Service & Maintenance Manual Models 3369LE 4069LE M3369 M4069 3121122 July 23, 2012
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - February 5, 2001 Revision - April 25, 2001 Revision - September 17, 2001 Revision - June 21, 2002 Revision - October 15, 2002 Revision - December 10, 2003 Revision - February 17, 2004 Revision - May 11, 2004 Revision - December 21, 2004 Revision - January 24, 2005 Revision - February 2, 2007 Revision - April 17, 2007 Revision - October 11, 2007 Revision - November 28, 2007 Revision - March 17, 2008 Revision - January 14, 2011 Revis
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A A.B A.C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) 4.14 4.15 4.16 4.17 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Drive Assist Valve . . . . . . .
TABLE OF CONTENTS 3-25. 3-26. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-11. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 5-1. 5-2. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 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. 3121122 Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 Hub Main Assembly . . . .
TABLE OF CONTENTS (Continued) 6-28. 6-29. 6-30. 6-31. Hydraulic Diagram - 3369LE and M3369 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 Hydraulic Diagram - 4069LE and M4069 (Fixed Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 Hydraulic Diagram - 4069LE and M4069 (Oscillating Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS Table 1-1. Operating Specifications Description Maximum Platform Height 3369LE/M3369 4069LE/M4069 33 ft (10.1 m) 40 ft (12.2 m) Maximum Occupants Gross Machine Weight (minimum) 2 9760 lbs (4427 kg) Travel Speed: High Drive Fwd/Rev (sec/50 ft) Elevated Drive Fwd/Rev (sec/50 ft) 10,560 lbs (4790 kg) 10.
SECTION 1 - SPECIFICATIONS 1.2 CAPACITIES Drive System Drive Motor - 48 VDC, 11.8 H.P. peak 5.5 H.P. continuous, rotation - reversible Table 1-2. Capacities Description 3369LE/M3369 4069LE/M4069 8.25 gal (31.2 liters) 5.4 gal (20.4 liters) @ full mark Hydraulic Tank Hydraulic System Steer System Tires - IN240/55-17.5 FF approx. 8.5 gal (32.1 liters) Torque Hubs (2) Drive Brake - 24 VDC, spring-applied, hydraulically released 17 ounces (0.5 liters) IN240/55-17.5 FF non marking 27.2/10.5LL-15.
SECTION 1 - SPECIFICATIONS 1.6 LUBRICATION 1.7 CYLINDER SPECIFICATIONS Table 1-5. Hydraulic Oil Table 1-8. Cylinder Specifications Hydraulic System Operating Temperature Range SAE Viscosity Grade DESCRIPTION BORE STROKE ROD DIA. 0° F to 23° F (-18°C to -5°C) 0° F to 210° F (-18°C to +99°C) 50° F to 210° F (+10°C to +99°C) 10W 10W-20, 10W- 0 20W-20 Lift Cylinder (M3369/3369LE) 4.00 in (10.16 cm) 63.69 in (161.77 cm) 2.75 in (6.98 cm) Upper Lift Cylinder (M4069/4069LE) 3.00 in (7.62 cm) 58.
SECTION 1 - SPECIFICATIONS 1.10 LUBRICATION Note: 500 Hrs. = 3 months 1000 Hrs. = 6 months 2000 Hrs. = 1 year 4000 Hrs. = 2 years 1 3 2 Figure 1-1. Lubrication Chart Table 1-11.
SECTION 1 - SPECIFICATIONS 1.11 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to the front of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left front of the machine frame. SERIAL NUMBER PLATE SERIAL NUMBER STAMPED Figure 1-2.
SECTION 1 - SPECIFICATIONS 1.12 TORQUE CHARTS 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.
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.
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.
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.
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.
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.
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.
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.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval. Hydraulic System 1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system. Pressure-Fit Parts 2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent.
SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION This will allow start up at temperatures down to -20° F (-29° C). However, use of this oil will give poor performance at temperatures above 120°F (49°C). Systems using DTE 13 oil should not be operated at temperatures above 200°F (94°C) under any condition. Hydraulic System 1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.
SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods. 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift Measure the drift of the platform to the ground. Fully elevate the platform. Maximum allowable drift is 2 in. (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following. 1. Pinned joints should be disassembled inspected if the following occurs: and a.
SECTION 2 - GENERAL 2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The inspection and maintenance code numbers for Table 2-3, Preventive Maintenance and Inspection Schedule, are as follows: The preventive maintenance and inspection checks are listed and defined in Table 2-3, Preventive Maintenance and Inspection Schedule. This table is divided into two basic parts, the “AREA” to be inspected, and the “INTERVAL” at which the inspection is to take place.
SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Inspection Schedule AREA PLATFORM INTERVAL 10 HOURS DAILY 1. Controller 1, 11 2. Switches 1, 11 3. Placards and Decals 1, 2 4. Control Tags 1, 2 5. Hoses and Cables 1 50 HOURS WEEKLY 200 HOURS MONTHLY 1000 HOURS 6 MONTHS 5, 8 6. Wear Pads 7. Handrail and Chains 500 HOURS 3 MONTHS 8 1, 4 CHASSIS 1. Batteries 3 2. Battery Charger 1 3. Hydraulic Pump/Motor 1 5 4. Valves 1 5 5. Hydraulic Filter* (Also see note) 5, 14 6.
SECTION 2 - GENERAL NOTES: 2-8 – JLG Lift– 3121122
SECTION 3 - CHASSIS & SCISSOR ARMS SECTION 3. CHASSIS & SCISSOR ARMS 3.1 CALIBRATIONS 6. Lift the platform up until it stops lifting, this will be the lift cut-out height. Elevation Sensor Calibration (Prior to Software V13.6) 7. Using the analyzer, press ESCAPE, scroll to DIAGNOSTICS, press ENTER, scroll to ELEV SENSOR and press ENTER. You should now see ANGLE SNSR. The setting here should be 0.60v - 0.70v.
SECTION 3 - CHASSIS & SCISSOR ARMS 13. Press ESCAPE, remove analyzer and assure all hardware is tight. Tilt Sensor Calibration: 1. Drive the machine onto a measured level surface (±0.5° for both x and y axis). Elevation Sensor Calibration (Software V13.6 and Higher) 2. Using the Analyzer, go to MENU: CALIBRATION; TILT SENSOR. Press Enter. LEVEL VEHICLE will display. Press Enter again to calibrate. Using the Analyzer, in Access Level 1, go to MENU: CALIBRATION: 1. SET STOW ELEV; 3.
SECTION 3 - CHASSIS & SCISSOR ARMS b. Tilt sensor mounting on machine or wedged crooked in control box: If the machine mounting/grade appears acceptable, open the Ground Control box carefully. Observe whether the tilt sensor is properly seated. For the following troubleshooting steps, a bubble level (smaller is better) will be needed and the machine must be on a level surface: 1. On the Analyzer, go to Diagnostics/System and read the tilt angle. If either angle reports +20.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.2 TILT SENSOR 1 Tilt Sensor, JLG P/N 4000006: 2 3 1 2 1. Ground Control Box 2. Tilt Sensor (JLG P/N 4000006) Figure 3-1. Tilt Sensor Location 1. Tilt Sensor (JLG P/N 4000006) Tilt Sensor Removal: 2. Screw, 6-32 x 3/4 3. Lockwasher NOTE: Refer to Figure 3-2., Tilt Sensor Removal for numbers in parenthesis. Figure 3-2. Tilt Sensor Removal 1. Disconnect the batteries. 2. Open the Ground Control Box to gain access to the Tilt Sensor Assembly. 3.
SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor, JLG P/N 4000021: 2 6 7 2 1 1 5 4 3 1. Ground Control Box 2. Tilt Sensor Assembly (JLG P/N 1810140) Figure 3-3. Tilt Sensor Location NOTE: Refer to Figure 3-4., Tilt Sensor Removal for numbers in parenthesis. 1. Tilt Sensor (JLG P/N 4000021) 2. Sensor Mount 1. Disconnect the batteries. 3. Screw, 6-32 x 1 2. Open the Ground Control Box to gain access to the Tilt Sensor Assembly. 4. Lockwasher 5. Standoff Insulator 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.3 BATTERY MAINTENANCE AND CHARGING ammonia) and wire brush. Replace cables and/or cable clamp bolts as required. 4. Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly. IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH AT LEAST 52 KG (115 LB). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH. 5.
SECTION 3 - CHASSIS & SCISSOR ARMS 2. To charge the batteries, connect the charger to a 230 volt source with a 15 amp minimum capacity. 3. The charge cycle is complete when the 100% LED is lit. Any other reading indicates the charge cycle is not complete. Battery Charger (Delta-Q) The battery charger is located on a tray behind the hinged JLG cover at the front of the machine, or on the sliding engine tray on the (M) model machines. 4.
SECTION 3 - CHASSIS & SCISSOR ARMS Battery Charger Maintenance Table 3-3. Delta-Q - Battery Charger Specs BATTERY CHARGER SPECIFICATION OUTPUT Nominal DC Output Voltage USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE. 48V Maximum DC Output Voltage 52V Maximum DC Output Current 20A Maximum Interlock Current LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION.
SECTION 3 - CHASSIS & SCISSOR ARMS Battery Charger Troubleshooting 4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service. No Lights at all No lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger. 1. Check the connections to AC power.
SECTION 3 - CHASSIS & SCISSOR ARMS [5 Flashes] - Over Temperature This fault indicates the charger has become too hot during operation. Though not damaging to the charger, charge time will be extended significantly. 1. This fault indication will not clear automatically, but the charger will restart charging automatically when the temperature drops. The fault indication must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.
