Pivot – JLG Lift – Figure 3-56. Swing Bearing Removal - Sheet 3 of 4 CENTER OF GRAVITY 227” (576.5 cm) Boom Assembly - 10,791 lbs.
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3121262 – JLG Lift – Figure 3-57. Swing Bearing Removal - Sheet 4 of 4 C L ROTATION Note: Attach Lifting Device to Turntable Cutouts Closest to This Side of Turntable Turntable - 12,850 lbs.
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SECTION 3 - CHASSIS & TURNTABLE 6. Lay the jib control valve aside on the jib. Secure it in place so it does not fall. 8. Remove the bolt and keeper pin securing the jib level cylinder pivot pin and remove the pin. Place blocking or a soft material under the cylinder rod to protect the rod surface from being scratched. 7. Disconnect the jib protractor sensor linkage from the boom. NOTE: The jib and platform assembly weighs approximately 2100 lbs. (953 kg.).
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SECTION 3 - CHASSIS & TURNTABLE 9. Attach an adequate supporting device to the jib to support its weight. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin. 11. At the rear of the turntable, tag and disconnect all wiring harnesses that run from the powertrack to the ground control station. The connector inside the ground control box will have to be removed from the wires to allow the harness to be pulled out of the control box.
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SECTION 3 - CHASSIS & TURNTABLE 13. Have a container or absorption material ready to catch residual hydraulic fluid. Disconnect the telescope hoses from the bottom of the hydraulic control valve. Cap or plug all openings. Pull the hoses out so the can be lifted away from the machine with the boom. 14. Have a container or absorption material ready to catch residual hydraulic fluid. Disconnect the pressure hose from the end of the main control valve. Cap or plug all openings. 3-106 15.
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SECTION 3 - CHASSIS & TURNTABLE 17. Using the Main Lift Crackpoint option under the Calibrations menu on the JLG Analyzer, lift the boom enough to access the boom lift cylinder rod pivot pin. Refer to Section 6 - JLG Control System for additional analyzer instructions. NOTE: To assist in determining when the lift cylinder is properly supported, use the JLG Analyzer and select Diagnostics > Moment > Actual Moment and get a reading as close to zero (0) as possible. 20.
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SECTION 3 - CHASSIS & TURNTABLE 24. Disconnect the negative battery terminal from the battery. 25. Place a container under the machine to catch escaping hydraulic fluid. 27. Remove the attaching hardware securing the side of the hood. 28. Remove the attaching hardware securing the top of the hood. 29. Remove the front hood from the machine. NOTE: The hood assembly weighs approximately 72 lbs. (33 kg). 26. Attach an adequate lifting device to the rear hood assembly. 30.
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SECTION 3 - CHASSIS & TURNTABLE 31. Tag and disconnect the hoses from the top of the swivel. Cap or plug all openings. Use a tie strap to secure the hoses together. NOTE: The complete swing drive assembly weighs approximately 290 lbs. (132 kg). 34. Remove the hardware securing the swing drive to the turntable and remove the swing drive. 32. Tie off the bundle of hydraulic hoses to the center support to prevent any damage to the hoses during the remainder of the procedure.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: The turntable assembly 20,650 lbs. (9370 kg). weighs approximately 37. Lift the turntable assembly off of the swing bearing and place it on adequate supports. 35. Using the lifting lugs and the center support, attach a lifting device to the front and rear of the turntable to support its weight. 36. Remove the swing bearing inner race bolts.
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SECTION 3 - CHASSIS & TURNTABLE 40. Install lifting eyes into the swing bearing for removal. Turntable/Swing Bearing Installation 1. Remove the attaching hardware securing the swivel and lay it off to the side. NOTE: The swing bearing weighs approximately 300 lbs. (136 kg). 41. Attach an adequate lifting device to the swing bearing and remove it from the frame. 2. Thoroughly clean the bearing mounting surface and mounting holes.
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SECTION 3 - CHASSIS & TURNTABLE 3. Locate the high spot on the swing bearing. This will be marked by blue paint and two X’s on the bearing teeth. 7. Install grease fittings into the bearing and also install two pins to facilitate turning the bearing by hand and for alignment of the turntable. 4. Place the new bearing onto the frame orienting the high spot as close as possible to where the swing drive gear will be. 8.
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SECTION 3 - CHASSIS & TURNTABLE 12. Lift the turntable into place on the bearing using the previously installed guide pins for alignment. 15. Connect the hoses to the top of the swivel as tagged during removal. Secure the hoses together with a tie strap as shown. 13. Install all of the inner race bearing bolts hand tight. Remove the guide pins to install the last two bolts. After all of the bolts are installed, tighten them until snug.
PAGE 162
SECTION 3 - CHASSIS & TURNTABLE 17. Position the swing drive mounting bolts and backlash adjusting shim, JLG p/n 4071041. Set backlash following the procedures in this section. 19. Lift the boom from its supports. 18. Attach the swing bearing remote lubrication lines to the turntable.
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SECTION 3 - CHASSIS & TURNTABLE 20. While lifting the boom into position, begin to route the hoses into position so they can be inserted into the powertrack. 22. Raise the boom enough to gain access to the lift cylinder rod pivot fitting. 23. Attach a lifting device to the lift cylinder barrel. Lift the lift cylinder up to align the lift cylinder rod pivot fittings. 21. Line up the boom pivot fittings and install the boom pivot pin.
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SECTION 3 - CHASSIS & TURNTABLE 25. Connect the hoses to the main valve and pressure filter as tagged during removal. 29. Place something under the front of the jib that will allow it to slide or move along the ground easily. Attach a lifting device to the rear of the jib, allowing the front to pivot on the ground. 26. Reconnect the negative battery terminal. 30. Lift the jib into position on the boom fly section and install the jib pivot pin.
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SECTION 3 - CHASSIS & TURNTABLE 31. Attach a lifting device to the front of the jib and align the jib level cylinder attachment fittings. Install the pivot pin. Apply JLG Threadlocker P/N 0100019 to the bolt and secure the pivot pin in place with the keeper pin and bolt. Torque the bolt to 165 ft.lbs. (224 Nm). 33. Install the wiring harnesses and hydraulic hoses on the jib valve as tagged during removal. 34. Install the jib valve protection plate. 35.
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SECTION 3 - CHASSIS & TURNTABLE 36. Position the hoods in place on the turntable and secure in place with the mounting hardware. Swing Bearing Torque Values 1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite. 2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite. 3. See Swing Bearing Torquing Sequence. CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS THEREAFTER. 37. Cycle test the machine and check for leakage and proper operation. 38.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-58. Swing Bearing Torque Sequence 3.19 SWING SPEED PROPORTIONING 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.
PAGE 168
SECTION 3 - CHASSIS & TURNTABLE 3.21 GENERATOR Every 500 hours Every 250 hours Every 250 hours of operation, check the drive belt for proper tension. Every 500 hours of operation, service the generator brushes and slip rings. Hostile environments may require more frequent service. 1/2 in. (13 mm) Every 500 hours of service, blow out the inside of the generator. If operating in a hostile environment, clean monthly.
PAGE 169
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 3-59.
PAGE 170
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. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-59.
PAGE 171
SECTION 3 - CHASSIS & TURNTABLE 3.22 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.
PAGE 172
SECTION 3 - CHASSIS & TURNTABLE 3.23 ENGINE NOTE: Refer to the engine manufacturer’s manual for detailed operating and maintenance instructions. 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 3-61., Deutz Engine Dipstick.
PAGE 173
SECTION 3 - CHASSIS & TURNTABLE Changing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-62., Engine Oil Viscosity for the proper grade. 1. Allow the engine to warm up. The engine oil should reach approximately 176° F (80° C). 2. Make sure the machine and engine are level. 3. Switch off the engine. 4. Place an oil tray under the engine. 5. Open the oil drain valve. Figure 3-62.
PAGE 174
SECTION 3 - CHASSIS & TURNTABLE 2. Using a suitable oil filter removal tool, loosen the lube oil filter cartridge and spin off. Replacing the Fuel Filter 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. WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEM. 1. Wipe the area around the filter to clean any dirt from the area. 2.
PAGE 175
SECTION 3 - CHASSIS & TURNTABLE Cleaning the Fuel Strainer 3.24 DEUTZ EMR 2 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.
PAGE 176
SECTION 3 - CHASSIS & TURNTABLE CONTROL ROD POSITION SENSOR/ACTUATOR COOLANT TEMPERATURE SENSOR POWER SUPPLY FLYWHEEL SPEED SENSOR GLOW PLUG JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM 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 3-63.
PAGE 177
3121262 – 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?
PAGE 178
Figure 3-65.
PAGE 179
Figure 3-66.
PAGE 180
Figure 3-67.
PAGE 181
SECTION 3 - CHASSIS & TURNTABLE Figure 3-68.
PAGE 182
SECTION 3 - CHASSIS & TURNTABLE Figure 3-69.
PAGE 183
Figure 3-70.
PAGE 184
Figure 3-71.
PAGE 185
Figure 3-72.
PAGE 186
Figure 3-73.
PAGE 187
Figure 3-74.
PAGE 188
SECTION 3 - CHASSIS & TURNTABLE 3.25 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. The DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with a cetane number of at least 51. DEUTZ engines for mobile machinery are designed for a cetane number of at least 45.
PAGE 189
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.
PAGE 190
SECTION 3 - CHASSIS & TURNTABLE 3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS This section is organized in the following manner: This section defines the diagnostics and recommended troubleshooting procedures associated with the engine control module (ECM) on the CAT 3.4 engine. 1st page of Diagnostic Information for a Given Fault (See Figure 3-75.) then: 2nd Page of Diagnostic Information for a Given Fault (See Figure 3-76.
PAGE 191
SECTION 3 - CHASSIS & TURNTABLE DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Yes Troubleshooting flow chart No Figure 3-76.
PAGE 192
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
PAGE 193
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
PAGE 194
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.
PAGE 195
SECTION 3 - CHASSIS & TURNTABLE DTC 116- ECT Higher Than Expected Stage 1 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 1 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.
PAGE 196
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.
PAGE 197
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.
PAGE 198
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.
PAGE 199
SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-151
PAGE 200
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 • Non-emissions related fault In the case of a diesel engine, an actuator controls a fuel injection pump, d
PAGE 201
SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-153
PAGE 202
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,
PAGE 203
SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-155
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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.
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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 • Check Condition-Engine Running • Fault Condition-Engine speed greater than the max governor override speed as defined in the diagnostic calibration • Corrective Action(s): Sound audible warning or illuminate secondary warning lamp, reduce throttle to limit speed.
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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
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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
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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 • Emissions related fault The crankshaft po
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SECTION 3 - CHASSIS & TURNTABLE DTC 521- Oil Pressure Sender/Switch High Pressure 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.
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SECTION 3 - CHASSIS & TURNTABLE DTC 524- Oil Pressure Low 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 running for z seconds as defined in the diagnostic calibration. For systems that use a switch this fault can be configured two different ways. It may use a normally closed switch or a normally open switch. If the switch is normally open, the fault will set if the circuit becomes grounded.
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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
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-165
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SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High BLACK RED/TAN • System voltage to ECM • Check Condition- Key on, Engine Cranking or Running 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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-167
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-169
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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
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-171
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-173
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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.
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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.
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SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 ECM Microprocessor RAM • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3-176 The ECM has checks that must be satisfied each time an instruction is executed.
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SECTION 3 - CHASSIS & TURNTABLE DTC 1613- Microprocessor Failure - RTI 2 ECM Microprocessor RAM • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121262 The ECM has checks that must be satisfied each time an instruction is executed.
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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 3-178 – JLG Lift – 3121262
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SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 ECM Microprocessor RAM • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121262 The ECM has checks that must be satisfied each time an instruction is executed.
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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 3-180 – JLG Lift – 3121262
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SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D ECM Microprocessor RAM • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121262 The ECM has checks that must be satisfied each time an instruction is executed.
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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 3-182 – JLG Lift – 3121262
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SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure interrupt ECM Microprocessor RAM • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121262 The ECM has checks that must be satisfied each time an instruction is executed.
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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 3-184 – JLG Lift – 3121262
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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.
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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) • Verify that all CAN devices are powered and are properly grounded • Verify that the CAN network is properly terminated • Corrective Action(s)- Illuminate MIL, so
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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) • Verify that all CAN devices are powered and are properly grounded • Verify that the CAN network is properly terminated • Corrective Action(s)- Illuminate MIL, soun
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-189
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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.
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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 • Throttle Actuator (with serial/digital position feedback) Diagnostic Aids • Check Condition- Key On, Engine Running and/or Stopped • Verify that the throttle actuator 5V supply voltage is present at the actuator. • Fault Condition- ECM is expecting to receive throttle position information from the throttle actuator and is not.
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-193
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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.
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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.
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SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT INDEX 3-196 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
PAGE 245
SECTION 3 - CHASSIS & TURNTABLE 3.27 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-77., Counterweight Bolt Torque.
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SECTION 3 - CHASSIS & TURNTABLE APPLY THREADLOCKER P/N 0100019 TO BOLT AND THREADS IN COUNTERWEIGHT. TORQUE TO 400 FT LBS (542 Nm). Figure 3-77.
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM SYSTEMS Transport Position Sensing System NOTE: For more detailed information concerning system adjustment and operation, refer to Section 6 - JLG Control 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.
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SECTION 4 - BOOM & PLATFORM 2 1 4 3 5 6 7 8 9 10 12 11 13 15 14 16 Figure 4-1.
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SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. 7. 8. Boom Cable Proximity Sensor Boom Length Sensor Boom Angle Sensor #1 Boom Angle Sensor #2 Boom Length & Angle Module Lift Cylinder Pivot Pin Main Boom Transport Limit Switch Jib Level Rotary Sensor 9. 10. 11. 12. 13. 14. 15. 16.
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SECTION 4 - BOOM & PLATFORM Drive/Steer – Boom Function Interlock System (CE ONLY) Envelope Tracking System 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.
PAGE 251
SECTION 4 - BOOM & PLATFORM Boom Control System (BCS) Functional Check (Push to Test) System Jib Leveling During Automatic/Manual Envelope Control The machine is equipped with a system for the operator to daily verify the proper functioning of the Boom Control System (Envelope Control System and the Moment Control System).
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SECTION 4 - BOOM & PLATFORM Press ENTER , the screen should read: Press ENTER To enable the level override mode 58237 must be entered as the code. When the code is entered, the screen will show: , the screen should read: Using the UP and DOWN arrow keys will toggle the override from off to on. Once turned on, operating the jib lift function will cause jib level to be activated. NOTE: Using this override may set the JIB LEVELING SYSTEM FAULT depending on how far out of level the jib is moved.
