Service Manual Manual

ManualsBrandsJLG ManualsSpecial machinery1250AJP

Service and Maintenance Manual

Model

1250AJP

P/N - 3121171

December 7, 2012

Summary of content (606 pages)

PAGE 1
Service and Maintenance Manual Model 1250AJP P/N - 3121171 December 7, 2012
PAGE 2
PAGE 3
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.
PAGE 4
INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised A-2 - April 15, 2004 - June 15, 2004 - August 14, 2004 - December 7, 2004 - January 12, 2006 - November 29, 2006 - January 17, 2007 - November 9, 2007 - March 20, 2008 - August 21, 2008 - March 18, 2010 - October 26, 2011 - December 7, 2012 – JLG Lift – 3121171
PAGE 5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS SECTION NO. 2.4 2.5 2.6 TITLE PAGE NO. Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7
TABLE OF CONTENTS SECTION NO. 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3121171 TITLE PAGE NO. Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65 Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 8
TABLE OF CONTENTS SECTION NO. 3.27 3.28 3.29 3.30 3.31 iv TITLE PAGE NO. Deutz EMR 2 (S/N 87575 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-120 Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-133 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133 Bio Fuel . .
PAGE 9
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26 4.27 3121171 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 10
TABLE OF CONTENTS SECTION NO. 4.28 4.29 4.30 4.31 TITLE PAGE NO. Hose Routing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-95 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 Normal Operation . .
PAGE 11
TABLE OF CONTENTS SECTION NO. 5.10 TITLE PAGE NO. Drive & Function Pump Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-77 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 SECTION 6 - JLG CONTROL SYSTEM 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 3121171 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 13
LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 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. 3121171 TITLE PAGE NO. Lubrication & Operator Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 14
LIST OF FIGURES FIGURE NO. 3-46. 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. 3-78. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. x TITLE PAGE NO. Swing Drive - Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 15
LIST OF FIGURES FIGURE NO. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 4-32. 4-33. 4-34. 4-35. 4-36. 4-37. 4-38. 4-39. 4-40. 4-41. 4-42. 4-43. 4-44. 4-45. 4-46. 4-47. 4-48. 4-49. 4-50. 4-51. 4-52. 4-52. 4-53. 4-54. 4-55. 4-56. 4-57. 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. 3121171 TITLE PAGE NO. Locations for Loctite Application - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 16
LIST OF FIGURES FIGURE NO. 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. 5-51. 5-52. 5-53. 5-54. 5-55. 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. 7-1. 7-2. 7-3. xii TITLE PAGE NO. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 17
LIST OF FIGURES FIGURE NO. 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. 3121171 TITLE PAGE NO. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 Connector Assembly Figure 1. . . . . . . . .
PAGE 18
LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 2-1 2-2 2-3 3-1 3-2 3-2 3-3 3-4 3-5 3-6 3-7 4-1 4-1 4-1 4-2 5-1 5-2 5-3 5-4 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 xiv TITLE PAGE NO. Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operating Specifications & Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 19
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES 1.3 CHASSIS SPECIFICATIONS Table 1-3. Chassis Specifications Table 1-1. Capacities Hydraulic Tank 53.3 gallons (201.7 liters) Fuel Tank 31 gallons (117 liters) Hydraulic System 65.4 gallons (247.5 liters) Drive Hub Bonfiglioli Reggiana Riduttori 1.2 2.1 quarts (2 liters) ± 10% 0.5 quarts (0.
PAGE 20
SECTION 1 - SPECIFICATIONS 1.5 DIMENSIONAL DATA Engine Data S/N 0300127698 to Present Table 1-7. Deutz TD2011L4 Specifications Table 1-5. Dimensional Data Type Liquid Cooled 8ft. 2in. (2.49 m) 12ft. 6in. (3.8 m) Number of Cylinders 4 Bore 3.7 in. (94 mm) 10ft. (3.05 m) Stroke 4.4 in. (112 mm) Stowed Length (Transport Mode) 37 ft. 7 in. (11.46 m) Total Displacement 190 cu. in. (3108 cm³) Stowed Length (Working Mode) 47 ft. 6 in. (14.48 m) Compression Ratio 17.5 Wheelbase 12ft. 6in. (3.