SECTION 3 - CHASSIS & SCISSOR ARMS Checking - Changing the Battery Charger Algorithm Table 3-4. Battery Algorithms The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Algorithms on Page 3-11. Contact JLG if your specific battery model is not listed. Each time AC power is applied with the battery pack not connected, the charger enters an algorithm select/display mode for approximately 11 seconds.
SECTION 3 - CHASSIS & SCISSOR ARMS BATTERY BOX BATTERY CHARGER BATTERY TEMPERATURE SENSOR (DELTA-Q CHARGER) BATTERY BOX ATTACHMENT BOLTS TO CONTACTOR BATTERY DISCONNECT BATTERY BOX Figure 3-8. Batteries and Battery Charger Removing the Battery Box To remove the battery box, perform the following steps. NOTE: The battery box and batteries complete weigh approximately 670 lbs (304 kg). 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.4 GENERATOR • Start Control Relay NOTE: Throughout the Generator section, the abbreviations RBS and CTS are used. RBS stands for Rotary Battery System, which is the generator system. CTS stands for Call To Start, which is the electronic inputs which signal the generator to start and charge the batteries. The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-9.
SECTION 3 - CHASSIS & SCISSOR ARMS Timing Sequences Table 3-6. RBS Startup Sequence NOTE: Throughout the Generator section, the abbreviations RBS and CTS are used. RBS stands for Rotary Battery System, which is the generator system. CTS stands for Call To Start, which is the electronic inputs which signal the generator to start and charge the batteries. • RBS Pre start Sequence 1.
Figure 3-10.
SECTION 3 - CHASSIS & SCISSOR ARMS To Connect the JLG Control System Analyzer to the Generator The JLG Control System Analyzer can be used to monitor generator settings and conditions. Connect the analyzer as follows: Alarms and Fault Flash Codes In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. NOTE: Alarms must be reset once the fault has been corrected. Table 3-8.
SECTION 3 - CHASSIS & SCISSOR ARMS • Underspeed • Finish Charging Current Enabled once TDBP (time delay bypass) period has elapsed after engine startup. If the engine speed drops below the underspeed limit, the engine will stop immediately and an engine underspeed alarm will be indicated. The finish charging current determines the level of the current alternator output must drop below for a low battery voltage CTS to be removed.
SECTION 3 - CHASSIS & SCISSOR ARMS b. The engine/camshaft rotation is not opening the injection fuel pump. Using the recoil starter, rotate the engine 1/3 of a turn and fuel should spill from the fuel injector pump. 2. Find where the harness attaches to the rear cover of the generator and the connection point for the new inline fuse. 10. Engine might run rough for 20 seconds or so, but it will clean out. 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. 5. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the conductors that lead to the new in-line fuse holder. Use insulated butt splice connectors for these conductors. 6. Re-install the harness with the new fuse in place. 7.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 JOYSTICK CONTROLLER Figure 3-11. Joystick Controller - (JLG P/N 1600308) Table 3-9. Joystick Specifications Table 3-10. Joystick Plug Loading Chart Input Voltage 4.3V (±0.1V) Terminal Color Function Centered Output Voltage 2.2V (±0.1V) 1 Yellow Steer Right Full Positive (Rev) Deflection Output Voltage 4.0V (±0.1V) 2 Green Steer Left Full Negative (Fwd) Output Voltage 0.4V (±0.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-12. Joystick Controller - (JLG P/N 1600403) Table 3-11. Joystick Specifications Input Voltage Table 3-12. Joystick Plug Loading Chart 5V Terminal Color Function Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right Reverse Voltage 4.60V to 4.80V 2 Green Steer Left Forward Voltage 0.40V to 0.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-13.
SECTION 3 - CHASSIS & SCISSOR ARMS Power Controller THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY. ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE. 1. Remove the two hex head bolts from the cover. Figure 3-14. Power Controller Table 3-13.
SECTION 3 - CHASSIS & SCISSOR ARMS ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STAND STILL. THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY. ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE. 4.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-15.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.8 DRIVE HUB The final drive consists of two stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load of distribution. All torque transmitting components are made of forged, quenched and tempered high-alloy steels. External gears are carborized. Precision roller bearings are used exclusively. Two large, tapered roller bearings support the sprocket or wheel loads.
SECTION 3 - CHASSIS & SCISSOR ARMS 1. Retaining Screws 9. Back-up Ring 17. Retaining Ring 2. Washers 10. Shaft 18. Bearing 3. Pressure Plate 11. Stator Disc 19. Retaining Ring 4. Case Seal 12. Sensor Ring 20. Dowel Pins 5. O-ring 13. Rotor Disc 21. Cover 6. Back-up Ring 14. Plate 22. Rotary Oil Seal 7. Piston 15. Springs 23. Brake to Hub Gasket 8. O-ring 16. Spring Retainer 24. Brake to Motor Gasket Figure 3-16.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.9 DRIVE BRAKE - MICO 3. Install new bearing (18) and retaining ring (19) on shaft (10). Disassembly 4. Install shaft assembly and retaining ring (17) in cover (21). 1. After removing the brake from its installation, place brake on a clean dry work bench with mounting plate uppermost. 2. Remove pressure plate (3) from cover (21) by removing cap screws (1) and washers (2). PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 680 KG (1500 LB).
SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 TORQUE HUB 1. Spindle 12. Thrust Washer 23. Needle Bearing 34. O-ring 2. Lip Seal 13. Spacer 24. Thrust Spacer 35. Retaining Ring, Int. 3. Tapered Bearing Cone 14. Seal Boot 25. Planet Shaft 36. Coupling 4. Tapered Bearing Cup 15. Thrust Spacer 26. Planet Gear 37. Input Shaft 5. Tapered Bearing cone 16. Input Carrier 27. Roll Pin 38. Input Sun Gear 6. Ring Gear 17. Thrust Washer 28. Thrust Washer 39. Output Sun Gear 7.
SECTION 3 - CHASSIS & SCISSOR ARMS Roll Test The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others.
SECTION 3 - CHASSIS & SCISSOR ARMS Main Disassembly 1. Coupling 7. Input Shaft 13. Housing 2. Retaining Ring 8. Carrier Subassembly 14. O-Ring 3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring 4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining Ring, Ext. 5. Washer 11. Flat Head Bolts 17. Retaining Ring, Ext. 6. First Stage Sun Gear 12. Ring Gear 18. ID Plate Figure 3-19.
SECTION 3 - CHASSIS & SCISSOR ARMS Disassembly Instructions: 1. Perform the Roll Check and Leak Check, if applicable prior to disassembling the unit. 2. Drain oil from the unit. 3. Remove the Coupling (1) from Spindle End first. 4. Remove the Retaining Ring (2) by prying the open end of the Retaining Ring out of the groove in the Ring Gear (3) with a screwdriver, then grasp the loose end with pliers and pull the Retaining Ring completely out of the groove.
SECTION 3 - CHASSIS & SCISSOR ARMS Output Carrier Disassembly 1. Roll Pin 5. Thrust Washers 2. Planet Shaft 6. Thrust Spacer 3. Carrier 7. Planet Gears 4. Needle Bearings 8. Thrust Washer Figure 3-20. Output Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (1) into the Planet Shaft (2) until it bottoms against the Carrier (refer to Figure 3-17.). 4.
SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Disassembly 1. Roll Pin 4. Planet Gears 2. Planet Shaft 5. Thrust Spacer 3. Carrier 6. Needle Bearings Figure 3-21. Input Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (1) into the Planet Shaft (2) until it bottoms against the Carrier (3). 2. Using a soft face hammer, tap the Planet Shaft (2) out of the Carrier (3). 3. Using a 1/8" diameter punch, drive the Roll Pin (1) out of the Planet Shaft (2). 4.
SECTION 3 - CHASSIS & SCISSOR ARMS Hub-Spindle Disassembly 1. Spindle 4. Bearing Cone 7. Boot Seal 2. Retaining Ring 5. Bearing Cup 8. Studs 3. Spacer 6. Hub 9. Bearing Cone Figure 3-22. Hub-Spindle Disassembly 1. Place unit on bench with Spindle (1) end down. 7. Remove Seal from Hub. 2. Remove Retaining Ring (2) with appropriate tool. NOTE: The Seal should NOT be reused when reassembling the unit. 3. Remove Spacer (3). 4. Remove "A" position Bearing Cone (4) from Bearing Cup (5) in Hub (6).
SECTION 3 - CHASSIS & SCISSOR ARMS Cover Disassembly 1. O-Ring 4. Hex Head Bolts 7. O-ring 2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs 3. Thrust Washer 6. Disengage Rod Figure 3-23. Cover Disassembly 1. Remove O-ring (1) from the groove in the Cover (2). 4. Pull Disengage Rod (6) out of the Cover. 2. Remove the Thrust Washer (3) from Cover pockets. 5. Use an appropriate tool to remove the O-ring (7) from the internal groove in the Cover. 3.
SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Sub-Assembly 1. Roll Pin 2. Planet Shaft 3. Carrier 4. Planet Gears 5. Thrust Spacer 6. Needle Bearings Figure 3-24. Input Carrier Sub-Assembly 1. Apply a liberal coat of grease to the bore of one Input Planet Gear (4). 6. Following the Thrust Washer, place the Planet Gear with Needle Bearings onto the Planet Shaft. 2. Line the inside of the Planet Gear with 14 Needle Bearings (6). 7.
SECTION 3 - CHASSIS & SCISSOR ARMS Output Carrier Sub-Assembly 1. Roll Pin 2. Planet Shaft 3. Carrier 4. Needle Bearings 5. Thrust Washers 6. Thrust Spacer 7. Planet Gears 8. Thrust Washer Figure 3-23. Output Carrier Sub-Assembly 7. Place the Thrust Washer (8) into counterbore of the Carrier (3). BE SURE the small diameter side of the Thrust Washer is facing the planet gear side. 1. Apply a liberal coat of grease to the bore of one Output Planet Gear (7). 2.