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SECTION 4 - BOOM & PLATFORM Attempts to lift the main boom while this override is on will result in a JIB LEVELING SYSTEM FAULT because during the override automatic jib leveling is disabled. To adjust the jib back to level go into override mode for the jib leveling. Turn it on, escape out of the Service Modes menu, and go to DIAGNOSTICS/BOOM SENSORS menu. Use the RIGHT ing screen.
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SECTION 4 - BOOM & PLATFORM Jib Lock Pin override is accessible in Access Level 1. Press ENTER Using the Left and Right screen shown below is reached. , the screen should read: arrow keys until the To enable the override mode 58237 must be entered as the code.
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SECTION 4 - BOOM & PLATFORM Use the Left or Right arrow key until you see: Using the Up and Down the following modes: arrow keys will allow • OFF • EXTEND • RETRACT Once the desired mode is selected, stepping into the footswitch with the machine running will perform extension or retraction of the jib lock pin. Reset or turning it off is achieved by escaping out of the service mode, by cycling power to the machine, or re-entering the service mode and manually turning it off.
PAGE 256
SECTION 4 - BOOM & PLATFORM Swing/Axle Extend Retract Restrictions Boom Recovery override is accessible in Access Level 1. In addition to the Direction Of Steer proximity switch in the chassis, a 360 degree dual rotary sensor is also used to calculate the turntable rotation angle. These sensors are used together to restrict swing when the machine is in the transport state.
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SECTION 4 - BOOM & PLATFORM To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press Enter . Once Enter is pressed using the Up or Down arrow key will turn the boom recovery on or off. Once turned on, main boom lift down will be enabled and main telescope in will be enabled to recover the boom. After the boom is brought down it will be trapped into transport.
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SECTION 4 - BOOM & PLATFORM 4.3 BOOM REMOVAL AND INSTALLATION 4. Disconnect the telescope hoses from the bottom of the hydraulic control valve. Pull the hoses out so the can be lifted away from the machine with the boom. Removal 1. Remove the Jib Assembly. Refer to Section 4.6 - Jib. 2. At the rear of the turntable, tag and disconnect all wiring harnesses that run from the powertrack to the ground control station.
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SECTION 4 - BOOM & PLATFORM 6. Remove the cover from the rear of the boom and disconnect the wiring harnesses and hoses running from the turntable to the boom. 8. Using the Main Lift Crackpoint option under the Calibrations menu, lift the boom enough to access the boom lift cylinder rod pivot pin. 7. Disassemble the end of the turntable to boom powertrack from the turntable. Use a lifting device to pull the powertrack up so the hydraulic hoses and wiring harnesses can be pulled out from the turntable.
PAGE 260
SECTION 4 - BOOM & PLATFORM 11. Remove the bolt and keeper pin securing the boom lift cylinder rod pivot pin and drive out the pivot pin. Installation 1. Lift the boom from its supports. 12. Lower the lift cylinder until it rests on the turntable. 13. Attach an adequate lifting device to support the rear of the boom. 14. Remove the bolt and keeper pin securing the boom pivot pin and remove the pivot pin. Remove the boom from the machine and place it on adequate supports.
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SECTION 4 - BOOM & PLATFORM 2. While lifting the boom into position, begin to route the hoses into position so they can be inserted into the powertrack. 4. Raise the boom enough to gain access to the lift cylinder rod pivot fitting. 5. Attach a lifting device to the lift cylinder barrel. Lift the lift cylinder up to align the lift cylinder rod pivot fittings. 3. Line up the boom pivot fittings and install the boom pivot pin.
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SECTION 4 - BOOM & PLATFORM 7. Connect the hoses to the main valve and pressure filter as tagged during removal. 11. Position the hoods in place on the turntable and secure in place with the mounting hardware. 8. Reconnect the negative battery terminal. 12. Cycle test the machine and check for leakage and proper operation. 9. Using auxiliary power, lower the boom to horizontal. 10. Connect all electrical harnesses as tagged during removal.
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SECTION 4 - BOOM & PLATFORM 4.4 BOOM DISASSEMBLY/ASSEMBLY & CABLE REPLACEMENT 6. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin. 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. Disassembly NEVER HANDLE WIRE ROPE WITH BARE HANDS. 1. Position the boom so that it is horizontal.
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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. 9. Unbolt the lower powertrack tube from the outer mid boom section and the mounting bracket from the inner mid boom section.. 10. Attach a strap or other similar device around the powertrack and boom to keep the powertrack secure throughout the cable replacement procedure.
PAGE 265
3121262 – JLG Lift – Boom Base Boom Inner Mid Boom Outer Mid Boom Fly Figure 4-3. Boom Assembly - Sheet 1 of 7 1. 2. 3. 4.
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4-20 – JLG Lift – 7. Retract Rope Retainer Plate 8. Lock Plate 9. Tele Cylinder Wear Pads Figure 4-3. Boom Assembly - Sheet 2 of 7 1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 2. Outer Mid Retract Sheave 5. Rope Retainer Block 3. Rope Retainer Block 6.
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1. 2. 3. 4. 5. 3121262 – JLG Lift – 6. 7. 8. 9. Shim Tele Cylinder Pulley Assembly Bottom Rear Wear Pad Shim Figure 4-3.
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1. 2. 3. 4. 5. 4-22 – JLG Lift – 6. 7. 8. 9. Rope Retainer Block Level Cylinder Front Lower Wear Pad Lock Plate Figure 4-4.
PAGE 269
3121262 – JLG Lift – 4. Shim 5. Lock Plate Figure 4-5. Boom Assembly - Sheet 5 of 7 1. Front Upper Wear Pad 2. Shim 3.
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4-24 – JLG Lift – 4. Outer Mid Retract Rope 5. Proximity Switch Spring 6. Switch Adjustment Block Figure 4-6. Boom Assembly - Sheet 6 of 7 1. Outer Mid Extend Rope 2. Fly Extend Rope 3.
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Figure 4-7.
PAGE 272
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. 13. Remove the cover over the boom length limit switch at the front of the boom base section. Remove the switch. 12. Remove the boom length plate. 14. Remove the rear boom cover.
PAGE 273
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. 3121262 18.
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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. 23. Remove the cover plate from the bottom of the boom and remove the sheave blocks. 22. Remove the cable mounting plate. 24. Remove the trunnion blocks that secure the telescope cylinder rod to the boom base section.
PAGE 275
SECTION 4 - BOOM & PLATFORM 25. Remove the outer mid retract cables from the attachment fixtures at the front of the boom base section. 27. Pull the inner mid, outer mid, and fly boom sections out of the base boom section. Use additional lifting devices and reposition any lifting straps as necessary as the sections are withdrawn. It will be helpful during this step to pull the outer mid retract cable out from the front of the base section as the other sections are being pulled out.
PAGE 276
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. 4-30 30. Remove the hardware attaching the outer mid extend block and remove the block and outer mid extend cables. 31.
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SECTION 4 - BOOM & PLATFORM 32. Remove the rear bottom wear pad. 34. Pull the fly boom extend cables from their mounting receptacles. 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. 35. Remove the top, side, and bottom wear pads from the front of the inner mid boom sections.
PAGE 278
SECTION 4 - BOOM & PLATFORM 36. 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.
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SECTION 4 - BOOM & PLATFORM 40. 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. 41. Remove the front wear pads from the outer mid boom section.
PAGE 280
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.
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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.
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SECTION 4 - BOOM & PLATFORM 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. 3. Install the fly retract wire rope button ends into the slots in the side of the fly boom, coil the remaining lengths of wire rope and place them into the fly boom, tape the slots to keep the rope from jumping out. 2.
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SECTION 4 - BOOM & PLATFORM Ft-Lbs. Nm A 165 224 B 165 224 C 35 49 D 50 70 Figure 4-8.
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SECTION 4 - BOOM & PLATFORM #0100019 #0100011 #0100011 #0100019 #0100019 #0100011 #0100011 SECTION A-A Figure 4-9.
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SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-10.
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SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-11.
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SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 Figure 4-12.
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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. 5. Apply JLG Threadlocker P/N 0100011 to the bolts and install the front lower wear pads and shims to the outer mid boom as marked during disassembly. Torque the bolts to 50 ft.lbs.
PAGE 289
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). 12. Apply a thin coat of moly paste lubricant to the inside diameter of the sheave composite bearings. Install the fly retract sheaves and bushings while guiding the wire ropes into the sheave grooves. Apply moly paste lubricant on the inside diameter of the sheave bushing cup.
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SECTION 4 - BOOM & PLATFORM 16. 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. 17. Using an adequate lifting device, align the outer mid boom section with the inner mid boom section. 20. Push the outer mid assembly part way into the inner mid boom section.
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SECTION 4 - BOOM & PLATFORM 21. 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. 22.
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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). 27. Apply a thin coat of moly paste lubricant to the inside diameter of the sheave composite bearings. Install the retract sheaves and bushings while guiding the wire ropes into the sheave grooves. Apply moly paste lubricant on the inside diameter of the sheave bushing cup. Ensure the sheaves move freely.
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SECTION 4 - BOOM & PLATFORM 32. Route the cables around the sheave on the cylinder and install the cable retainer block. 29. Install a new sheave on the telescope cylinder. 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. Install the other end of the outer mid extend cables into the cable guide block.
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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). 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.
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SECTION 4 - BOOM & PLATFORM 40. Push the inner mid boom assembly the rest of the way into the boom base section, adjusting the lifting device as necessary to keep the weight balanced. 46. Install the outer mid retract cable adjustment nuts at the front of the boom base section. 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.
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SECTION 4 - BOOM & PLATFORM 4.5 LOAD SENSING PIN REMOVAL AND INSTALLATION 1. Place the machine on a firm, level surface. NOTE: Replacing the load sensing pin requires the boom sensors be re-calibrated. Make sure the machine is in an area where this can be accomplished after installation of the new pin. 4846765. If the Load Pin Removal Tool is not available, use an arbor of the proper size (as shown below).
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SECTION 4 - BOOM & PLATFORM Figure 4-13.
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SECTION 4 - BOOM & PLATFORM 4.6 JIB additional lines to gain access to certain fittings. Cap or plug all openings. Removal 1. Lower the platform to the ground or onto blocking to support the weight of the jib. 2. Tag and disconnect the electrical harnesses that run to the jib. If necessary, loosen the guide block to allow the harnesses and hoses to move more freely. 5. Unbolt the valve from the boom. 3. Remove the jib valve protection plate. 6. Lay the jib control valve aside on the jib.
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SECTION 4 - BOOM & PLATFORM 7. Disconnect the jib protractor sensor linkage from the boom. NOTE: The jib and platform assembly weighs approximately 2100 lbs. (953 kg.). 9. Attach an adequate supporting device to the jib to support its weight. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin. 8. Remove the bolt and keeper pin securing the jib level pivot pin and remove the pin.
PAGE 300
SECTION 4 - BOOM & PLATFORM Installation 1. Attach an adequate lifting device to the jib and position it in front of the boom. 3. Lift the jib into position on the boom fly section and install the jib pivot pin. Secure the pin in place with the keeper pin and bolt. 2. Place something under the front of the jib that will allow it to slide or move along the ground easily. Attach a lifting device to the rear of the jib, allowing the front to pivot on the ground.
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SECTION 4 - BOOM & PLATFORM 4. Attach a lifting device to the front of the jib and align the jib level cylinder attachment fittings. Install the pivot pin. Apply JLG Threadlocker P/N 0100019 to the bolt threads and secure the pin in place with the keeper pin and bolt. Torque the bolt to 165 ft.lbs. (224 Nm). 5. Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section. 6. Install the wiring harnesses and hydraulic hoses on the jib valve as tagged during removal. 7.
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SECTION 4 - BOOM & PLATFORM JIB ROTARY ACTUATOR JIB LIFT CYLINDER PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR JIB BASE BOOM JIB LOCK CYLINDER JIB POWER TRACK JIB FLY BOOM PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR 1001118868-A Figure 4-14.
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SECTION 4 - BOOM & PLATFORM PIN KEEPER BOLT * TORQUE 120 FT.LBS. (163 Nm) PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR PIN KEEPER BOLT PIN KEEPER BUSHING BOLT TORQUE 120 FT.LBS. (163 Nm) * * TORQUE 35 FT.LBS. (47 Nm) TORQUE 420 FT.LBS. (569 Nm) HEX HEAD TORQUE 700 FT.LBS. (950 Nm) CAPSCREW BOLT * ** JIB PIVOT BEARING * BOLT KEEPER PIN TORQUE 165 FT.LBS. (224 Nm) JIB LIFT CYLINDER BOLT JIB KEEPER ROTATE PIN ACTUATOR TORQUE 165 FT.LBS. (224 Nm) * * BOLT KEEPER PIN TORQUE 165 FT.LBS.
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SECTION 4 - BOOM & PLATFORM BOLT LOCKPIN CYLINDER CAP ALIGN CUTOUT IN CAP INWARD AS SHOWN (SEE SECTION A-A BELOW) ALIGN LOCK CYL WITH PROTRUSIONS CAP (SEE SECTION A-A BELOW) JIB LOCK CYLINDER LOCKNUT TORQUE 220 FT.LBS.
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SECTION 4 - BOOM & PLATFORM 4.7 BOOM LUBRICATION APPLICATION 4.8 PLATFORM LEVELING CYLINDER This procedure applies to booms after assembly or during annual application using Super Lube® lubricant (JLG p/n 3020042). Removal 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). 1. Ensure the platform is supported by blocking or an adequate lifting device. 2.
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SECTION 4 - BOOM & PLATFORM 4. Lift the platform to allow enough room for removal of the cylinder. Installation 1. Attach a lifting or jacking device to the platform and position the platform to provide adequate room to install the platform leveling cylinder. NOTE: The platform level cylinder weighs approximately 79 lbs. (36 kg.). 2. Coat the retaining pin holes with an anti-seize compound to lubricate the holes and prevent rust. 5.
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SECTION 4 - BOOM & PLATFORM 5. Secure the pivot pin in place with the keeper pin. Loosely install the bolt, but do not tighten it at this time. 4.9 JIB TELESCOPE CYLINDER Removal 1. Remove the guide pad at the rear of the jib to provide more room for cylinder removal. 6. Thread the length sensor harness around the cylinder and up to the platform box. Connect the harness to the connector under the platform box. 7. Route the hydraulic hoses around the cylinder.