PAGE 21
SECTION 1 - SPECIFICATIONS 1.7 TORQUE REQUIREMENTS 1.8 MAJOR COMPONENT WEIGHTS Table 1-9. Torque Requirements Description Wheel Bolts Torque Value (Dry) Table 1-11. Component Weights Interval Hours 180 ft. lbs. (252 Nm) 150 Counterweight Bolts 400 ft. lbs. (542 Nm) As required Swing Bearing Bolts 190 ft. lbs. (260 Nm) 50/600* Starter or Aux Pump Solenoid Contacts Coil 95 in. lbs. (10.5 Nm) 40 in. lbs. (4.
PAGE 22
SECTION 1 - SPECIFICATIONS 1.10 HYDRAULIC OIL Table 1-14. Mobilfluid 424 Specs Table 1-13.Hydraulic Oil Specifications Hydraulic System Operating Temperature Range NOTE: NOTE: 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 SAE Grade 10W30 Gravity, API 29.0 Density, Lb/Gal. 60°F 7.35 Pour Point, Max -46°F (-43°C) Flash Point, Min.
PAGE 23
SECTION 1 - SPECIFICATIONS Table 1-16. UCon Hydrolube HP-5046 Table 1-18. Quintolubric 822-220 Type Synthetic Biodegradable Specific Gravity 0.91 @ 60°F (°C) Specific Gravity 1.082 Pour Point, Max -15°F (-26°C) Pour Point, Max -58°F (-50°C) Flash Point, Min. 500°F (260°C) pH 9.
PAGE 24
SECTION 1 - SPECIFICATIONS Figure 1-1. Lubrication & Operator Maintenance Diagram 1.11 LUBRICATION & OPERATOR MAINTENANCE NOTE: NOTE: The following numbers correspond to those in Figure 1-1., Lubrication & Operator Maintenance Diagram. It is recommended as a good practice to replace all filters at the same time. 1. Swing Bearing - Remote Lube Table 1-19. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
PAGE 25
SECTION 1 - SPECIFICATIONS 2. Swing Gearbox NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. 4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128) Lube Point(s) - Fill Plug Capacity - 79 ounces (2.3 L) Lube - GL-5 Interval - Check level every 150 hrs/Change every 1200 hours of operation. Fill to cover ring gear. 3. Swing Brake Lube Point(s) - Fill Plug Capacity - 2.
PAGE 26
SECTION 1 - SPECIFICATIONS C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to Present) 6. Hydraulic Charge Filter or Lube Point(s) - Level/Fill Plug Capacity - 0.5 quarts (0.5 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 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port. 5. Hydraulic Return Filter (See Figure 1-2.
PAGE 27
SECTION 1 - SPECIFICATIONS A - Red = Filter Restricted; Filter Bypassed B - Green = Filter Good; Not Restricted Figure 1-2. Hydraulic Return Filter Condition Indicator - Prior to S/N 139396 Red = Filter Restricted; Filter Bypassed Green = Filter Good; Not Restricted Figure 1-3.
PAGE 28
SECTION 1 - SPECIFICATIONS 7. Main Valve Filter 9. Suction Strainers (In Tank) Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter 8. Hydraulic Oil Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation. Remove and clean at time of hydraulic oil change. 10.
PAGE 29
SECTION 1 - SPECIFICATIONS 13. Oil Change w/Filter - CAT 11. Fuel Filter - Deutz Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation Lube Point(s) - Fill Cap/Spin-on Element (element can be accessed from below engine tray) 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. 12. Fuel Strainer - Deutz 14.
PAGE 30
SECTION 1 - SPECIFICATIONS 15. Air Filter 16.
PAGE 31
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.
PAGE 32
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.
PAGE 33
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.
PAGE 34
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.
PAGE 35
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.
PAGE 36
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.
PAGE 37
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.
PAGE 38
SECTION 1 - SPECIFICATIONS NOTES: 1-20 – JLG Lift – 3121171
PAGE 39
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.
PAGE 40
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 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.
PAGE 41
SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
PAGE 42
SECTION 2 - GENERAL fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles. Changing Hydraulic Oil 1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual.
PAGE 43
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.
PAGE 44
SECTION 2 - GENERAL Table 2-3.
PAGE 45
SECTION 2 - GENERAL Table 2-3.