SECTION 3 - CHASSIS & SCISSOR ARMS Hub-Spindle Sub-Assembly 1. Spindle 2. Retaining Ring 3. Spacer 4. Bearing Cone 5. Bearing Cup 6. Hub 7. Boot Seal 8. Studs 9. Bearing Cone Figure 3-24. Hub-Spindle Sub-Assembly 6. Press Seal Boot (7) onto Hub, if required. Turn Hub over and lower onto Spindle (1). NOTE: Apply a light coat of oil on all component parts during assembly. 7. Install Bearing Cone (4) into Bearing Cup, position "A". 1. Place the Hub (6) into a pressing base.
SECTION 3 - CHASSIS & SCISSOR ARMS Cover Sub-Assembly 1. O-Ring 4. Hex Head Bolts 7. O-ring 2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs 3. Thrust Washer 6. Disengage Rod Figure 3-25. Cover Sub-Assembly 1. Grease O-Ring (7) and insert groove in Cover (2). 2. Assemble Disengage Cap (5) onto Cover using two Hex Head Bolts (4). Torque bolts to 70-80 in-lbs. 3. Insert Disengage Rod (6) into hole in Cover until it touches the inside of the Disengage Cap. 4.
SECTION 3 - CHASSIS & SCISSOR ARMS Main Assembly 1 3 8 15 6 4 2 18 5 13 14 12 16 7 9 17 11 1. Coupling 7. Input Shaft 13. Housing 2. Retaining Ring 8. Carrier Subassembly 14. O-Ring 3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring 4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining ring Ext. 5. Washer 11. Flat Head Bolts 17. Retaining Ring Rxt. 6. First Stage Sun Gear 12. Ring Gear 18. ID Plate Figure 3-26.
SECTION 3 - CHASSIS & SCISSOR ARMS 8. Place the Input Shaft spline end into mesh with the Internal Coupling (1) splines. NOTE: All components should receive a generous amount of lubricant oil as they are being assembled. 9. With the modified spline end facing up, place the Output Sun Gear into mesh with the Output Planet Gears. 1. Place Hub-Spindle Sub-Assembly on a bench. 2. Grease O-Ring (14) and place it into the groove of the Housing (13). 3. Place the Ring Gear (12) onto the Hub.
SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-44 – JLG Lift – 3121122
SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 SERVICING AND MAINTENANCE GUIDELINES 3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc. have been removed and that no adjacent parts are interfering. General Component Disassembly and Reassembly The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.
SECTION 4 - HYDRAULICS 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat treated bolts, studs and steel nuts, in accordance with recommended shop practices. hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced at the specified intervals required in Section 1. Always examine filters for evidence of metal particles. Hydraulic Lines and Electrical Wiring 3.
SECTION 4 - HYDRAULICS 3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service. Lubrication Specifications Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose requirements.
SECTION 4 - HYDRAULICS selected, remaining until a function switch and both directions are no longer selected. 4.9 CYLINDER CHECKING PROCEDURES When the controller is returned to neutral, the controller will control smooth stopping of the machine, using plug braking, before the brake is allowed to operate. NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system operation is suspected.
SECTION 4 - HYDRAULICS lines. Carefully remove hydraulic hoses from appropriate cylinder port block. 4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the following cylinder repairs must be made. If the retract port is leaking, the piston is leaking, the piston seals are defective and must be replaced.
SECTION 4 - HYDRAULICS 4.11 CYLINDER REPAIR 5. Using a suitable spanner wrench, loosen the spanner nut retainer and remove the spanner nut from the cylinder barrel. NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. 6. Attach a suitable pulling device to the cylinder rod port block or cylinder rod end, as applicable.
SECTION 4 - HYDRAULICS Cleaning and Inspection GARMAX BUSHING 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 damage. Dress threads as necessary. 4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary. 5.
SECTION 4 - HYDRAULICS 2. Using a soft mallet, tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable head gland groove. Figure 4-8. Piston Seal Kit Installation (Typical) Figure 4-6. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head. WHEN REBUILDING THE LIFT CYLINDER, APPLY LOCTITE #242 T O TA P E R E D B U S H I N G B O LT S , T H E N T I G H T E N B O LT S SECURELY.
SECTION 4 - HYDRAULICS Table 4-3. Holding Valve Torque Specifications EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. Figure 4-10. Rod Assembly Installation Description Torque Value Sun - 7/8 hex M20 x1.
SECTION 4 - HYDRAULICS 27. If applicable, install the cartridge type holding valve and fittings in the rod port block using new o-rings as applicable. Refer to Table 4-3, Holding Valve Torque Specifications for proper torque. 4.13 OSCILLATION CYLINDER BLEEDING Bleeding Procedure 1. Run one side wheel onto a ramp or block of wood. On the other side, the lockout cylinder should be extended.
SECTION 4 - HYDRAULICS Oscillating Axle Lockout Test (If Equipped) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure platform is fully lowered prior to beginning lockout cylinder test. 1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left front wheel. 2. From platform control station, select LOW drive speed. 3.