PAGE 308
SECTION 4 - BOOM & PLATFORM 4. Remove the retaining rings securing the retaining pins on the powertrack side of the jib and remove the pins. 8. Tag and disconnect the hoses going to the jib telescope cylinder. 5. Attach a strap or similar device between the jib base boom and the jib fly boom to ensure the jib fly boom will not extend inadvertently when the jib is raised. 9. Place blocking underneath the cylinder to prevent it from falling when the retaining bolts are removed.
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SECTION 4 - BOOM & PLATFORM 4. Connect the hydraulic hoses to the cylinder as tagged during removal. Installation 1. If installing a new cylinder, test fit the retaining pins that secure the jib telescope rod to the jib fly boom to ensure they fit properly. Apply an anti-seize compound to the attachment holes in the cylinder rod. 2. Lift the cylinder into place, adjusting the lifting device as necessary to maintain balance. 3. Fasten the cylinder barrel to the jib base boom with the attaching bolts.
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SECTION 4 - BOOM & PLATFORM 4.10 JIB LIFT CYLINDER 3. Remove the bolt and keeper pin that secure the jib lift cylinder barrel pivot pin. Remove the jib lift cylinder barrel pin. Removal 1. Ensure the weight of the jib is fully supported. 2. Place a strap or similar device in place to support the weight of the cylinder. 4-64 – JLG Lift – 4. Lower the cylinder enough to tag and disconnect the cylinder length sensor harness. Readjust the lifting device as necessary to balance the weight of the cylinder.
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SECTION 4 - BOOM & PLATFORM 5. Remove the bolt and keeper pin that secure the jib lift cylinder rod pivot pin. Remove the jib lift cylinder rod pivot pin. Installation 1. If installing a new cylinder, test fit the pivot pins in the cylinder to ensure they fit properly. Apply an antiseize compound to the attachment holes in the cylinder rod and barrel. 1. Lift the cylinder into position to install the jib lift rod pivot pin. Install the pivot pin. 2. Secure the pin in place with the keeper pin.
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SECTION 4 - BOOM & PLATFORM 4. Raise the cylinder into position to allow the jib lift barrel pivot pin to be installed and install the pin. 5. Secure the pin in place with the keeper pin. Apply JLG Threadlocker P/N 0100011 to the retaining bolt. Install the retaining bolt to secure the keeper pin and torque to 165 ft.lbs. (224 Nm). 4.11 JIB STRAIGHT SHIMMING PROCEDURE See Figure 4-17., Jib Straight Shimming. 1.
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SECTION 4 - BOOM & PLATFORM PIVOT PAD MOUNT JIB ROTATOR BOTTOM PLATE TORQUE 20 FT.LBS. (27 Nm) WEAR PAD SHIMS (NOMINAL QTY SHOWN) Figure 4-17.
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SECTION 4 - BOOM & PLATFORM 4.12 BOOM CLEANLINESS GUIDELINES 4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest exiting point from the boom. Make sure that all debris is removed before operating the machine. The following are guidelines for internal boom cleanliness for machines that are used in excessively dirty environments. 5.
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TELESCOPE TANK HOSE (INSIDE OF BEND RADIUS) 3121262 – JLG Lift – INCORRECT HOSES AND CABLES SHOULD NOT BE PULLED TIGHT AGAINST THE INSIDE RADIUS OF THE POWERTRACK Figure 4-18.
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Figure 4-19.
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Figure 4-20.
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SECTION 4 - BOOM & PLATFORM 4.14 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of the powertrack. One Piece Bracket Maintenance 1. Place the powertrack on a workbench. 4. Pull up on the loose side of the round bar to allow the poly roller to slide off. 2. Remove the screws from the bars on one side of the powertrack on the first link.
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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.
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SECTION 4 - BOOM & PLATFORM 10. 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. 11. Repeat the previous step on the other side. 2. Slide the roller off the bar. 12. Slide the bracket off of the powertrack. 3. Hold the bar tightly and remove the other screw.
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SECTION 4 - BOOM & PLATFORM 7. Slide the link out. 4. Hold the flat bar and remove the screws. 5. Remove the snap rings and pins. 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. Remove the screws from the bar. Remove the snap ring and pin.
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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 An open snap ring is shown below. 10-24 x 0.812 button torx socket head with blue locking patch: • Tighten to 45-50 in.lbs. (5-5.6 Nm). • 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.
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SECTION 4 - BOOM & PLATFORM 4.15 WIRE ROPE Three Month Inspection 1. Remove boom covers and visually (with flashlight) inspect the ropes for rust, broken wires, frays, abuse, or any signs of abnormalities. Inspection NOTE: The pictures in this paragraph are just samples to show the replacement criteria of the rope. 1. Inspect ropes for broken wires, particularly valley wire breaks and breaks at end terminations. 2. Check rope tension by deflecting the ropes by hand...
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SECTION 4 - BOOM & PLATFORM 4.16 WIRE ROPE TENSIONING ADJUSTMENT ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALIBRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD. Before adjusting wire rope tension, the boom sections must be in the proper position as shown in Figure 4-22., Wire Rope Tensioning. This is so the wire ropes are equalized on both sides of the sheaves and are seated properly in the sheave grooves. This is necessary for proper tensioning of the wire ropes.
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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 4-22., repeat the Outer Mid Boom positioning procedure. b. If the Outer Mid Boom falls within the dimension and tolerance of Figure 4-22., proceed to the Fly Boom Section Positioning procedure in this section.
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SECTION 4 - BOOM & PLATFORM 4. If the Fly Boom needs extended: a. Loosen the Fly Boom Retract Adjustment Nuts by an amount equal to twice the distance the boom needs to move to be in tolerance. 1. Remove any covers necessary to access the wire rope adjustment nuts. Fly Boom Retract Adjusting Nuts and Lock Plates b. Extend the boom 3-4 feet (1-1.5m). c. To remove the slack caused by the previous step, tighten the Fly Boom Retract Adjustment Nuts until they just contact the plate. d.
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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.
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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 4 feet (1.3 m) from fully retracted position. 12. Verify the Fly Boom and Outer Mid Boom Retract wire rope torques. a.
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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 4-22.
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Figure 4-23.
PAGE 331
Figure 4-24.
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SECTION 4 - BOOM & PLATFORM 1. 2. 3. 2" Socket 3/4” Socket Retaining Bolt Figure 4-25.
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SECTION 4 - BOOM & PLATFORM 4.17 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust after assembling the switch block, compression spring, and torquing the wire ropes. 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.
PAGE 334
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.
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SECTION 4 - BOOM & PLATFORM 4.19 ROTARY ACTUATOR Each actuator is individually serial numbered. The serial number is a five or six digit number and must be provided before parts and/ or service issues can be addressed. The serial number can be found on the Identification (ID) Tag that is affixed to all actuators. The tag is a thin, silver colored, plastic material with a self-adhesive backing. Information is imprinted in black.
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SECTION 4 - BOOM & PLATFORM Tools Required 9. PLASTIC MANDREL 10. PRY BAR Removal of end cap and manual rotation of shaft. 11. FELT MARKER Highlights timing marks and outlines troubled areas. Permanent ink is recommended. 12. T-HANDLE SCREW EXTRACTOR 13. HEX WRENCH SET Removal and replacement of port plugs and set screws (106,110). Several basic tools are required for the disassembly and reassembly of the actuator. The tools and their intended functions are outlined below: 1. PIPE VISE 2.
PAGE 337
SECTION 4 - BOOM & PLATFORM Disassembly Inspect the actuator for corrosion prior to disassembly. Severe corrosion can make it difficult to remove the lock pins (109) and unthread the end cap (04). If corrosion is evident, soak the lock pins and end cap with penetrating oil for several hours before disassembling. 4. Remove the lock pins using a screw extracting tool such as an "Easy Out" (a size #2 is shown).
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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 4-28.
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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. Exclusion Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 401 Counterbalance Valve Figure 4-29.
PAGE 340
SECTION 4 - BOOM & PLATFORM marker before disassembly as outlined in the steps below. 7. Remove the end cap (4) and carefully set aside for later inspection. 8. Remove the stop tube (400) if the actuator is equipped with one. The stop tube is an available option that limits the rotation of the actuator. 9. Every actuator has two sets of small punched timing marks that indicate timing between the gear sets. The location and appearance of the marks can vary slightly between models.
PAGE 341
SECTION 4 - BOOM & PLATFORM 11. Remove the shaft (2) by rotating counterclockwise. As the shaft is rotated, it will disengage from the piston sleeve (3) and can be removed. It may be necessary to strike the threaded end of the shaft with a rubber mallet. 12. As in step 9, before removing the piston (3), mark the housing (1) ring gear in relation to the piston outside diameter gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2). 13.
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SECTION 4 - BOOM & PLATFORM 17. Remove the main pressure seal (205). 20. Remove the outside diameter piston seal (202) from the piston. 18. Remove the thrust washer (304) from the end cap (4) and shaft (2). 21. Remove the inside diameter piston seal (200). 19. Remove the O-ring (304.1) from its groove in the end cap (4) and shaft (2). Inspection PRIOR TO ASSEMBLY OF ACTUATOR, THESE STEPS MUST BE CLOSELY FOLLOWED TO ENSURE PROPER OPERATION OF THE ACTUATOR. 1.
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SECTION 4 - BOOM & PLATFORM Assembly 1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal orientations. 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. 5. Install the wear guide (302) on the end cap (4) and shaft (2). 2. Coat the thrust washers (304) with a generous amount of Lithium grease.
PAGE 344
SECTION 4 - BOOM & PLATFORM 7. Install the inner T-seal (200) into the appropriate groove in the piston (3). Use a circular motion to ensure the seal is correctly seated in the groove. 8. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) contacts the inside housing bore. Install the outer T-seal (202) by stretching it around the groove in a circular motion. Each T-seal has 2 back-up rings (see Assembly Drawing for orientation).
PAGE 345
SECTION 4 - BOOM & PLATFORM 10. Looking into the bore from the opposite end of the housing (1) be sure the timing marks align correctly. Rotate the piston as necessary until aligned, then gently tap the piston (3) into the housing until the gear teeth mesh together. Tap the piston into the housing until it completely bottoms out against the ring gear. 11. Insert the shaft (2) into the piston (3). Be careful not to damage the piston seals. Do not engage the piston gear teeth yet. 12.
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SECTION 4 - BOOM & PLATFORM 14. Install the stop tube (400) onto the shaft end if necessary. Stop tubes are an available option to limit the rotation of an actuator. 17. Tighten the end cap (4) using a metal bar. In most cases the original holes for the lock pins will align. 15. Coat the threads on the end of the shaft with antiseize grease to prevent galling. 18. Insert the lock pins (109) provided with the Helac seal kit into the holes with the dimple side up.
PAGE 347
SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Installing Counterbalance Valve 1. After the actuator is assembled but before it is put into service, the thrust washer area must be packed with Lithium grease. Refer to Figure 4-30., Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Loctite. There are two grease ports located on both the shaft flange and the end cap.
PAGE 348
SECTION 4 - BOOM & PLATFORM Figure 4-30.
PAGE 349
SECTION 4 - BOOM & PLATFORM Installation and Bleeding After installation of the actuator on the equipment, it is important that all safety devices such as tie rods or safety cables are properly re-attached. To purge air from the hydraulic lines, connect them together to create a closed loop and pump hydraulic fluid through them. Review the hydraulic schematic to determine which hydraulic lines to connect.
PAGE 350
SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem 1. Shaft rotates slowly or not at all Cause Solution a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator. b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for restrictions and leaks. c. Control or counterbalance valve has internal leak c.
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SECTION 4 - BOOM & PLATFORM 4.20 JIB ROTATOR TORQUING PROCEDURE See Figure 4-31., JIb Rotator Torque 3. Torque the top bolts in a crossing star pattern to 300 ft.lbs. (410 Nm). 4. Torque the center bolt to a final torque of 700 ft.lbs. (950 Nm). 1. Torque the center bolt to 350 ft.lbs. (475 Nm). 2. Torque the bottom bolts in a crossing star pattern to 170 ft.lbs. (230 Nm). Figure 4-31.
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SECTION 4 - BOOM & PLATFORM NOTES: 4-106 – JLG Lift – 3121262
PAGE 353
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM When assembling connectors in the hydraulic that use oring fittings, it is necessary to lubricate all fittings with hydraulic oil prior to assembly. To lubricate the fittings, use one of the following procedures. 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.
PAGE 354
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. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this manner: 2. Hold the fitting over a suitable catch can. 3. Spray the entire o-ring surface with a medium coat of oil.
PAGE 355
SECTION 5 - HYDRAULICS 5.2 HYDRAULIC CYLINDERS the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. Axle Extension Cylinder 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. Figure 5-2. Cap Screw Removal 2.
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SECTION 5 - HYDRAULICS 7 22 23 4 5 9 14 4 23 22 13 18 19 11 18 15 12 6 17 2,3,16 20 1,2,21 8 1684102-D 1. 2. 3. 4. 5. Thread Locker Locking Primer Loctite RC 609 Bolt Tapered Bushing 6. 7. 8. 9. 10. Head Barrel Rod Piston Not Used 11. 12. 13. 14. 15. Wear Ring Backup Ring Backup Ring O-ring O-ring 16. 17. 18. 19. 20. Rod Wiper Seal Wear Ring T-Seal Washer Ring 21. Bolt 22. Holding Valve 23. Plug Figure 5-4.
PAGE 357
SECTION 5 - HYDRAULICS 9. Loosen and remove the capscrew which attach the tapered bushing to the piston. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary. 4.
PAGE 358
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 359
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 8. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-9. Wiper Seal Installation 3.
PAGE 360
SECTION 5 - HYDRAULICS 12. Remove the cylinder rod from the holding fixture. 13. Place a new t-seal and wear rings in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the seal.) 17. Secure the cylinder head gland using the washer ring, JLG Threadlocker (P/N 0100011) and socket head bolts. Torque to 35 ft.lbs. (50 Nm) Figure 5-14. Rod Assembly Installation 18.
PAGE 361
SECTION 5 - HYDRAULICS Axle Lockout Cylinder the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder.
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SECTION 5 - HYDRAULICS 11 6 24 24 11 1 12 10 4 3 19 10 20 16 5 18 15 17 23 22 8,9,21 17 25 7,8,13 2 11 11 1684081-E 1. 2. 3. 4. 5. Barrel Rod Piston Bushing Head 6. 7. 8. 9. 10. Counterbalance Valve Thread locking Compound Locking Primer Loctite RC 609 Bolt 11. 12. 13. 14. 15. Bearing Plug Bolt Not Used Wear Ring 16. 17. 18. 19. 20. Backup Ring Lock Ring Backup Ring O-ring O-ring 21. 22. 23. 24. 25. Wiper Seal Rod Seal Bleeder Valve Washer Ring Figure 5-18.