PAGE 46
SECTION 2 - GENERAL Table 2-3.
PAGE 47
SECTION 2 - GENERAL 120 F(49 C) NO OPERATION ABOVETHIS AMBIENTTEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) SUMMER GRADE FUEL ENGINE SPECIFICATIONS 70 F(21 C) 60 F(16 C) 50 F(10 C) 40 F(4 C) 30 F(-1 C) ENGINEWILLSTARTAND OPERATEUNAIDED ATTHIS TEMPERATUREWITHTHERECOMMENDED FLUIDSAND A FULLYCHARGED BATTERY.
PAGE 48
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.
PAGE 49
SECTION 3 - 1CHASSIS & TURNTABLE SECTION 3. 1CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Tire Replacement 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. • Equal or greater ply/load rating and size of original Tire Damage • Tire tread contact width equal or greater than original For pneumatic tires, JLG Industries, Inc.
PAGE 50
SECTION 3 - 1CHASSIS & TURNTABLE Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL. Tighten the lug nuts to the proper torque to prevent wheels from coming loose.
PAGE 51
SECTION 3 - 1CHASSIS & TURNTABLE 3.2 AXLE EXTENSION SYSTEM The Axle Extension System allows each of the four axles to be extended and retracted together while maintaining full steering control as the machine is driven. The system allows the axles to extend or retract only while the boom is in the transport position (see Section 4.
PAGE 52
SECTION 3 - 1CHASSIS & TURNTABLE 4. Ensure the arm will clear the axle (without bottoming out to 70° stroke of the switch) in the retracted position. 5. Check for proper operation. Axle set light is to deactivate when the axle is retracted 0.625 inches (16 mm) maximum from fully extended. 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.
PAGE 53
SECTION 3 - 1CHASSIS & TURNTABLE Wheel angle sensor failures will result in an approximated steering control logic that will allow the operator to move the machine until it can be repaired. The wheel at the failed sensor will be driven based on the information available from the other sensors. This wheel will not track perfectly and will become farther out of position over time.
PAGE 54
SECTION 3 - 1CHASSIS & TURNTABLE 0274670 D Figure 3-5.
PAGE 55
SECTION 3 - 1CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. Axle Limit Switch (Right Front) Steer Angle Sensor (Right Front) Steer Valve (Front) Axle Lockout Valve Traction Valve Steer Valve (Rear) Steer Angle Sensor (Right Rear) Axle Limit Switch (Right Rear) 9. 10. 11. 12. 13. 14. 15. Axle Limit Switch (Left Rear) Steer Angle Sensor (Left Rear) Chassis Module Swivel/Collector Ring Axle Lockout Pressure Switch Steer Angle Sensor (Left Front) Axle Limit Switch (Left Front) Figure 3-6.
PAGE 56
SECTION 3 - 1CHASSIS & TURNTABLE 0274670 D Figure 3-7.
PAGE 57
SECTION 3 - 1CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Headlight 2500W Generator 2500W Generator Control Box Alternator Throttle Actuator Oil Temperature Switch Oil Pressure Switch Glow Plugs Engine Speed Sensor Starter Drive Pump Starter Relay 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
PAGE 58
SECTION 3 - 1CHASSIS & 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 - 1CHASSIS & TURNTABLE 9 11,12,B,G 3 6 11,12,A,G 8 10 11,12,C,G DETAIL A 7 11,12,E,G 11,12,F,G 2 4 A - Assemble to Axle Box Mid Plate; Typical 8 Places DETAIL B B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 inches (12.7 ± 1.587 mm) thread engagement. C - Assemble to Side Plates of Axle Weldments; Typical 16 Places. D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
PAGE 60
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-11.
PAGE 61
SECTION 3 - 1CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes 1. Spindle 2. Angle Sensor Assembly 3. Steer Cylinder A Apply Loctite #242 B Apply Loctite #271 C Apply Loctite #222 D Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut 4. Steer Cylinder Pivot Pin 5. King Pin 6. Axle Figure 3-12.
PAGE 62
SECTION 3 - 1CHASSIS & TURNTABLE 3.10 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 (see Section 4.2, Transport Position Sensing System) and drive is commanded.