SECTION 4 - HYDRAULICS 4.14 CYLINDER ASSEMBLIES 18 20 19 21 22 3 23 24 25 1 4 17 7 8 5 6 9 12 13 11 14 10 15 2 16 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.
SECTION 4 - HYDRAULICS 18 20 19 21 22 26 LOWER LIFT CYLINDER 3 23 24 OR 25 UPPER LIFT CYLINDER 17 1 4 7 8 5 6 9 12 13 11 14 10 15 16 2 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.
SECTION 4 - HYDRAULICS 24 26 25 23 SCHEMATIC FOR PORT BLOCK 22 17 16 21 20 19 18 8 15 14 13 12 11 10 9 7 6 5 4 3 2 1 1. 2. 3. 4. 5. 6. 7. Jack Pad Lock Washers Round Head Hex Screws Snap Ring Rod Protector Plate Snap Ring Cylinder Rod 8. 9. 10. 11. 12. 13. 14. Rod Gland O-Ring Snap Ring Outer Rod Seal Inner Rod Seal O-Ring Backing Ring 15. 16. 17. 18. 19. 20. 21. O-Ring Spacer Piston O-Ring Wiper Seal Piston Seal (4 Piece) Wiper Seal 22. 23. 24. 25. 26.
SECTION 4 - HYDRAULICS 8 20 19 10 11 9 19 12 11 13 15 4 21 14 16 17 18 1 5 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Cylinder Barrel Jack Pad Special Screw, 1/2" - 13NC x 1-1/4 Cylinder Rod Retaining Ring Plate End Cap Locknut Piston Flatwasher, 1-1/4" Wear Ring Piston Seal O-Ring Head Wear Ring O-Ring Polyseal Wiper Seal Plug Counter Balance Valve (see note) Check Valve (see note) 6 5 3 3 2 3 Figure 4-13.
SECTION 4 - HYDRAULICS 11 12 8 9 10 7 3 5 2 6 3 5 4 3 13 14 16 17 15 18 17 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Cylinder Barrel Jack Pad Special Screw, 1/2" - 13NC x 1 1/4 Cylinder Rod Retaining Ring Plate End Cap Head Hydrolock Wiper Seal O-Ring Wear Ring Locknut Flatwasher, 1 1/4" Piston Guidelock Polyseal O-Ring Plugs Counter Balance Valve (see note) Check Valve (see note) 20 21 19 1 Figure 4-14.
SECTION 4 - HYDRAULICS (1 - 3 not used) 4. 5. 6. 7. 8. Trailer Ball Bolt, 3/8" - 16NC Grade 8 Cap Head Rod 9. 10. 11. 12. 13. 14. 15. Barrel Plug (not used) Nut Jack Pad Piston Plate 16. 17. 18. 19. 20. 21. 22. Retainer Ring Locking Screw Wear Ring Guidelock O-Ring O-Ring Wiper Seal 23. 24. 25. 26. Polyseal Hydrolock Spacer Tube Counter Balance Valve (see note) 27. Check Valve (see note) Figure 4-15.
SECTION 4 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1 Barrel Rod Guide Locknut Piston Piston Seal O-Ring Back-Up Ring Seal Wiper Retainer Ring O-Ring 4 6 5 7 8 9 3 10 11 12 2 Figure 4-16.
SECTION 4 - HYDRAULICS 21 22 18 19 21 11 20 12 1 10 13 14 15 9 16 17 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Barrel Weldment Washer Ring Cap-screws, 5/16" - 18NC x 1" Cylinder Rod Jam Nut, 3/4" - 16NF Roll-pin Rod End Composite Bearing Head Piston Wear Ring T-Seal Wear Ring O-Ring Back-Up Ring Rod Seal Wiper Seal O-Ring Plug #6 O-Ring Plug #4 Bleeder Valve Bushing Thermal Relief Valve 3 OR 4 8 4 6 5 7 Figure 4-17.
SECTION 4 - HYDRAULICS 4.15 PRESSURE SETTING PROCEDURES NOTE: On the back of the control valve is a flow control valve. This valve is used to adjust the lift down speed. Main Relief at Pump Table 4-4. Valve Component Torque Values 1. Install pressure gauge at port “MP” on control valve. 2. Remove the plug from the lift coil. COMPONENT 3. Activate and bottom out Lift Up. Adjust Main Relief to 3000 psi (207 bar). 4. Replace the plug on the lift coil. Lift Relief 1.
SECTION 4 - HYDRAULICS BRAKE HIGH PRESSURE FILTER MP PRESSURE SWITCH STEER MAIN RELIEF FLOW CONTROL STEER RELIEF LIFT RELIEF LIFT Figure 4-18. Control Valve 4.16 DRIVE TORQUE HUB the output shaft. The lip seal will be automatically removed during this procedure. Disassembly NOTE: If bearing replacement is necessary, the bearing cups can be removed with a slide hammer puller or driven out with a punch. 1. Loosen all cover bolts and drain oil from unit. 2.