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SECTION 5 - HYDRAULICS 9. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 10. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 364
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 365
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 8. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-23. Wiper Seal Installation 3.
PAGE 366
SECTION 5 - HYDRAULICS 12. Remove the cylinder rod from the holding fixture. WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. 14. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
PAGE 367
SECTION 5 - HYDRAULICS Jib Level Cylinder the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder.
PAGE 368
SECTION 5 - HYDRAULICS 9** 4 10 108 5 8** 2* 3 107 13 107 7 109 108 102 103 102 104 101 12 105 106 11 14 * Torque 9 ft.lbs. (12 Nm) ** Torque 50-55 ft.lbs. (68-75 Nm) *** Torque 170 ft.lbs. (230 Nm) 1,6*** 1001118142-B 1. 2. 3. 4. 5. 6. Threadlocker Bolt Tapered Bushing Plug Plug Bolt 7. 8. 9. 10. 11. 12. Spacer Holding Valve Counterbalance Valve Barrel Rod Head 13. Piston 14. Washer Ring 101.Wear Ring 102.Backup Ring 103.O-ring 104.O-ring 105.Seal 106.Rod Wiper 107.Seal 108.
PAGE 369
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 9. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 370
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 371
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-38. Wiper Seal Installation 3.
PAGE 372
SECTION 5 - HYDRAULICS 13. Remove the cylinder rod from the holding fixture. WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
PAGE 373
SECTION 5 - HYDRAULICS Platform Level Cylinder 7. Using a spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY 8. Attach a suitable pulling device to the cylinder rod end. 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. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.
PAGE 374
SECTION 5 - HYDRAULICS 1,8 17 200 6,16 203 202 201 18**** 13 4 6,9* 4 4 2** 18**** 3 101 108 7 108 104 106 104 101 102 107 105 10 103 6 14*** 110 109 * Torque to 4 in.lbs. (0.5 Nm) ** Torque to 9 ft.lbs. (12 Nm) *** Torque to 200 ft.lbs. (271 Nm) **** 30 to 35 ft.lbs. (41-47.5 Nm) 15 1001117968-D 1. 2. 3. 4. 5. 6. 7. Threadlocker Bolt Tapered Bushing Plug Not Used Lubricant Piston 8. 9. 10. 11. 12. 13. 14. Bolt Setscrew Spacer Not Used Not Used Barrel Head 15. Rod 16.
PAGE 375
SECTION 5 - HYDRAULICS 10. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 11. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 376
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 377
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-52. Wiper Seal Installation 3.
PAGE 378
SECTION 5 - HYDRAULICS 13. If removed, install the spacer sleeve, sensor magnet, and retaining ring. 16. Position the cylinder barrel in a suitable holding fixture. 14. Remove the cylinder rod from the holding fixture. WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.
PAGE 379
SECTION 5 - HYDRAULICS Boom Lift Cylinder the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder.
PAGE 380
SECTION 5 - HYDRAULICS 30 28*** 30 9 29* 27*** 5 10 4** 13 12 22 16 12 21 18 2,17 19 15 20 14 15 14 26 13 7 8 23 1,2,25**** 30 * Torque 25-27 ft.lbs. (34-36.5 Nm) ** Torque to 60 ft.lbs. (81 Nm) *** Torque 30-35 ft.lbs. (40.5-47.5 Nm) **** Torque 300 ft.lbs. (410 Nm) 30 1001118442-B 1. 2. 3. 4. 5. 6. Threadlocker Locking Primer Not Used Bolt Tapered Bushing Not Used 7. 8. 9. 10. 11. 12. Head Rod Barrel Plug Not Used Guide Ring 13. 14. 15. 16. 17. 18.
PAGE 381
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 9. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 382
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 383
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-66. Wiper Seal Installation 3.
PAGE 384
SECTION 5 - HYDRAULICS 13. Remove the cylinder rod from the holding fixture. WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
PAGE 385
SECTION 5 - HYDRAULICS Jib Lift Cylinder the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder.
PAGE 386
SECTION 5 - HYDRAULICS * Torque to 4 in.lbs. (0.5 Nm) **Torque to 9 ft.lbs. (12 Nm) *** Torque to 120 ft.lbs. (163 Nm) **** Torque 50-55 ft.lbs. (68-75 Nm) 1001118082-B 1. 2. 3. 4. 5. 6. 7. Threadlocker Bolt Screw Tapered Bushing Cable Clamp Cylinder Head Plug 8. 9. 10. 11. 12. 13. 14. Plug Plug Lubricant Piston Washer Ring Bolt Bolt 15. 16. 17. 18. 19. 20. 21. Setscrew Spacer Holding Valve Counterbalance Valve Cylinder Length Sensor Retainer Cap Barrel 22. Rod 101.Wear Ring 102.Backup Ring 103.
PAGE 387
SECTION 5 - HYDRAULICS 9. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 10. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 388
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 389
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-81. Wiper Seal Installation 3.
PAGE 390
SECTION 5 - HYDRAULICS 13. Remove the cylinder rod from the holding fixture. WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
PAGE 391
SECTION 5 - HYDRAULICS Jib Lock Cylinder CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. DISASSEMBLY 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 3. Inspect inner surface of cylinder barrel tube for scoring or other damage.
PAGE 392
SECTION 5 - HYDRAULICS 3 101 108 4 105 102 104 1,2 103 107 106 1001119313-B 1. Head 2. Lubricant 3. Barrel 4. Rod 101.Wear Ring 102.Backup Ring 103.Wear Ring 104.O-ring 105.O-ring 106.Rod Wiper 107.Seal 108.Seal Figure 5-88.
PAGE 393
SECTION 5 - HYDRAULICS ASSEMBLY 3. Place a new O-rings and backup ring in the outside diameter groove of the cylinder head and new wear rings and polyseal in the inside diameter grooves of the cylinder head. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 4. Carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end.
PAGE 394
SECTION 5 - HYDRAULICS Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for easy realignment. Unscrew the cylinder cap from the barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2.
PAGE 395
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. Piston 7. Backup Ring 8. Wear Ring 9. Wear Ring 10. O-ring 11. O-ring 12. Wiper 13. Piston Seal 14. Loctite #222 (not shown) Figure 5-95.
PAGE 396
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation. b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced. 9. Loosen and remove the lock nut that secures the piston to the cylinder rod. 10. Remove the piston from the cylinder rod. c.
PAGE 397
SECTION 5 - HYDRAULICS than the O.D.of the piston is recommended to install the seal.) WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. Figure 5-99. Piston Seal Installation 11. Position the cylinder barrel in a suitable holding fixture. Figure 5-98. Cylinder Head Seal Installation 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove.
PAGE 398
SECTION 5 - HYDRAULICS Jib Telescope Cylinder INSPECTION USE CARE IN REMOVAL OF ANY, AND ALL, COMPONENTS AS COUNTERBALANCE VALVES MAY RETAIN CONSIDERABLE PRESSURE WITHIN THE CYLINDER ASSEMBLY. USE EXTREME CARE REMOVING PLUGS, VALVES, AND/OR THE ROD ASSEMBLY TO ENSURE THE INTERNAL CYLINDER PRESSURE HAS BEEN RELIEVED. NOTE: The jib telescope cylinder weighs approximately 130.5 lbs. (59.2 kg). DISASSEMBLY 1. Retract cylinder and support equipment to allow for cylinder removal.
PAGE 399
SECTION 5 - HYDRAULICS * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max 1001118663-C 1. 2. 3. 4. 5. 6. Barrel Rod Gland Piston Stop Tube Wear Pad 7. 8. 9. 10. 11. 12. Pad Support O-ring O-ring Rod Seal Backup Ring Rod Wiper 13. 14. 15. 16. 17. 18. Wear Ring Plug Plug Wear Ring Piston Seal Capscrew 19. 20. 21. 22. 23. 24. Lockwasher Nut Capscrew Shuttle Valve Counterbalance Valve Counterbalance Valve Figure 5-100.
PAGE 400
SECTION 5 - HYDRAULICS ASSEMBLY ROD, GLAND, PISTON ASSEMBLY 1. Lubricate I.D. of head gland assembly with hydraulic fluid, and slide onto rod (rod wiper end first) using caution not to damage rod wiper or seal on rod end. NOTE: Refer to the Seal Detail provided at the end of this Service Manual for the particular model being serviced for proper seal locations and orientations. Improper seal orientation will compromise performance! 2. Slide stop tube (with o-ring) onto rod. Do not scratch rod chrome. 3.
PAGE 401
SECTION 5 - HYDRAULICS Figure 5-101. Jib Telescope Cylinder Head Gland Detail Figure 5-102.
PAGE 402
SECTION 5 - HYDRAULICS Main Boom Telescope Cylinder the cylinder head retainer capscrews, and remove capscrews from cylinder barrel. 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. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder.
PAGE 403
SECTION 5 - HYDRAULICS * 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 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. 25. 26. 27. 28. Piston Capscrew Capscrew Capscrew Spacer Valve Assembly Flatwasher 29. Flatwasher 30. O-Ring Plug 31.
PAGE 404
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 9. Loosen and remove the capscrews which attach the tapered bushing to the piston. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3.
PAGE 405
SECTION 5 - HYDRAULICS 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to assembly. a.
PAGE 406
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the cylinder head gland groove. Install a new wear ring into the cylinder head gland groove. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 9. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-111. Wiper Seal Installation 3.
PAGE 407
SECTION 5 - HYDRAULICS 13. Remove the cylinder rod from the holding fixture. 14. Place a new t-seal and wear rings in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the seal.) 18. Secure the cylinder head gland using the washer ring, JLG Threadlocker (P/N 0100011), and socket head bolts. Torque to 120 ft.lbs. (163 Nm) Figure 5-116. Rod Assembly Installation 19.
PAGE 408
SECTION 5 - HYDRAULICS 5.3 CYLINDER LENGTH SENSOR 5. Remove the plug that is over the setscrew that secures the sensor in place. Both the jib lift cylinder and the platform level cylinder utilize a cylinder length sensor which communicates with the JLG control system. These sensors can be removed from without the cylinder being disassembled. 6. Using an allen wrench, remove the setscrew. Figure 5-117. Cylinder Length Sensor Removal 1. Lower the platform to the ground or on suitable blocking.
PAGE 409
SECTION 5 - HYDRAULICS 7. Using an allen wrench, remove the bolts securing the retaining cap and remove the cap. 3121262 – JLG Lift – 8. Pull sensor out of the cylinder. DO NOT use the wiring harness to pull the sensor out as this will cause damage to the wiring.
PAGE 410
SECTION 5 - HYDRAULICS Installation 1. Carefully insert the sensor into the cylinder. It may be necessary to gently tap the end of the sensor to seat the o-ring into the sensor bore. DO NOT tap on the wiring harness. 3. Apply lubricant JLG P/N 3020039 to the setscrew and install the setscrew. Torque the setscrew to 4 in. lbs. (0.45 Nm). 4. Install the plug over the setscrew. 2. Install the cap and secure in place with the retaining bolts. 5.
PAGE 411
SECTION 5 - HYDRAULICS Figure 5-118.
PAGE 412
SECTION 5 - HYDRAULICS Table 5-1. Platform Valve Specifications # Item Torque ft.lbs. Nm Ohms 1 Pressure Check Port 17-18 23-24.5 -- 2 Pressure Compensator 25-30 34-41 -- 3 Relief Valve 25-30 34-41 -- 4 Relief Valve 25-30 34-41 -- 5 Pressure Compensator 25-30 34-41 -- 6 Relief Valve 25-30 34-41 -- 7 Inlet Valve 2-3 3-4 7.4 8 Platform Level Valve 16-20 22-27 9.8 9 Platform Rotate Valve 16-20 22-27 9.8 2-3 3-4 7.4 10 Jib Lock Pin Valve Figure 5-119.
PAGE 413
SECTION 5 - HYDRAULICS Table 5-2. Fitting Torque Specifications # Torque ft.lbs. Nm 1 24 32.5 2 24 32.5 3 40 54 4 15 20 Figure 5-120.
PAGE 414
SECTION 5 - HYDRAULICS Figure 5-121.
PAGE 415
SECTION 5 - HYDRAULICS Figure 5-122.
PAGE 416
SECTION 5 - HYDRAULICS Figure 5-123.
PAGE 417
SECTION 5 - HYDRAULICS Table 5-1. Platform Valve Specifications # Item Torque ft.lbs. Nm Ohms 1 Pressure Compensator 25-30 34-41 -- 2 Pressure Compensator 25-30 34-41 -- 3 Jib Lift Valve 16-20 22-27 9.8 4 Jib Tele Valve 16-20 22-27 7.2 5 Jib Level Valve 16-20 22-27 9.8 6 Jib Swing Valve 16-20 22-27 9.8 7 Inlet Valve 29-37 39-50 7.
PAGE 418
SECTION 5 - HYDRAULICS Table 5-4. Fitting Torque # Torque ft.lbs. Nm 1 24 32.5 2 60 81 3 40 54 4 24 32.5 5 15 20 6 15 20 7 40 54 8 35 47.5 Figure 5-125.
PAGE 419
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 5-126.
PAGE 420
SECTION 5 - HYDRAULICS Table 5-5. 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 5 30-35 40.6-47.4 12 30-35 40.6-47.4 30-35 40.6-47.4 13 30-35 40.6-47.4 6 30-35 40.6-47.4 14 30-35 40.6-47.5 7 30-35 40.6-47.4 15 30-35 40.6-47.5 8 30 40.6 Figure 5-127.
PAGE 421
SECTION 5 - HYDRAULICS 5.4 OIL SAMPLING 4. Unscrew the knurled end which is attached to the chain. See Figure 5-127., Oil Sampling Port. 5. Place a drip pan under the spout and push in for approximately 10 seconds. This should flush out the valve. This machine is equipped with an oil sampling valve to allow for verification of hydraulic oil condition. 6. Open and place the sample bottle under the spout. Procedure 7. Push in on the end of the valve and fill up the bottle. 1.
PAGE 422
SECTION 5 - HYDRAULICS 5.5 PRESSURE SETTING PROCEDURE Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures.
PAGE 423
SECTION 5 - HYDRAULICS 3. To make an adjustment to this pressure, go to the engine compartment, locate the function pump. The stand by adjustment is the adjustment outside adjustment, closest to the turntable. Use the same tools that were used in the High pressure adjustment procedure. SWING NOTE: Left and right are done with one adjustment. 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).