PAGE 63
SECTION 3 - 1CHASSIS & TURNTABLE Oscillating Axle Lockout Test 6. Drive machine off of block and ramp back onto the level surface. The front axles will oscillate when the boom is in the transport position. NOTE: The machine is in transport mode until one of the following three factors are exceeded: Main boom extended more than 4 ft. (1.2 m) OR Main boom 6° above horizontal (w/tower stowed OR Tower above horizontal. 7.
PAGE 64
SECTION 3 - 1CHASSIS & TURNTABLE 3.12 DRIVE HUB (PRIOR TO S/N 100128) The final drive consists of two planetary stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load distribution. All torque transmitting components are made of forged quenched and tempered highalloy steels. External gears are carburized. Precision roller bearings support the sprocket or wheel loads. A shaft seal protects the unit against contamination.
PAGE 65
SECTION 3 - 1CHASSIS & TURNTABLE Assembly of First Stage Planetary Assembly (7) 6. Before installation of motor, CHECK THAT THERE IS 1-2 mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER (62). 1. Pre-freeze planet pins (5) and install into planet carrier (7). 7. Install the motor and reconnect hydraulic lines. 8. Roll motor so that one fill plug is at 12 o’clock position, and the other is at 3 o’clock. Fill to bottom of 3 o’ clock plug with gear oil. reinstall plugs. 2.
PAGE 66
Figure 3-13.
PAGE 67
1. 2. 3. 4. 5. 7. 8. 9. 10. 11. 12. 13. Planet Gear Planet Gear Sun Gear Shaft Nut Planet Pin Planet Carrier Cover Thrust Button Roller Bearing Roller Bearing Ball Bearing Hex Bolt 14. 15. 16. 17. 19. 20. 21. 22. 23. 24. 27. 3121171 – JLG Lift – 28. 30. 33. 41. 42. 43. 45. 46. 47. 48. 51. Washer Ring Gear O-ring Planet Carrier Sun Gear Sun Gear Planet Pin Roller Bearing Retaining Ring Retaining Ring Cover 52. 53. 54. 55. 60. 61. 62. 63. 64. 65. 66.
PAGE 68
SECTION 3 - 1CHASSIS & TURNTABLE 3.13 DRIVE HUB - BONFIGLIOLI (S/N 100128 TO PRESENT) 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. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Section 3.14, Drive Hub - Reggiana Riduttori (S/N 134389 to Present). Do not use different hubs on the same machine. Product Identification 2.
PAGE 69
SECTION 3 - 1CHASSIS & 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. After having finished running-in the gearbox, follow the steps given below. 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.
PAGE 70
SECTION 3 - 1CHASSIS & TURNTABLE 1= M18x1,5..........................Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..........Brake port Figure 3-16.
PAGE 71
SECTION 3 - 1CHASSIS & TURNTABLE Table 3-3.
PAGE 72
SECTION 3 - 1CHASSIS & 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 3-17. 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 73
SECTION 3 - 1CHASSIS & 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. Maintenance Information PERIODIC MAINTENANCE The gearbox only requires the scheduled maintenance procedures set out by the manufacturer (see Table 3-4). Good maintenance will ensure an ongoing functioning in time as well as maximum reliability.
PAGE 74
SECTION 3 - 1CHASSIS & TURNTABLE TROUBLESHOOTING The following table is provided to help locate problems in the gearbox. Table 3-5.
PAGE 75
SECTION 3 - 1CHASSIS & 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). 3121171 4. Mark the position of the springs (45) as a reference for the reassembly.
PAGE 76
SECTION 3 - 1CHASSIS & 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 77
SECTION 3 - 1CHASSIS & 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 78
SECTION 3 - 1CHASSIS & 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). 3-30 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.
PAGE 79
SECTION 3 - 1CHASSIS & 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). 3121171 24. Remove the end cover (7).
PAGE 80
SECTION 3 - 1CHASSIS & 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). 3-32 30. By using pliers remove the circlips (19) from their seats in the flanged hub's pins (31).
PAGE 81
SECTION 3 - 1CHASSIS & TURNTABLE 31. By using a puller remove the planet assemblies of the 3rd reduction (20). 34. By using a tackle place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 32. Remove the spacer (21) from their seats in the pins of the flanged hub (31). 35. By using the torque multiplier (ATZ.09.016.0) loosen the ring nut (22). NOTE: In order to proceed with the gearbox disassembly, it is now necessary to remove it from the machine and bring it to a properly equipped workshop.