SECTION 4 - HYDRAULICS Assembly 8. Sun gear is installed, meshing with the teeth of the large diameter cluster gear. The counterbore on the sun gear locates on the shoulder of the input spacer. This is to be a slip fit and should operate freely. 1. With the hub shaft sub-assembly resting on the shaft install internal gear. The spline of the internal gear. bore will mesh with the spline of the output shaft. 2. Thrust washer is installed on the face of the output shaft.
SECTION 4 - HYDRAULICS 4.17 DRIVE ASSIST VALVE 2L 1R T1 PR T PL 2R MPR 1L MPL 1L MPL 2L PL 2R 1R PR MPR T1 T VALVE SCHEMATIC Figure 4-19.
SECTION 4 - HYDRAULICS NOTES: 4-24 – JLG Lift – 3121122
SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER men u: HELP:PRESS ENTER Analyzer Display Escape Key Enter Key To return home or access previous menu Stores and selects Top Level, Sub Level, and item menus Left & Right Arrow Keys Up & Down Arrow Keys Used to move between Top Level, Sub Level, and item menus Value Selector Figure 5-1. Hand Held Analyzer To Connect the Hand Held Analyzer: 1.
SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: With the machine power on and the analyzer connected properly, the analyzer will display the following: In platform mode: HELP: EVERYTHING OK, In ground mode: HELP: GROUND MODE OK If ENTER is pressed again, the display moves to the following display: MENU: HELP:PRESS ENTER log: 1:Startup(2/1) HELP: PRESS ENTER At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER.
SECTION 5 - JLG CONTROL SYSTEM while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key. Once the correct password is displayed, press ENTER.
SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION. PERSONALITIES: DRIVE ACCEL 1.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to Table 5-3, Machine Model Adjustment, and Table 5-4, Machine Configuration Programming Information for the default settings. 5.2 PC BOARDS PCB - JLG P/N 0610143 Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings. CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
SECTION 5 - JLG CONTROL SYSTEM 5.3 FLASH CODES/DTC’S AND DESCRIPTIONS NOTE: Machines with software prior to P1.0 will display the Flash Code on the JLG Analyzer as shown below. The 2 digit Flash Code is scrolled at the end of the Help Message. Refer to "Flash Code" column of Table 5-1. hel p: n g chan ge ( 2/ 2) . NOTE: Diagnostic Trouble Codes (DTC’s) will only show for machines with software P1.0 and above.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 2-1 210 POWER UP 211 POWER CYCLE A new system power up has occurred since the last help message. 212 KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously. 220 PLATFORM CONTROLS 221 FUNCTION PROBLEM - HORN PERMANENTLY SELECTED Horn switch in platform control box closed at start up. Release switch to clear fault.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 2-5 250 FUNCTION PREVENTED 251 ELEV ANGLE SESOR FAULTY - VOLTAGE OUT OF RANGE The sensor signal input voltage is outside acceptable range. This could be a short to IGN, short to B+, short to ground, or sensor not properly mounted. 2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE Platform elevated for 5 sec. and elevation voltage change not detected. Fault sensor, wire harness, or ground module.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 4-4 440 BATTERY SUPPLY 441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Recharge batteries or check for damaged batteries. 442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Disconnect battery charger. Check that the correct voltage batteries are being used. N/A BATTERY CHARGE TOO LOW - SYSTEM SHUTDOWN 660 COMMUNICATION 661 CANBUS FAILURE: POWER MODULE Lost communication to power module.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2.
3121122 – JLG Lift – *(Outrigger Option Only) Figure 5-2. Analyzer Flow Chart - SW V13.
BY PRESSING THESE ARROW KEYS ( 5-12 – JLG Lift– Figure 5-3. Analyzer Flow Chart - SW V13.X - Sheet 2 of 3 ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS.
3121122 – JLG Lift – - Item to be Viewed or Changed - Sub Level Menu - Top Level Menu ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. Figure 5-4. Analyzer Flow Chart - SW V13.
5-14 – JLG Lift– *(Outrigger Option Only) Figure 5-5. Analyzer Flow Chart - Software P1.
3121122 – JLG Lift – ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. Figure 5-6. Analyzer Flow Chart - Software P1.
5-16 – JLG Lift– - Item to be Viewed or Changed - Sub Level Menu - Top Level Menu ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. Figure 5-7. Analyzer Flow Chart - Software P1.
SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Model Adjustment Adjustment Adjustment Range Default Values - 3369LE Default Values - 4069LE ACCEL 1.0 - 5.0 (sec) 3.5 3.5 0.1 DRIVE DECEL 0.1 - 5.0 s(sec) 0.1 MINIMUM 1 - 6% 4 4 MAXIMUM 30 - 100% 100 100 ELEVATED 1 - 15% 10 10 LOW MAX 35 - 65% 50 50 BRAKE FLOW 15 - 100% 75 75 OSC AXLE 15 - 100% 50 50 OSC AXLE 0.1 - 5.0 (sec) 1.0 1.0 4WA MAX 35 - 65% 40 40 ACCEL 1.0 - 5.0 (sec) 2.0 2.0. DECEL 0.1 - 5.