PAGE 424
SECTION 5 - HYDRAULICS STEERING, FRONT AND REAR 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. The Analyzer is required to perform the pressure check procedure through access of the calibration menu.
PAGE 425
SECTION 5 - HYDRAULICS Figure 5-128.
PAGE 426
SECTION 5 - HYDRAULICS 4. 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. 5. Install a pressure gauge at the front axle/steer valve at MS2 port. This should be located on the left side of the valve closest to the left front wheel spindle.
PAGE 427
SECTION 5 - HYDRAULICS 8. 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.
PAGE 428
SECTION 5 - HYDRAULICS 12. 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).
PAGE 429
SECTION 5 - HYDRAULICS Adjustments Made at the Jib Valve JIB LEVEL DOWN 1. Install a high pressure gauge at the MLA port. JIB LEVEL UP 1. Install a high pressure gauge at the MLB port. 2. Using the analyzer, select Jib Level. 3. Using the Jib Down switch, fully retract the jib level cylinder or cap port LB. 2. Using the analyzer, select Jib Level. 3. Using the Jib Up switch, fully extend the jib level cylinder or cap port LA. 4. Set the Level Up pressure to 2600 psi (179 Bar).
PAGE 430
SECTION 5 - HYDRAULICS JIB TELESCOPE IN JIB TELESCOPE OUT 1. Install a high pressure gauge at the MTB port. 1. Install a high pressure gauge at the MTA port. 2. Fully extend the jib boom. 2. Fully retract the jib boom. 3. Set the Jib Telescope pressure to 3000 psi (206.8 Bar). Turning the adjustment clockwise increases pressure, turning the adjustment counterclockwise decreases pressure. 3. Set the Jib Telescope In pressure to 3000 psi (206.8 Bar).
PAGE 431
SECTION 5 - HYDRAULICS JIB LIFT UP JIB LIFT DOWN 1. Install a high pressure gauge at the MJA port. 1. Install a high pressure gauge at the MJB port. 2. Fully extend the jib lift cylinder or cap port JB. 2. Fully retract the jib lift cylinder or cap port JB. 3. Set the Jib Lift Up pressure to 2800 psi (193 Bar). Turning the adjustment clockwise increases pressure, turning the adjustment counterclockwise decreases pressure. 3. Set the Jib Lift Down pressure to 1200 psi (82.7 Bar).
PAGE 432
SECTION 5 - HYDRAULICS 5.6 DRIVE PUMPS 2. Transmission does not propel the machine, diesel engine running properly - Charge Pump/Relief Valve Troubleshooting Procedure 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 To aid in troubleshooting, refer also to the pressure measuring port connections for test gauge installation information as shown on the hydraulic circuit diagram.
PAGE 433
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 i. Remove and inspect charge pump assemblies. Are they damaged? No - Proceed to step 2.j Yes - Repair and/or replace damaged components and return to step 2.a j.
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SECTION 5 - HYDRAULICS 7. Transmission Does Not Find or Hold Neutral 5. Transmission Drives in one direction only a. Are electrical connections to pump control proportional solenoids correct, intact and without defects? Yes - Proceed to step 5.b No - Rectify the problem b. Check hot oil flushing valve cartridge #120 located in the Traction Control Manifold. Remove and inspect flushing valve cartridge for stuck spool or damaged cartridge O-ring seals & backup rings. c.
PAGE 435
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). 11. Transmission Pump(s) Do Not Develop Maximum Horsepower (Flow & Pressure) a. Does the charge pump pressure meet specification? No - Return to step 2.a Yes - Proceed to step 11.
PAGE 436
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. Tighten jam nut, stop the pump drive, remove the hose connecting ports X1 and X2. Hydraulic Centering of Control Modules PREPARATION FOR ADJUSTMENT When control modules are exchanged or replaced, it is generally necessary to center the new module.
PAGE 437
SECTION 5 - HYDRAULICS If difficulties are encountered in obtaining neutral position of the HD or EP control modules, check that the ends of the control 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).
PAGE 438
SECTION 5 - HYDRAULICS to reassembly. 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.
PAGE 439
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: c. If hose connections are disassembled, it is imperative that the utmost care be taken that no foreign bodies infiltrate the oil circuit. Catastrophic component failure may occur. 5. Oil Level Inspection a.
PAGE 440
SECTION 5 - HYDRAULICS Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap ring. 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.
PAGE 441
SECTION 5 - HYDRAULICS 5.7 FUNCTION PUMP Figure 5-129. Function Pump - Sectional View Spare Parts 2. Drive Shaft 1. Sealing kit, existing spare parts: shaft sealing ring, o-rings, and a circlip. 3. Bearing set, miscellaneous parts.
PAGE 442
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. 1. Remove the snap ring. 5. Swash Plate. 2. Change the shaft seal and check its sliding surface (drive shaft) and housing. Grease the sealing ring. 6.
PAGE 443
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. Disassembly and Assembly of the Complete Unit 5.
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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. 5-92 13. Disassemble the plug.
PAGE 445
SECTION 5 - HYDRAULICS 14. Disassemble the control piston while moving the swash plate. 18. Remove both bearing shells. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disassemble the piston rod. 20. Disassemble the snap ring. 16. Remove the swash plate. 21. Disassemble the sealing ring. 17. Remove the spring.
PAGE 446
SECTION 5 - HYDRAULICS 22. The external front bearing ring is pulled out of the pump housing. 23. Remove the o-ring. Lifting of the valve plate isn’t shown. 25. The spring has additional pretension while you disassemble the three pressure pins inside the cylinder. Assembly 1. Measurement of the taper roller bearing pretention. 24. 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.
PAGE 447
SECTION 5 - HYDRAULICS 3. Pumps clockwise driven must have a position of the valve plate 4 degrees out of center in the same direction de-centered 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 de-centered in the counterclockwise position.
PAGE 448
SECTION 5 - HYDRAULICS Figure 5-130. Function Pump, Pressure and Flow Control - Sheet 1 Figure 5-131.
PAGE 449
SECTION 5 - HYDRAULICS Figure 5-132. 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.
PAGE 450
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).
PAGE 451
SECTION 5 - HYDRAULICS 5.8 DRIVE & FUNCTION PUMP START UP PROCEDURES Start-Up Procedure The Boom Lift utilizes a Triple Combination Pump coupled to the Deutz diesel engine. The pumps are connected inline 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.
PAGE 452
SECTION 5 - HYDRAULICS 10. Operate the drive system in the "turtle mode", forward and reverse. 11. De-aerate the system by bleeding fluid from the Ma & Mb ports. 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. 13. With the joystick in neutral, check for creep in neutral.
PAGE 453
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Introduction WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS. IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
PAGE 454
SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer 1. Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer.
PAGE 455
SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS ACTIVATE TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE (level 1 only) CALIBRATIONS (view only) DRIVE BOOM SYSTEM DATALOG VERSIONS If you press ENTER , at the HELP: PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen.
PAGE 456
SECTION 6 - JLG CONTROL SYSTEM Press ENTER to select the ACCESS LEVEL menu. Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1, and a personality Using the UP or DOWN first digit of the password, 3. arrow keys, enter the item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password.
PAGE 457
SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press the UP or DOWN ple: arrow keys to adjust its value, for examCHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE. ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
PAGE 458
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION ACCEL ACT A/D AMB.
PAGE 459
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION S/C MEANING SHORT CIRCUIT SEL SELECTOR SN SERIAL NUMBER SPD STOW STOWD SW SPEED STOWED STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ.
PAGE 460
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number NOTE: The machine configuration must be completed before any personality settings can be changed.
PAGE 461
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number ENGINE SHUTDOWN: 7 0 DISABLED: No engine shutdown. 1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI. 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep.
PAGE 462
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit GEN SET/WELDER: 13 GEN SET CUTOUT: 14* Number Description 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. Default Number 1 0 * Only visible if Gen Set / Welder Menu selection is not 0.
PAGE 463
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description FUNCTION CUTOUT: 17* 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. Default Number 0 * Only visible under certain market selections. * Certain market selections will limit function cutout options or alter default setting.
PAGE 464
SECTION 6 - JLG CONTROL SYSTEM Australia Japan 3 3 3 3 Envelope Height 1 1 1 1 1 1 Market 0 1 2 3 4 5 Engine 3 3 3 3 3 3 Glow Plug Starter Lockout Engine Shutdown Tilt Jib 4 Wheel Steer Drive Type Soft Touch Gen Set / Welder Gen Set Cutout Head & Taillights Load System 6-12 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 0 0 0 0 0 0 1 1 1 1 1 1 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5
PAGE 465
SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS AND FUNCTION SPEEDS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-4. Machine Personality Settings and Function Speeds SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) DRIVE: PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) RANGE DEFAULT VALUES Displays/adjusts drive acceleration 0.1 to 5.0 sec 2 DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.
PAGE 466
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) MAIN LIFT: PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE DEFAULT VALUES ACCEL X.Xs DECEL X.Xs Displays/adjusts main lift acceleration Displays/adjusts main lift deceleration 0.1 to 5.0 sec 0.1 to 3.
PAGE 467
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE DEFAULT VALUES MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1 MIN IN XX% Displays/adjusts minimum main telescope in speed.
PAGE 468
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) JIB LIFT: JIB SWING: JIB TELESCOPE: 6-16 PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE DEFAULT VALUES ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1 MIN UP XX% Displays/adjusts minimum jib up speed.
PAGE 469
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds SUBMENU (DISPLAYED ON ANALYZER 1ST LINE) JIB LEVEL: GROUND MODE: PARAMETER (DISPLAYED ON ANALYZER 2ND LINE) DESCRIPTION RANGE DEFAULT VALUES ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts jib level deceleration 0.1 to 3.0 sec 0.5 MIN UP XX% Displays/adjusts minimum jib level up speed.
PAGE 470
SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDS Test Notes LIFT UP, from platform control, lowest elevation up to maximum elevation, boom retracted, jib retracted. 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance. LIFT DOWN, from platform control, maximum elevation down to minimum elevation, boom retracted, jib retracted. 2. Stop watch should start when the function is activated.
PAGE 471
SECTION 6 - JLG CONTROL SYSTEM 6.4 CANBUS COMMUNICATIONS CANbus: CAN (Control Area Network) is a two wire differential serial link between the Platform Module, Jib 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” (2.5v) when no signal is being sent.
PAGE 472
SECTION 6 - JLG CONTROL SYSTEM Figure 6-2.
PAGE 473
SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATION INSTRUCTIONS Table 6-5. 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 recalibration.
PAGE 474
6-22 – JLG Lift – ACCESS LEVEL: CODE 00000 MENU: ACCESS LEVEL 1 (See Figure 6-4.) MENU: PERSONALITIES (See Figure 6-5.) MENU: MACHINE SETUP (See Figure 6-6.) MENU: CALIBRATIONS HELP: GROUND MODE OK SERVICE MODE: JIB & SWING? JIB & SWING: BOOM RECOVERY? JIB & SWING: SWING ENVELOPE? JIB & SWING: JIB LOCK PIN? JIB & SWING: JIB LEVEL? MENU: HELP:PRESS ENTER MENU: SERVICE MODE (See Figure 6-7.) or (See Figure 6-8.) or (See Figure 6-9.
PAGE 475
3121262 – JLG Lift – JIB LIFT: DECEL X.XS JIB LIFT: MIN LEFT X% JIB LIFT: MAX LEFT X% JIB LIFT: MIN RIGHT X% JIB LIFT: MAX RIGHT X% JIB LIFT: DECEL X.XS JIB LIFT: MIN UP X% JIB LIFT: MAX UP X% JIB LIFT: MIN DOWN X% JIB LIFT: MAX DOWN X% MAIN LIFT: CREEP DOWN X% DRIVE: CREEP MAX X% JIB LIFT: ACCEL X.XS MAIN LIFT: MAX DOWN X% DRIVE: ELEV. MAX X% JIB LIFT: ACCEL X.
PAGE 476
6-24 – JLG Lift – GROUND ALARM: NO CLEARSKY: NO GROUND ALARM: DRIVE GROUND ALARM: DESCENT GROUND ALARM: MOTION FUNCTION CUTOUT: BOOM CUTOUT FUNCTION CUTOUT: DRIVE CUTOUT FUNCTION CUTOUT: DRIVE CUT E&T LEVELING MODE: LEVEL LIFT 1: Only Available in Access Level 1 DISPLAY UNITS: METRIC FUEL TANK SIZE: 52 GALLON LOAD TYPE: CAN LSS LOAD TYPE: 4 UNDER BASKET NOTE: The layout shown includes all possible analyzer screens.
PAGE 477
3121262 – JLG Lift – POSITION 1: CHECK SYSTEM? POSITION 1: CHECK SYSTEM? CALIBRATIONS: JIB SENSORS CALIBRATE LEVEL UP CRACKPOINT? CALIBRATIONS: LEVEL UP CRKPT POSITION 1: CHECK SYSTEM? CALIBRATIONS: LSS CALIBRATE LEVEL DOWN CRACKPOINT? CALIBRATIONS: LEVEL DOWN CRKPT CALIBRATE CHECK SYSTEM? CALIBRATIONS: UNLOCK BOOM CALIBRATE LEVEL UP CRACKPOINT? CALIBRATIONS: JIB LVL UP CRKPT DEUTZ SETUP: SETUP 4 DEUTZ SETUP: SETUP 3 DEUTZ SETUP: SETUP 2 DEUTZ SETUP: SETUP 1 CALIBRATIONS: DEUTZ SETUP: CAL
PAGE 478
6-26 – JLG Lift – CREEP SWITCH: CLOSED CREEP MODE: OFF CHASSIS TILT: XX.X DEGREES CHASSIS TILT X-AXIS: X.X CHASSIS TILT Y-AXIS: X.
PAGE 479
3121262 – JLG Lift – JIB TRANSPORT 2 SWITCH NC: CLOSED MAIN BOOM ANGLE2: XX.X DEG MAIN BOOM A/D LENGTH: XXXXX MAIN BOOM A/D ANGLE1: XXX.X MAIN BOOM A/D ANGLE2: XXX.
PAGE 480
FROM: SHEET 2 6-28 MAIN ANGLE 2 HI CAL: X LENGTH RETRACTED CAL: XXXXX LENGTH EXTENDED CAL: XXXXX YELLOW WITNESS MARK CAL: X LENGTH SWITCH CAL: XXXXX MAIN CYL ANGLE 1 LO CAL: XXXXX MAIN CYL ANGLE 1 HI CAL: XXXXX MAIN CYL ANGLE 2 LO CAL: XXXXX MAIN CYL ANGLE 2 HI CAL: XXXXX TURNTABLE ANGLE 1 CAL: XXXXX PLATFORM DOWN CAL: X LEFT FORWARD DRIVE CAL: XXXX RIGHT FORWARD DRIVE CAL: XXXX LEFT REVERSE DRIVE CAL: XXXX RIGHT REVERSE DRIVE CAL: XXXX L FRONT STEER CAL: XXXXX R FRONT STEER CAL: XXXXX L REAR STEER CAL: X
PAGE 481
Figure 6-10.