PAGE 82
SECTION 3 - 1CHASSIS & 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 83
SECTION 3 - 1CHASSIS & 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). 1. Follow the steps below to prepare the lifetime seal for assembly: metallic rings in volatile solvent or industrial degreasing alcohol. c.
PAGE 84
SECTION 3 - 1CHASSIS & 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.
PAGE 85
SECTION 3 - 1CHASSIS & 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). 3121171 11. By using the mutiplier (ATZ.09.016.0), tighten the ring nut (22), using a torque wrench with an input multiplier torque of 71 ± 3 ft.lbs.
PAGE 86
SECTION 3 - 1CHASSIS & 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.
PAGE 87
SECTION 3 - 1CHASSIS & 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 88
SECTION 3 - 1CHASSIS & 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 89
SECTION 3 - 1CHASSIS & 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).
PAGE 90
SECTION 3 - 1CHASSIS & 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). 3-42 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.
PAGE 91
SECTION 3 - 1CHASSIS & 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 92
SECTION 3 - 1CHASSIS & 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 93
SECTION 3 - 1CHASSIS & 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 94
SECTION 3 - 1CHASSIS & TURNTABLE r Figure 3-20.
PAGE 95
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-21.
PAGE 96
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-22.
PAGE 97
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-23.
PAGE 98
SECTION 3 - 1CHASSIS & TURNTABLE 3.14 DRIVE HUB - REGGIANA RIDUTTORI (S/N 134389 TO PRESENT) 8. Wrench for M6, M8, M10 socket head screws and 1/ 4"G plug. 9. Socket wrench for M6 hexagonal screw. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Section 3.13, Drive Hub - Bonfiglioli (S/N 100128 to Present). Do not use different hubs on the same machine.
PAGE 99
SECTION 3 - 1CHASSIS & TURNTABLE Ø30 25 5x45° Ø210 Ø130 M- 1321 LOCTITE 2701 110 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-26. Bearing Spacer Mountng CO16117 Figure 3-27.
PAGE 100
SECTION 3 - 1CHASSIS & 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 3-30. Anti-rotation Block M- 1317 M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-28. Wrench For Ring Nut M- 1126 Ø20 Ø80 32 n° 12 Hole to 30° Ø6.5 20 10.5 Ø20 H7 (+0.021 ) n°12 Hole to 30° 0 30 T.U.
PAGE 101
SECTION 3 - 1CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-32.
PAGE 102
SECTION 3 - 1CHASSIS & TURNTABLE M- 1548 Ø93.5 Ø48 Ø46 +0.1 2.5x15° Ø40.5 Ø46 80 70 Ø13.5 5 Ø8.5 50 20 5 8.5 9 Ø20+0.2 5 M- 1546 Ø105 M- 1547 0 Ø20 -0.1 88.5 3.5 t.u. 12 Ø39.5 M8 VTCEI M8X16 n°1 Figure 3-33.
PAGE 103
SECTION 3 - 1CHASSIS & 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 104
Figure 3-34.
PAGE 105
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 3121171 – 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 106
SECTION 3 - 1CHASSIS & TURNTABLE 9. Loosen the M6x6 socket headless screws and also remove the 3/16" balls. 6. Loosen the M10x25 flathead socket screws and remove the planetary ring without damaging the ORing. 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. 3-58 10. Loosen the ring nut using the special wrench. 11. Remove the hub support together with the roller bearing inner track.
PAGE 107
SECTION 3 - 1CHASSIS & 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 108
SECTION 3 - 1CHASSIS & 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 109
SECTION 3 - 1CHASSIS & TURNTABLE 9. Now check the unit roll torque and proceed in the following order: 10. 7.) By keeping the spindle locked, apply a setting preload by tightening the ring nut at 40daNm, turn completely the hub support twice using the special wrench to recover any bearing cage misalignments. Release and tighten the ring nut at the final torque of 30daNm (alternate tightening and some setting turns). Check the roll torque with seal which must be within 1÷1,5 daNm. 11.
PAGE 110
SECTION 3 - 1CHASSIS & TURNTABLE 13. Fit the bearings onto the 3rd stage planetary gears and using a spacer mounting mount everything on 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.