SECTION 5 - JLG CONTROL SYSTEM NOTE: When configuring an LE scissors machine, the machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default. Table 5-4.
SECTION 5 - JLG CONTROL SYSTEM 5.4 GROUND CONTROL CIRCUIT BOARD Software Version 13.6 Table 5-5.
SECTION 5 - JLG CONTROL SYSTEM Table 5-6.
SECTION 5 - JLG CONTROL SYSTEM Table 5-6. J2 Connector PIN TAGNAME FUNCTION TYPE 37 4WAF 4 Wheel Assist Forward Solenoid Valve DIGITAL OUTPUT 38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT 39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT 40 DO22 Spare High-Side Digital Otput 22 (12V, 5A) DIGITAL OUTPUT Table 5-7.
SECTION 5 - JLG CONTROL SYSTEM Table 5-8. J4 Connector PIN TAGNAME FUNCTION TYPE 1 12V 12V Sensor Supply POWER OUTPUT 2 TILTX X-Axis Tilt Input (PWM) ANALOG INPUT 3 TILTY Y-Axis Tilt Input (PWM) ANALOG INPUT 4 GND Ground POWER OUTPUT Table 5-9.
SECTION 5 - JLG CONTROL SYSTEM Software Version P1.0 Table 5-11.
SECTION 5 - JLG CONTROL SYSTEM Table 5-12.
SECTION 5 - JLG CONTROL SYSTEM Table 5-12. J2 Connector PIN TAGNAME FUNCTION TYPE 38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT 39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT 40 DO22 Spare High-Side Digital Otput 22 (12V, 5A) DIGITAL OUTPUT Table 5-13.
SECTION 5 - JLG CONTROL SYSTEM Table 5-14. J4 Connector PIN TAGNAME FUNCTION TYPE 1 12V 12V Sensor Supply POWER OUTPUT 2 TILTX X-Axis Tilt Input (PWM) ANALOG INPUT 3 TILTY Y-Axis Tilt Input (PWM) ANALOG INPUT 4 GND Ground POWER OUTPUT Table 5-15.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL This section contains 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.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector Assembly (2 of 4)). 2. Pull back on the contact wire with a force of 1 or 2 lbs.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 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. Figure 6-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 6-12. DT/DTP Contact Installation 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. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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. Figure 6-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing. HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal 11.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Components Installation PUMP/MOTOR DRIVE CONTACTOR TO BATTERIES RIGHT DRIVE MOTOR DRIVE CONTROLLER F2 LEFT DRIVE MOTOR MAIN VALVE PLATFORM CONSOLE BOX BATTERY CHARGER TO GROUND CONTROL BOX TERMINAL J1 LIFT CYLINDER PRESSURE TRANSDUCER OR OVERLOAD CUT-OUT Figure 6-18.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO MOTOR/ GENERATOR GENERATOR MODULE J2 TO ANALYZER PROXIMITY SENSOR SWITCH (USA BUILT MACHINES S/N 0200138293 TO PRESENT) 4WD LEFT SIDE MOTOR OSCILLATING AXLE CYLINDERS PROXIMITY SENSOR SWITCH (USA BUILT MACHINES PRIOR TO S/N 0200138293 & ALL BELGIUM BUILT MACHINES) ROTARY ANGLE SENSOR SWITCH HORN TO BEACON LIGHT HARNESS GROUND CONTROL BOX TO ANALYZER PC BOARD CONTROLLER TO ANALYZER Figure 6-19.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS LEVEL JACK SWITCHES TO GENERATOR MODULE (M3369 & M4069) LEVEL JACK VALVES ALARM TO PLATFORM BEACON LIGHT VALVE HARNESS GROUND CONTROL BOX Figure 6-20.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DRIVE CONTROLLER DRIVE CONTACTOR CIRCUIT BREAKER RECEPTACLE AT PLATFORM PLATFORM CONSOLE BOX PLATFORM WORKLIGHTS Figure 6-21.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870130_G Sht. 1 of 2 Figure 6-22.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870130_G Sht. 1 of 2 Figure 6-23.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870130_G Sht. 2 of 2 Figure 6-24.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870130_G Sht. 2 of 2 Figure 6-25.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 0270787_F Electrical Schematic - Yanmar Engine - 0270787 RevF Figure 6-26.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS This Page Intentionally Left Blank.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792443 RevE 2792443_E Figure 6-27.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792444 RevG 2792444_G Figure 6-28.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792445 RevF 2792445_F Figure 6-29.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram - 2792446 RevH 2792446_H Figure 6-30.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Schematic - 2792442 RevF 2792442_F Figure 6-31.
3121122 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 +55 19 3295 1025 +55 19 3295 0407 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.