PAGE 482
SECTION 6 - JLG CONTROL SYSTEM Connector J1 (Natural) Connector J2 (Gray) Connector J3 (Black) Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 THROTTLE ACTUATOR (DIESEL ONLY) SPARE (LP NOT USED) TOWER BOOM LIFT POWER GROUND GROUND TOWER TELESCOPE ENABLE SPARE (LP NOT USED) GROUND GROUND IGNITION ON RELAY START SOLENOID (DIESEL ONLY) GLOW PLUG (DIESEL ONLY OPTION) AUXILIARY POWER COOLANT TEMP (DIESEL ONLY) OIL PRESSURE (DIESEL ONLY) FLYWHEEL SPEED P
PAGE 483
SECTION 6 - JLG CONTROL SYSTEM Connector J7 (Black) Connector J12 (Black) Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Pin 1 2 3 4 5 6 7 8 Function PLATFORM EMS PLATFORM MODE GROUND MODE TOWER CYLINDER PRESSURE REFERENCE VOLTAGE CAN TERMINATION SPARE SPARE ANALOG INPUT 2 GROUND GROUND BOOM RETRACTED CLOSED BROKEN CABLE SWITCH CAN HI GROUND MODE OUT TO PLATFORM FOOTSWITCH ENGAGE REFERENCE VOLTAGE CAN TERMINATION CAN SHEILD SPARE PIN SPARE ANALOG IN
PAGE 484
SECTION 6 - JLG CONTROL SYSTEM Connector J8 (Black) Connector J4 (Blue) Pin 1 2 3 4 GROUND FROM BATTERY GROUND EMS GROUND TO PLATFORM GROUND EMS OUT TO PLATFORM Function Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 AXLES SET LAMP 500# CAPACITY LAMP BOOM CONTROL SYSTEM LAMP START SWITCH BASKET LEVEL DOWN BASKET LEVEL DOWN UPPER TELESCOPE IN JIB DOWN JIB LEFT TOWER UP MAIN TOWER TRANSPORT ANGLE OPEN HOUR METER BCS CALIBRATED LAMP OVERLOAD LAMP SPA
PAGE 485
SECTION 6 - JLG CONTROL SYSTEM Connector Connector Pin FUNCTION 1 Power Feed Thru to J2-1 Power I/O 2 Power Feed Thru to J2-2 Power I/O 3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output 4 Master Ground Connect Power Input 2 Ground Power Output Input 3 CANbus High Serial I/O 4 CANbus Low Serial I/O 5 J1 (Grey) Master Ignition Connect Power Connector Pin FUNCTION 1 Power Feed Thru to J1-1 Power I/O 2 Power Feed Thru to J1-2 Power I/O 3 Ground
PAGE 486
SECTION 6 - JLG CONTROL SYSTEM Connector Connector Pin FUNCTION 1 Power Feed Thru to J2-1 Power I/O 2 Power Feed Thru to J2-2 Power I/O 3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output 4 Master Ground Connect Power Input 2 Ground Power Output Input 3 CANbus High Serial I/O 4 CANbus Low Serial I/O 5 J1 (Grey) Master Ignition Connect Power Connector Pin FUNCTION 1 Power Feed Thru to J1-1 Power I/O 2 Power Feed Thru to J1-2 Power I/O 3 Ground
PAGE 487
SECTION 6 - JLG CONTROL SYSTEM Connector J1 (Grey) Connector Pin FUNCTION 1 Power Feed Thru to J2-1 Power Type I/O 2 Power Feed Thru to J2-2 Power I/O 3 Signal Feed Thru to J2-4 Digital Input 1 4 Master Ground Connect Power Input 5 Master Ignition Connect Power Input 6 CANbus High Serial I/O Connector Pin J4 (Grey) Type FUNCTION Pin FUNCTION 1 Power Feed Thru to J1-1 Power Type I/O 2 Power Feed Thru to J1-2 Power I/O Ignition Power Output 3 Ground 2 Ground
PAGE 488
SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-17.
PAGE 489
SECTION 6 - JLG CONTROL SYSTEM 6.6 CONTROL SYSTEM BOOM SENSORS Sensor #2 - Main Boom Angle Sensors NOTE: Note: The machine is defined as being in transport mode if: Axles are retracted. Main boom lift is below elevation angle. Main boom telescope is fully retracted. Jib boom telescope is fully retracted. Jib boom locked inline with the main boom via the jib lock pin. Turntable swung so that the main boom is between the rear wheels.
PAGE 490
SECTION 6 - JLG CONTROL SYSTEM MAIN BOOM LIMIT SWITCH MAIN BOOM STRING POT MAIN BOOM PROTRACTOR SENSOR MAIN BOOM ANGLE SENSORS JIB TELESCOPE PROXIMITY SENSORS PLATFORM LEVEL SENSORS WIRE ROPE PROXIMITY SENSOR JIB ROTATE SENSORS JIB LEVEL PROTRACTOR SENSOR JIB LOCK PIN PROXIMITY SENSORS Figure 6-18.
PAGE 491
SECTION 6 - JLG CONTROL SYSTEM Sensor #3 - Main Boom Length Sensor Sensor #4 - Main Boom Cylinder Angle Sensor This sensor's function is to measure Main Boom angle in relationship to the turntable. A rotary type sensor is mounted to the Turntable and attached to the Main lift cylinder. This sensor is used for velocity control only. Sensor #5 - Main Boom Transport Length Switch This sensor measures total stroke of the Main Boom.
PAGE 492
SECTION 6 - JLG CONTROL SYSTEM Sensor #6 - Jib Level Angle Sensor Sensor #7 - Jib Lock Pin Switch This sensor is used to indicate the Jib Lock Pin is fully engaged. It is an inductive proximity switch mounted to the Jib Pivot weldment with both Normally Open and Normally Closed contacts wired into the control system. Sensor #8 - Jib Stow Angle Sensor This sensor is used to measure Jib Level angle in relationship to the Main Boom.
PAGE 493
SECTION 6 - JLG CONTROL SYSTEM Sensor #10 - Dual Capacity / Jib Transport Length Switches Sensor #11 - Platform Level Cylinder Angle Sensor This sensor is used to measure Platform angle in relationship to the Jib. A linear position sensor is located inside the Platform Level cylinder to measure cylinder stroke and be translated into Platform angle. This sensor is used for velocity control only.
PAGE 494
SECTION 6 - JLG CONTROL SYSTEM 6.7 JIB CONTROL MODULE 6.8 CAN GATEWAY See Figure 6-16., Jib Control Module. The Jib Control Module is mounted at the end of the main boom to aid in control of Jib Lift, Jib Level, Jib Telescope, and Jib Swing functions and also to process the information transmitted by the Jib Level angle sensor, the Jib Rotate angle sensor, and the Jib lock pin sensing proximity switch. 6-42 The CAN gateway is located in the ground control box.
PAGE 495
SECTION 6 - JLG CONTROL SYSTEM 6.9 SYSTEM TEST 3. Before proceeding, ensure that the switches on the platform console are in the following positions: The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Test from the Platform 1. Position the Platform/Ground select switch to the Platform position. a. Drive speed switch is in the Middle position. (Turtle Icon) b. 4WS switch is in the Middle position.
PAGE 496
SECTION 6 - JLG CONTROL SYSTEM 4. 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 6-19., System Test Flow Chart - Platform Tests and go through the component tests. Hit the ESC key during any part of the test to return to the main menu without completing all tests or wait until all tests are complete.
PAGE 497
Figure 6-19.
PAGE 498
SECTION 6 - JLG CONTROL SYSTEM Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the engine. 1. Position the Platform/Ground select switch to the Ground position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector inside the Ground control box. 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 6-20.
PAGE 499
Figure 6-20.
PAGE 500
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer RUNNING 6-48 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).
PAGE 501
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. 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.
PAGE 502
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TEST ALL INPUTS? TESTS COMPLETE 6-50 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.
PAGE 503
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 504
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 505
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. 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.
PAGE 506
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. 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: 6-54 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.
PAGE 507
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) 3121262 Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description HI TILTED - NO/YES Displays status of hi tilt input.
PAGE 508
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. 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.
PAGE 509
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) MOMENT: 3121262 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.
PAGE 510
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. 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.
PAGE 511
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 512
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 513
SECTION 6 - JLG CONTROL SYSTEM 6.10 CALIBRATING STEER When calibrating steering, each individual wheel must be calibrated in order to make the tire and wheel parallel with the frame. Two methods to help ensure proper calibration are the use of a carpenter’s square to square the spindle to the axle or aligning the two wheels on one side using a stretched string. 1. Position the Platform/Ground select switch to the Platform position. 2.
PAGE 514
SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the engine. 8. Use the arrow keys to reach Steer. The screen will read: 4. The analyzer screen should read: 9. Hit Enter. The screen will 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.
PAGE 515
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.
PAGE 516
SECTION 6 - JLG CONTROL SYSTEM 6.11 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the engine. 1. Position the Platform/Ground select switch to the Platform position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector at the base of the platform control box. 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.
PAGE 517
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.
PAGE 518
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 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.
PAGE 519
SECTION 6 - JLG CONTROL SYSTEM 6.12 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS There are three possible level valve driver errors, short to battery, short to ground, and open circuit. Platform Leveling Fault Warning 1. In the case of a short to ground or an open circuit, the platform valve cannot be turned on and the following will occur: The JLG Control System takes a snapshot of the two sensor values and records the difference once on each power up.
PAGE 520
SECTION 6 - JLG CONTROL SYSTEM 6.13 CALIBRATING PLATFORM LEVEL TILT SENSOR ERRORS If the secondary tilt sensor is faulty, the control system will continue to utilize information from the primary sensor. If the primary sensor is faulty, the control system will switch to the backup sensor for control. STEP 1: SETTING THE PLATFORM VALVE MINIMUMS In both cases above the following will occur: 1. Position the Platform/Ground select switch to the Ground position. 1.
PAGE 521
SECTION 6 - JLG CONTROL SYSTEM STEP 2: BLEEDING THE PLATFORM VALVES 4. The analyzer screen should read: 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the arrow button to reach PERSONALITIES adjust the following personalities. Refer to the Personality Ranges/Defaults table for proper setting values.
PAGE 522
SECTION 6 - JLG CONTROL SYSTEM STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 4. The analyzer screen should read: 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 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.
PAGE 523
SECTION 6 - JLG CONTROL SYSTEM 11. Using UP ARROW, increase the value until you see the basket up movement. 4. The analyzer screen should read: 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.
PAGE 524
SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector at the base of the platform control box. 4. The analyzer screen should read: 3. Pull out the Emergency Stop switch and Start the engine. 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.
PAGE 525
SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach Upper Lift Crack Point (UPPER LIFT CRKPT). The screen will read: 10. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 9. Hit enter. 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.
PAGE 526
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: 6.15 CALIBRATING TELESCOPE CRACK POINT 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. 14. Hit Enter. The screen will read: 15. Repeat steps 10 thru 12 for the Lift Down function. 16.
PAGE 527
SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the engine. 8. Use the arrow keys to reach Upper Telescope Crack Point (UPPER TELE CRKPT). The screen will read: 4. The analyzer screen should read: 9. Hit Enter. The screen will 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.
PAGE 528
SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: NOTE: In the following step, a minimum value of 10 must be indicated on the analyzer before the crack point can be set. The JLG Control System will not accept a value less than 10 and the analyzer will not advance to "CAL COMPLETE" if the crack point is set at a lesser value. 12.
PAGE 529
SECTION 6 - JLG CONTROL SYSTEM 14. Hit Enter. The screen will read: 15. Hit Enter. The screen will read: 16. Repeat steps 10 thru 12 for the Tele In function. 17. After completing all the Tele Calibrations, hit ESC twice to go back to CALIBRATIONS.
PAGE 530
SECTION 6 - JLG CONTROL SYSTEM 6.16 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground control box. 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. 4.
PAGE 531
SECTION 6 - JLG CONTROL SYSTEM 9. Use the arrow keys to reach the TILT SENSOR. The screen should read: 11. When prompted, swing turntable 180° to opposite end of chassis. 12. Press ENTER. The screen should read: 10. Press ENTER. 13. Upon completing swing calibration, swing turntable 180° back to the stowed position. 14. Hit ESC twice to go back to CALIBRATIONS.
PAGE 532
SECTION 6 - JLG CONTROL SYSTEM 6.17 JIB SENSOR CALIBRATIONS 4. The analyzer screen should read: To calibrate the jib sensors, the analyzer must be in access level 1. All jib sensors can be calibrated at one time or each calibration can be performed on an individual basis. 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271.
PAGE 533
SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach the JIB SENSORS. The screen should read: 10. Press ENTER. The screen should read as shown below. When it does, activate boom lift until the control system stops it at 20 degrees boom angle. 9. Press ENTER.
PAGE 534
SECTION 6 - JLG CONTROL SYSTEM 11. Press ENTER. The screen should read as shown below. When it does, the operator can either press enter to begin the jib lift sensor calibration, or use the right or left arrow key to locate the desired jib sensor calibration. The available sensor calibrations are: played. At this point, lift the jib up to the mechanical stop. JIB LIFT JIB LEVEL JIB SWING PLATFORM LEVEL 13. When the jib is at the mechanical stop, press ENTER. The screen shown below will be displayed.
PAGE 535
SECTION 6 - JLG CONTROL SYSTEM 14. Once the jib is stopped the screen shown below will be displayed. 15. Hitting the escape key (ESC) will take the system back to the initial jib lift calibration display. 16. Hitting the ENTER key at this point will take the operator to the next jib sensor calibration. The screen will show: 17. Press Enter. The screen will show: NOTE: At this point the left or right arrow key may be used to skip to any of the other jib sensor calibrations.
PAGE 536
SECTION 6 - JLG CONTROL SYSTEM 18. Operate jib lift down until the jib stops. When the jib is at the mechanical stop the operator must hit ENTER again. The screen will show: 19. When the system completes this step, the next screen will show: 6-84 20. Press ENTER. The screen should read: 21. Operate jib lift up until the jib stops. When the jib is at the mechanical stop, Hit ENTER again.