PAGE 111
SECTION 3 - 1CHASSIS & 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 112
SECTION 3 - 1CHASSIS & 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 3-36.
PAGE 113
SECTION 3 - 1CHASSIS & TURNTABLE 3.15 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 114
SECTION 3 - 1CHASSIS & TURNTABLE Motor Control Valve Disassembly 1. Place unit on bench with the motor end up. 4. Using a wrench, loosen jam nuts on Elbow Fittings (36) and remove fittings from Brake (26) and Motor Control Valve (32). 2. Remove O-ring Plug (1J) and drain the oil from the gearbox. 5. Remove O-ring Plugs (21) from Motor Control Valve (32). 3. Remove Hydraulic Tubing Assembly (35) by loosening fittings on both ends of tube with a wrench. 6.
PAGE 115
SECTION 3 - 1CHASSIS & 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 116
SECTION 3 - 1CHASSIS & 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). 2. Thread either 1/2-13 UNC eye bolts or motor mounting Bolts (29) into threaded holes in Input Cover (6) and pull Input Cover (6) off on the main assembly. 3.
PAGE 117
SECTION 3 - 1CHASSIS & 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 118
SECTION 3 - 1CHASSIS & 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 119
SECTION 3 - 1CHASSIS & 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 120
SECTION 3 - 1CHASSIS & 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.
PAGE 121
SECTION 3 - 1CHASSIS & TURNTABLE 3A. 3B. 3C. 3D. Carrier Tanged Thrust Washer Needle Bearing Thrust Washer 3E. 3F. 3G. 3H. Planet Shaft Cluster Gear Roll Pin Ball Indented Washer Figure 3-43.
PAGE 122
SECTION 3 - 1CHASSIS & 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.
PAGE 123
SECTION 3 - 1CHASSIS & 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 3-44.
PAGE 124
SECTION 3 - 1CHASSIS & TURNTABLE Motor and Brake Assembly 1. Place O-ring (27) onto end of Brake (26) and locate brake into pilot of cover. 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. 2. Place Gasket (31) onto the brake face and line up the holes. 5. Fill Brake (26) with 2.7 oz. (80cc) of BRAKOILVG32 (DTE24). 3. Place Motor (10) into Brake pilot against the Gasket (31). 10.
PAGE 125
SECTION 3 - 1CHASSIS & 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).
PAGE 126
SECTION 3 - 1CHASSIS & TURNTABLE 3.16 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.
PAGE 127
SECTION 3 - 1CHASSIS & TURNTABLE Installation Position 1-off gasket (5) over male pilot on brake housing (4). Locate brake shaft (1) and secure brake in position using 2-off 1/2” UNC mounting bolts in the through mounting (fixing) holes provided. Connect hydraulic pressure supply to brake pressure inlet port. Ensure that the hydraulic pressure is set to the required level up to a maximum of 3000 psi (200 bar) and check that the brake disengages and re-engages correctly.
PAGE 128
SECTION 3 - 1CHASSIS & TURNTABLE 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or equivalent) silicone grease and assemble together with backing rings (16 & 18) to piston (9). 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. 7.
PAGE 129
SECTION 3 - 1CHASSIS & TURNTABLE 3.17 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.
PAGE 130
SECTION 3 - 1CHASSIS & TURNTABLE 1. Special Bolts 2. End Cover 3. Seal Ring-Commutator 4. Seal Ring 5. Commutator Ring 6. Commutator Ring 7. Manifold 8. Rotor Set 8A.Rotor 8B. Stator or Stator Vane 8C. Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 12. Coupling Shaft 13. Bearing/Bushing, Inner 14. Thrust Washer 15. Thrust Bearing 16. Seal 17. Back-up Washer 18. Housing 18A. O-Ring 19. Bearing/Bushing, Outer 20. Dirt & Water Seal 21. Plug Figure 3-49. Swing Drive Motor 5.
PAGE 131
SECTION 3 - 1CHASSIS & 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.
PAGE 132
SECTION 3 - 1CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice.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.
PAGE 133
SECTION 3 - 1CHASSIS & 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 134
SECTION 3 - 1CHASSIS & 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.
PAGE 135
SECTION 3 - 1CHASSIS & TURNTABLE 21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.
PAGE 136
SECTION 3 - 1CHASSIS & 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).