PAGE 537
SECTION 6 - JLG CONTROL SYSTEM 22. When the system completes this step, the next screen will show: 24. When the system completes the previous step, the screen will read: 23. Press ENTER. The screen should read as shown below. The control system will jib level down and stop the jib leveling command. 25. Hitting the escape key (ESC) will take the system back to the initial jib lift calibration display.
PAGE 538
SECTION 6 - JLG CONTROL SYSTEM 26. Hitting the ENTER key at this point will take the operator to the next jib sensor calibration. The screen will show: 27. Press Enter. The screen shown below will be displayed. At this point, use the platform rotate right function switch to swing the jib right. 6-86 28. When the jib reaches the mechanical stop, press ENTER. The screen will show: 29. When the system is complete with this step, the screen below will be displayed.
PAGE 539
SECTION 6 - JLG CONTROL SYSTEM 30. Press Enter. The screen shown below will be displayed. At this point, use the platform rotate left function switch to swing the jib left. 32. At the finish of the jib swing lift calibration the jib lock pin will be locked by the control system. The screen will read: 31. When the jib is at the mechanical stop, press ENTER. The screen will show: 33. Press ENTER. The screen will show: 34.
PAGE 540
SECTION 6 - JLG CONTROL SYSTEM NOTE: At this point the left or right arrow key may be used to skip to any of the other jib sensor calibrations. 37. When the platform level up is at mechanical stop, Press ENTER. The screen will show: 35. Hitting the ENTER key at this point will continue the calibration sequence. The screen will show: 38. When the system is complete with this step, the screen below will be displayed. 36. Press Enter. The screen shown below will be displayed.
PAGE 541
SECTION 6 - JLG CONTROL SYSTEM 39. Press ENTER. The display will then show: 40. The control system will stop the platform level and the screen will show: 41. Pressing ENTER will take you back to the beginning and escape (ESC) will take you to the initial screen. Calibrating the Jib Level Up and Down Valve Crackpoints 1. Position the Platform/Ground select switch to the Ground position.
PAGE 542
SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector inside the Ground control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Go to the CALIBRATIONS menu and hit ENTER. 8. Go to the JIB LVL UP CRKPT Screen. Hit ENTER. 9. CALIBRATE? prompt should appear. Hit ENTER again. 10. You will hear engine go to 1800 rpm. 11. Using UP ARROW, increase the value until you see the jib level movement. 12. Hit ENTER again. CAL.
PAGE 543
SECTION 6 - JLG CONTROL SYSTEM 6.18 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the Ground position. 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. 4 INCHES [10 CM] OR MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER OPERATION OR THE NEED FOR BLEEDING, THEN PROCEED WITH THE BOOM SENSOR CALIBRATION PROCEDURE.
PAGE 544
SECTION 6 - JLG CONTROL SYSTEM 5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 10. Hit Enter. The screen will read: 7. Enter the Access Code, 33271. 8. Use the right Arrow key to reach CALIBRATIONS. Hit Enter.
PAGE 545
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.
PAGE 546
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: 6-94 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.
PAGE 547
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.
PAGE 548
SECTION 6 - JLG CONTROL SYSTEM 23. After making sure the machine is in Calibration Position 1, hit Enter. The screen will read: 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. Figure 6-22.
PAGE 549
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 6-23. Boom Sensor Calibration Position 3 When the machine is in the proper position, hit Enter.
PAGE 550
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 6-24.
PAGE 551
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 6-25.
PAGE 552
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 6-27. Boom Sensor Calibration Position 7 When the machine is in the proper position, hit Enter. The screen will read as follows: Figure 6-26. Boom Sensor Calibration Position 6 When the machine is in the proper position, hit Enter.
PAGE 553
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 6-28. Boom Sensor Calibration Position 8 When the machine is in the proper position, hit Enter. The screen will read: Press Enter.
PAGE 554
SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The screen will read: 31. 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 6-29.
PAGE 555
SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: When the boom is in the proper position, the screen will read: 32. Telescope in to green witness mark (controller will find the position - operator must visually verify the position). Pressing enter will bring up: Figure 6-30.
PAGE 556
SECTION 6 - JLG CONTROL SYSTEM 33. Operate the Lift Up function switch. The control system will stop the boom at the desired angle. The display will read: 35. Operate the Jib Telescope Out function to the mechanical stop. Press ENTER. The display will read: 34. Operate the Telescope Out function switch. The control system will stop the boom at the desired length. The display will read: 36.
PAGE 557
SECTION 6 - JLG CONTROL SYSTEM 37. Operate the Jib Telescope In function switch until the jib is telescoped in to the mechanical stop. Press ENTER. The display will read: 39. When the calibration step is done, the display will read: 40. Press ENTER. The display will read: 38. Operate the Boom Telescope In function switch. The control system will stop the boom at the desired length.
PAGE 558
SECTION 6 - JLG CONTROL SYSTEM 41. Operate the Main Boom Telescope function until the main boom is telescoped in to the stop. The display will read: 43. Press ENTER. The display will read: 44. After completing all the Boom Sensors Calibrations, hit ESC twice to go back to Calibrations. 42. Operate the Boom Lift Down function until the main boom is lifted down to the rest. The display will read: 6-106 45. Cycle the emergency stop switch.
PAGE 559
SECTION 6 - JLG CONTROL SYSTEM 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. 5. Push and hold the gray Boom Control System Test Button on the ground control panel.
PAGE 560
SECTION 6 - JLG CONTROL SYSTEM 1706741A FAULT CODE LIGHT 1705744 A 1702566 B 1702565 B 1001125195 B 1001125194 A 1702938 1705170 A PLATFORM CONTROL MODULE GROUND CONTROL MODULE FAULT CODE LIGHT Figure 6-31.
PAGE 561
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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.
PAGE 562
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 220 22 0 <<< PLATFORM CONTROLS >>> 227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are closed simultaneously. 2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed - Can be reported during for more then seven secpower-up. onds. 2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Footswitch open.
PAGE 563
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 240 24 0 Fault Message Fault Description Check <<< OTHER CONTROLS >>> 250 25 0 <<< FUNCTION PREVENTED >>> 259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE The model selection has EMS been changed. 2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the vehicle generator is running AND is configured to prevent drive.
PAGE 564
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to - Chassis Module equipped the Right Forward Drive vehicles only. Valve. 3318 33 18 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the Right Forward Drive Valve.
PAGE 565
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3343 33 43 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground - CAT engines only. to the Cold Start Advance Solenoid. 3344 33 44 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to - CAT engines only. the Cold Start Advance Solenoid. 3345 33 45 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the Cold Start Advance Solenoid.
PAGE 566
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to - Head Light equipped vehithe Head Light Relay. cles only. 3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the Head Light Relay. 3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the Hour Meter.
PAGE 567
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Main Telescope Out Valve. 33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the Throttle Actuator. 33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the Throttle Actuator.
PAGE 568
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Main Telescope In Valve. 33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the Horn. 33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the Horn. 33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the Horn.
PAGE 569
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 344 34 4 347 34 348 Fault Message Fault Description Check PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open Circuit to the Platform Level Up Valve. - Electronic leveling system equipped vehicles only. 7 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Level Down Valve.
PAGE 570
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 433 43 434 Fault Message Fault Description 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading is > 6.6V. - Deutz engine only. 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading is < 0.1V for more then 5 seconds. - Deutz engine only. - Not reported during engine start. 435 43 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sensor reading is < 0.1V.
PAGE 571
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 663 66 3 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE 666 66 6 6610 66 6611 Fault Description Check CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN communication lost. - ECM equipped engine only. 10 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only. 66 11 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN communication lost.
PAGE 572
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 827 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are not possible while the Load Sensing System indicates the Platform is overloaded AND is configured to prevent drive and boom functions while the Platform is overloaded.
PAGE 573
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8315 83 15 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads - Electronic leveling system the sensor values at equipped vehicles only. power-up. The fault is triggered when there is a ± 5 degree difference from the initial reading. 8316 83 16 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial communication lost.
PAGE 574
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 844 84 4 845 84 846 Fault Message Fault Description Check BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not changing during a boom telescope command. - Envelope Control equipped vehicles only. 5 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of - Envelope Control equipped range high. vehicles only.
PAGE 575
SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
PAGE 576
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Right Front Steer Left Valve. 8610 86 10 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery OR OPEN CIRCUIT or an Open Circuit to the Left Front Steer Right Valve. 8611 86 11 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Left Front Steer Right Valve.
PAGE 577
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has become decoupled. 8625 86 25 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has become decoupled. 8626 86 26 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is not responding to steer commands.
PAGE 578
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 993 99 3 Fault Message Fault Description Check LSS INTERNAL ERROR - PIN EXCITATION 994 99 4 LSS INTERNAL ERROR - DRDY MISSING FROM A/D 998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS 9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFT- The Platform Module softWARE VERSION IMPROPER ware version is not compatible with the rest of the system.
PAGE 579
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart DTC Flash Code Sequence 9925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER 9926 99 26 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE The BLAM software verVERSION IMPROPER sion is not compatible with the rest of the system. 9927 99 27 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant data requires an updated.
PAGE 580
SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-128 – JLG Lift – 3121262
PAGE 581
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL Polarity This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
PAGE 582
SECTION 7 - BASIC ELECTRICAL INFORMATION & 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.
PAGE 583
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connections: • Main Boom Rotary sensor connections (on Celesco Sensor), • LSS Modules connections, • Deutz EMR 2 ECM connection.
PAGE 584
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only. NOTE: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal more difficult. Deutsch HD, DT, DTM, DRC Series The Deutsch connector system is commonly used for harsh environment interconnect. Follow the installation instructions.
PAGE 585
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs AMP Mate-N-Lok Follow the installation instructions. 3121262 Exclusions A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application. Dielectric grease may not be required in properly sealed enclosures.
PAGE 586
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion and an o-ring seal for moisture integrity. If dielectric grease is mistakenly applied to this connector system, the low-force contacts cannot displace the grease to achieve electrical contact. Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required).
PAGE 587
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-9.). Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-7.). Proceed as follows: Figure 7-7. Connector Assembly Figure 1 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-9.). Figure 7-8.
PAGE 588
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. 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 7-10.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-11.). Figure 7-11. Connector Assembly Figure 4 Figure 7-10.
PAGE 589
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7. 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.
PAGE 590
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13.
PAGE 591
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly A A B B C C D Figure 7-14. DT/DTP Contact Installation Figure 7-15. 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.
PAGE 592
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A C C Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp barrel. 9. Hold connector with rear grommet facing you. 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. 11.
PAGE 593
3121262 V40-JIB LIFT DOWN V39-JIB LIFT UP V34-JIB ENABLE – JLG Lift – J1 J4 J2 J5 JIB CONTROL MODULE J3 Figure 7-20.
PAGE 594
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 13 21 BLACK WHITE FRONT OF MACHINE 14 22 AXLE LIMIT SWITCH WIRING - TYP. STEER ANGLE SENSOR BLACK WHITE AXLE POWERTRACK AXLE LIMIT SWITCH SWIVEL STEER VALVE V167-FRONT AXLES EXTEND V162-LEFT FRONT STEER RIGHT V163-RIGHT FRONT STEER RIGHT TRACTION VALVE V165-RIGHT FRONT STEER LEFT AXLE POWERTRACK V164-LEFT FRONT STEER LEFT V166-FRONT AXLES RETRACT AXLE LIMIT SWITCH STEER ANGLE SENSOR Figure 7-21.
PAGE 595
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS REAR OF MACHINE STEER ANGLE SENSOR AXLE POWERTRACK SWITCH STEER VALVE V161-REAR AXLES RETRACT V153-LEFT REAR STEER LEFT V159-RIGHT REAR STEER LEFT CHASSIS MODULE J5 J4 J2 J1 J3 V124-RIGHT REAR STEER RIGHT AXLE POWERTRACK V123-LEFT REAR STEER RIGHT V160-REAR AXLES EXTEND AXLE LIMIT SWITCH STEER ANGLE SENSOR 1001119385-C Figure 7-22.
PAGE 596
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERATOR CONTROL BOX ALTERNATOR OIL TEMP SWITCH OIL PRESS SWITCH ENGINE SPEED SENSOR HYDRAULIC PUMPS HEADLIGHT V279-DRIVE LEFT SIDE FORWARD (SAUER) V278-DRIVE RIGHT SIDE REVERSE (SAUER/REXROTH) V280-DRIVE LEFT SIDE REVERSE (REXROTH) DEUTZ EMR2 MODULE 110V / 220V GENERATOR V279-DRIVE LEFT SIDE FORWARD (REXROTH) V280-DRIVE LEFT SIDE REVERSE (SAUER) V277-DRIVE RIGHT SIDE FORWARD (SAUER/REXROTH IN HEAD STYLE GLOW PLUG STARTER TRANSPORT LIMIT
PAGE 597
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: 13 RED TRANSPORT LIMIT SWITCH WIRING. 14 22 WHITE BLACK 21 DO NOT ATTACH ANY WIRING HARNESSES TO FUEL SUPPLY, RETURN OR VENT HOSES. APPLY IN ALL UNSEALED CONNECTORS PER MPS FI-001 AND FI-042.
PAGE 598
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1 2 3 4 5 6 SW223 SEE ZONE-[6,C] SW228-2 1 SW228-1 1 YEL/RED 2-40-10 YEL/RED 2-40-05 ORN/RED 49-102 1 2 3 4 5 6 SW221 BRN 13-2 YEL/RED 2-40-03 BRN 14-2 YEL/RED 2-40-10 1 2 3 4 5 6 SW220 WHT 21-2 YEL/RED 2-40-01 WHT 22-2 YEL/RED 2-40-02 GD275 3 4 5 6 1 2 ORN/RED 49-20 YEL/RED 2-40-07 BLK 000-31-11 IP212 YEL/RED 2-3 GRN CAN1-L_MDI YEL CAN1-H_MDI TAN 3-2 YEL/RED 2-40-02 TAN 3-3 YEL/RED 2-40-03 1 2 3 4 5 6 SW219 87 30 87a 85 86 4 1 3 2 5 RL80 I
PAGE 599
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS YEL/RED 2-8-5 BRN/WHT 47-9 1 2 LB238 1000# CAP LIGHT RED/YEL 54-5 BLK 000-31-02 BLK 000-31-01 (CE ONLY) PLATFORM OVERLOAD 1 2 LB237 1 2 LB236 ORN/RED 49-101 BLK 000-31-04 BLK 000-31-03 1 2 LB235 ORN/RED 49-103 BLK 000-31-05 BLK 000-31-04 1 2 LB234 NO ALTERNATOR MOMENT CNTL BOOM CONTROL OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT BRN/WHT 47-8 BLK 000-31-06 BLK 000-31-05 BRN/WHT 47-5 BLK 000-31-07 BLK 000-31-06 1 2 LB233 LOW OIL PRES LIGHT 1 2 LB23
PAGE 600
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally.
PAGE 601
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27.
PAGE 602
15 15 14 14 13 13 12 12 11 11 10 10 6 6 5 5 4 4 9 9 8 8 2 2 7 7 1 1 3 3 X154 X155 7-22 1 B 28 27 16 17 9 10 31 23 24 32 34 35 13 7 8 3 4 29 11 12 30 5 6 22 14 15 21 18 WHT/YEL 48-5 ORN 55-46 YEL 55-16 YEL 55-17 PNK 25-1 PNK 26-1 BLU/ORN 52-1 YEL/WHT 43-1 YEL/WHT 44-1 ORN/RED 49-11 RED/WHT 55-30 RED/WHT 55-31 BLK 000-53 GRY 23-1 GRY 24-1 BRN 29-1 BRN 30-1 ORN/RED 49-40 BLU 27-1 BLU 28-1 BLU/ORN 52-12 BRN 13-1 BRN 14-1 ORN/RED 49-120 WHT/YEL 48-1 BRN/ORN 53-1 RED/YEL 54-1 YEL/RED 2-10 ORN/RED 49-11 YEL/R
PAGE 603
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1 2 3 4 5 6 SW74 1 2 3 4 5 6 SW72 1 2 3 4 5 6 SW135 DRIVE ORIENTATION TOGGLE SWITCH H YEL/RED 2-10 ORN 55-50 YEL/RED 2-10 YEL/RED 2-10 RED/YEL 54-1 YEL/RED 2-10 WHT/YEL 48-1 YEL/RED 2-10 BRN/ORN 53-1 YEL/RED 2-10 RE YEL/ YEL/RED 2-10 ORN/RED 49-120 1 2 3 4 5 6 SW71 BRN 13-1 YEL/RED 2-10 BRN 14-1 YEL/RED 2-10 YEL/RED 2-10 MAIN BOOM TELESCOPE TOGGLE SWITCH BLU/ORN 52-12 YEL/RED 2-10 1 2 3 4 5 6 SW70 YEL/RED 2-10 YEL/RED 2-10 ORN/RED 49-40
PAGE 604
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3 4 PLATFORM DUMP 1 2 JIB TRANSPORT-2 PROXIMITY SENSOR V27 V33 1 2 JIB LOCK PIN - OUT 1 2 JIB LOCK PIN - IN V31 1 2 PLATF ROT RIGHT 1 2 PLATF ROT LEFT V29 V28 1 2 PLATF LEVEL PLATF LEVEL UP DOWN V30 SENSOR #1 (RH) PLATFORM LEVEL SENSOR V32 2 SENSOR #2 (LH) PLATFORM LEVEL SENSOR 1 2 1 G 12 21 4 13 14 18 20 X141 3 4 2 1 SN136 RED (12) BLK (12) BLK 000-46-6 WHT 55-6 BLK 000-46-8 WHT 55-5 BLK 000-46-7 GRY 24-3 GRY 23-3 PNK 2
PAGE 605
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GND IGN IGN GND CAN1S CAN1L CAN1H J2 (BLACK) J5 (RUST) GND 1 2 5 6 3 4 7 8 9 10 11 12 CO49-J5 1 2 RED (12) BLK (12) S157 BLU 27-3-1 BLU 28-3-1 BRN 29-3 BRN 30-3 WHT 60-3 WHT 59-3 S158 JIB CONTROL MODULE SN84 IGN GND IGN GND JUMP TO J2-1 JUMP TO J2-2 CAN1H CAN1L CAN1S 5VREF ROT2 GND 5VREF ROT1 GND 5VREF LVL2 GND 5VREF LVL1 GND 10 11 12 7 8 9 4 5 6 1 2 3 CO49-J3 RED WHT BLK ORN BLU GRN RED WHT BLK ORN BLU GRN RED WHT BLK ORN BLU GRN B D A F
PAGE 606
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1 2 3 PUMP CONNECTOR SEE SHEET 7 ZONE B-1 4 Boom Angle Sensor #2 Left Side 1 2 6 3 4 5 X62 Boom Angle Sensor #1 Right Side 1 2 3 SN07 BLK RED BLU BLK ORN YEL BLK BLK ORN 8-2-1 ORN 8-3-1 BLK 000-10 ORN 7-2-1 ORN 7-3-1 1 2 3 SN06 X56 1 2 6 3 4 5 H X38 1 2 3 4 MNANG1 GND IGN MNANG2 GND AXLE E IGN GND CAN1H CAN1L CAN1S CO11-J4 7 8 6 1 2 3 4 5 RED BLK GRN WHT BLK A B D E S85 CO11-J2 ORN 7-2-1 12 ORN 7-3-1 11 10 ORN/RED 49-111 8 BLK
PAGE 607
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 5 6 7 MAIN DUMP SN242 13 21 22 14 SN241 1 4 3 RED BLK WHT WHT H BRN BLK BLU Sheet_3 (Platf_and_Jib)-[8,D] Sheet_3 (Platf_and_Jib)-[8,D] BLU (12) ORN (12) STROBE LIGHT 8 BOOM LENGTH LIMIT SWITCH SWING RIGHT X244 X146 1 1 2 2 6 6 3 3 4 4 5 5 7 7 8 8 9 9 10 10 11 11 12 12 WHT BLK RED BLK (12) RED (12) Sheet_3 (Platf_and_Jib)-[8,D] Sheet_3 (Platf_and_Jib)-[8,D] BROKEN CABLE PROXIMITY SENSOR BLU BLK BRN RED (12) BLK (12) ORN (12) BLU (12)
PAGE 608
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ***120 SW228-2 1 BRN 29-2 YEL/RED 2-40-05 BRN 30-2 YEL/RED 2-40-04 WHT 21-2 YEL/RED 2-40-01 WHT 22-2 TAN 3-2 TAN 3-3 BRN 13-2 BRN 14-2 BRN 29-2 BRN 30-2 BLU 28-2 BLU 27-2 12 34 25 35 23 33 7 30 11 22 8 19 20 9 BLK CAN2-SHIELD SWGLT IGN SWGRT LIFTUP LIFTDN TELEIN TELEOT JIBIN JIBOUT JIBDN JIBUP BLK CAN2-SHIELD SHIELD TP-CBL12 Sheet_5 (Ground Box)-[7,C] GRN CAN2-LOW Sheet_5 (Ground Box)-[7,C] Sheet_5 (Ground Box)-[7,C] YEL CAN2-HIGH GRN CAN2-LO
PAGE 609
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1 2 LB238 H RED/YEL 54-5 BLK 000-31-02 BLK 000-31-01 1000# CAP LIGHT ORN/RED 49-100 BLK 000-31-03 BLK 000-31-02 1 2 LB236 ORN/RED 49-101 BLK 000-31-04 BLK 000-31-03 1 2 LB235 ORN/RED 49-103 BLK 000-31-05 BLK 000-31-04 BRN/WHT 47-8 BLK 000-31-06 BLK 000-31-05 BRN/WHT 47-5 BLK 000-31-07 BLK 000-31-06 1 2 LB234 NO ALTERNATOR MOMENT CNTL BOOM CONTROL OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT 1 2 LB233 LOW OIL PRES LIGHT 1 2 LB232 HIGH COOLANT TEMP
PAGE 610
A 7-30 LEFT FRONT STEER SENSOR RIGHT FRONT STEER SENSOR 1 2 – JLG Lift – SN81 1 2 3 SN92 1 2 3 3 4 3 2 1 X113 WHT RED BLK S122 S121 S199 RED/WHT 50-5-1 BLK 000-18-1 BLK 000-19 8 2 6 5 4 3 7 1 CO21-J4 GND GND IGN IGN IGN 12 10 9 6 7 8 5 4 3 2 1 11 CO21-J1 GND CANT CANT CAN1H CAN1L CAN1S IGN GND J1 (GRAY) RED/WHT 50-5-2 BLK 000-18-2 BRN/BLK BRN/BLK VREF FTRTSTR GND VREF FTLTSTR GND GND RERTSTR VREF GND RELTSTR VREF J3 (GREEN) 4 3 2 1 X106 BLK WHT RED CO21-J3 1 2 3 4 5 6 9 8 7 12
PAGE 611
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 6 SN176 1 2 LEFT FRONT AXLE EXTEND LIMIT SWITCH 8 RIGHT FRONT AXLE EXTEND LIMIT SWITCH LEFT REAR AXLE RETRACT LIMIT SWITCH H RIGHT REAR AXLE RETRACT LIMIT SWITCH BLK WHT BLK WHT BLK WHT BLK WHT ORN 55-47-2 BLK 000-14 ORN 55-45 BLK 000-17 1 2 V194 TWO SPEED VALVE 1 2 V195 BRAKE VALVE 7 PROXIMITY SENSOR DRIVE ORIENTATION 5 G YEL/RED 2-1-3 WHT S187 BLK S188 ORN/RED 49-104 WHT BLK S189 YEL/RED 2-1-2 WHT S190 BLK S191 ORN/RE
PAGE 612
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2 3 4 WHT/YEL 48-13 (8) 30 87 86 1 RL197-87 WHT/YEL 48-12 (12) 1 RL197-30 85 1 RL197-86 1 RL197-85 BLK (14) WHT/YEL 48-3 RED (1/0) RED (1/0) 30 87 86 1 RL198-87 WHT/YEL 48-13 (8) 1 RL198-30 85 1 RL198-86 1 RL198-85 BLK (14) BLK (14) WHT/YEL 48-9 RED (1/0) RED (1/0) X270 1 BLK (1/0) X269 1 ENGINE BLOCK BLK (14) BLK (1/0) BLK (1/0) X268 1 ENGINE TRAY PIVOT PIN 1 EC91 START RELAY GLOWPLUG RELAY H IN HEAD GLOW PLUGS 1 G X
PAGE 613
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally.
PAGE 614
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2 3 1 CONNECT TO BON ENGINE TRAY 1 CONNECT TO B+ ON AUX POWER RELAY 1 CONNECTED TO BON AUX POWER RELAY 1 1 1 BLACK WHITE RED 1-1 (12) WHITE WHITE WHITE WHITE G CONNECT TO X147 IN TURNTABLE BLACK BLACK 5 2 3 1 4 86 85 87a 30 87 RIGHT FRONT LIGHT 1 LEFT FRONT LIGHT HEAD & TAIL LIGHT RELAY H 4 1 1 BLU/ORN 52-12 BLACK #14 FUSIBLE LINK BLACK WHITE BLACK 1 LEFT REAR LIGHT F 1 BLACK BLACK 1 WHITE WHITE BLACK 1 BLACK (
PAGE 615
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 5 6 7 8 (OPTION) 7500W GENERATOR CONTROL BOX YEL/RED 2-8-8 BLU/ORN 52-5 BLK 000-22 A B C H ENGINE CONNECTOR #2 REFERENCE ONLY X201 4 5 1 3 6 2 7 8 5A YEL/RED 2-8-8 IP328 BLU/ORN 52-5 BLK 000-22 G WIRES INSERTED ON ASSY LINE 7500W GENERATOR F 86 85 87a 30 87 110V GENERATOR RELAY WHITE BLU/ORN 52-6 GREEN BLACK 2 1 J8_1 BLACK E 3A ENGINE CONNECTOR #2 IP325 IP324 3A BLU/ORN 52-5 YEL/RED 12AWG BLK 12AWG BLK 16AWG RED 1-3 (12) B
PAGE 616
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-41.
PAGE 617
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001120628-F Figure 7-42.
PAGE 618
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-43.
PAGE 619
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001120628-F Figure 7-44.
PAGE 620
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS M14 Front Drive Pump M14 C2 C1 M3 MB F00B C1 C2 Rear Drive Pump MC E F00A F00B F00A L3 L1 CW M5 M4 CW L2 MA A B C MD D M5 M4 To port B, Main control valve, page 1.
PAGE 621
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Front Pump Fire coil C1; flow to port A, measure at port M4 Fire coil C2; flow to port B; measure at port M5 Rear Pump Fire coil C1; flow to port C; measure at port M4 Fire coil C2; flow to port D; measure at port M5 CHARGE PUMP FILTER B5 >= 200 BYPASS 50 PSI CHARGE PUMP 1.025 in3 30 Mesh 3 PSI Bypass Oil Cooler Option Port L3 of the pump to the inlet of the cooler. Cooler outlet back to tank.
PAGE 622
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MIDDLE DRIVE PUMP 2.75 in3 FRONT DRIVE PUMP 2.
PAGE 623
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PORT #7 FRONT AXLE LEFT MOTOR B V V P P G G1 L L1 A OSCILLATING AXLE CIRCUIT FRONT DRIVE BRAKES B G G1 L L1 DRIVE SYSTEM REXROTH PUMPS A 1001120628-F Figure 7-48.
PAGE 624
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS C2 C1 JIB STOW ROTATOR 66 CU IN 10:1 PILOT RATIO SPRING 3300 PSI V1 T V2 JIB TELESCOPE CYLINDER BORE 2.5" 4.91 sq in ROD 1.5" 1.78 sq in ANNULAR 3.14 sq in STROKE 118" RATIO 1.56:1 JIB LEVEL CYLINDER BORE 5.5" 23.76 sq in ROD 2.5" 4.91 sq in ANNULAR 18.85 sq in STROKE 16.59" RATIO 1.26:1 JIB LIFT CYLINDER BORE 5" 19.63 sq in ROD 2.5" 4.91 sq in ANNULAR 14.73 sq in STROKE 25.15" RATIO 1.
PAGE 625
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM ROTATOR 14.1 cu in 3:1 PILOT RATIO SPRING 3000 PSI C2 C1 PLATFORM LEVEL CYLINDER BORE 3.5" 9.62 sq in ROD 1.5" 1.76 sq in ANNULAR 7.85 sq in STROKE 14.79" RATIO 1.23:1 JIB LOCK CYLINDER BORE 2.5" 4.91 sq in ROD 1.75" 2.41 sq in ANNULAR 2.50 sq in STROKE 13.375" RATIO 1.96:1 V2 V1 T V2 V1 ML1 L2 ML2 L1 R1 R2 S1 S2 2000 + 0 - 50 PSI 2500 +50 PSI - 0 2000 +50 PSI - 0 0.2 GPM T2 T1 MP 2.
PAGE 626
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-46 – JLG Lift – 3121262
PAGE 627
PAGE 628
3121262 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 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.