PAGE 137
SECTION 3 - 1CHASSIS & 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.
PAGE 138
SECTION 3 - 1CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 5. On the Torqlinks™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2. 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.
PAGE 139
SECTION 3 - 1CHASSIS & 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.
PAGE 140
SECTION 3 - 1CHASSIS & 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 141
SECTION 3 - 1CHASSIS & 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 142
SECTION 3 - 1CHASSIS & 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.
PAGE 143
SECTION 3 - 1CHASSIS & 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.
PAGE 144
SECTION 3 - 1CHASSIS & TURNTABLE 3.18 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.
PAGE 145
SECTION 3 - 1CHASSIS & 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. 3.19 SWING DRIVE LUBRICATION Figure 3-51.
PAGE 146
SECTION 3 - 1CHASSIS & TURNTABLE 3.20 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 d. Swing the turntable 90 degrees, and check some selected bolts at the new position. 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.
PAGE 147
SECTION 3 - 1CHASSIS & TURNTABLE MAIN BOOM FULLY ELEVATED FEELER GAUGE MEASURING POINT DIAL INDICATOR MEASURING POINT Figure 3-52.
PAGE 148
SECTION 3 - 1CHASSIS & TURNTABLE MAIN TELESCOPE FULLY EXTENDED TOWER TELESCOPE FULLY EXTENDED DIAL INDICATOR & FEELER GAUGE MEASURING POINT Figure 3-53.
PAGE 149
SECTION 3 - 1CHASSIS & 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 3-54.
PAGE 150
3-102 Figure 3-55. Swing Bearing Removal 29,100 lbs. Gross Weight: Upper Works above Turntable Bearing – JLG Lift – CENTER OF GRAVITY C L ROTATION 20” 50.
PAGE 151
SECTION 3 - 1CHASSIS & TURNTABLE 7. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame-mounted components. Refer to Figure 3-55., Swing Bearing Removal. 3. Refer to the Torque Sequence diagram as shown in Figure 3-56., Swing Bearing Torque Sequence. Spray a light coat of Safety Solvent 13 on the new bearing bolts.
PAGE 152
SECTION 3 - 1CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-56. Swing Bearing Torque Sequence 3.21 SWING SPEED PROPORTIONING Swing Speed Proportioning uses the main boom length switches and envelope control 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 and when the tower boom is lowered in angle.
PAGE 153
SECTION 3 - 1CHASSIS & TURNTABLE 3.22 CHASSIS TILT INDICATOR SYSTEM The Chassis Tilt Indicator System measures the turntable angle in comparison to level ground. The tilt sensor (which is an integral part of the ground module) has three settings; 3.0° side tilt, 5.0° omni directional tilt, and 8.0° omni directional tilt. The 5.0° omni directional angle setting is used to warn the operator by using the chassis tilt light in the platform display panel.
PAGE 154
SECTION 3 - 1CHASSIS & TURNTABLE 3.23 ROTARY COUPLING 6. Reassemble O-ring. 7. Heat cap seals in hydraulic oil for 5 minutes at 300° F (149° C). Use the following procedure to for installing the seal kit. 1. Remove snap ring from end. 8. Assemble cap seals over O-rings 2. Remove thrust ring from same end. 9. Reinsert center body into housing (lube with hydraulic oil). 3. Remove center body from housing. 4. Cut off old seals. 10. Replace thrust ring and snap ring. 5.
PAGE 155
SECTION 3 - 1CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 5A. Loctite #242 Bolt Bolt Swivel Bracket Rotary Coupling & Collector Ring Assembly Rotary Coupling 5B. 6. 7. 8. 9. Rotary Circuit Contactor Locknut Not Used Flatwasher Nut Figure 3-58.
PAGE 156
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-59.
PAGE 157
SECTION 3 - 1CHASSIS & TURNTABLE Every 500 hours Table 3-6. Coupling Port Information Table Port Port No. Size Description Operating Pressure PSI (Bar) Proof Pressure PSI (Bar) 1 -12 Return 250 (17) 375 (26) 2 -10 Steer/Axle Extend (Pressure) 3000 (207) 4500 (310) 3 -10 Drive A 5000 (345) 7500 (517) 4 -10 Drive B 5000 (345) 7500 (517) 5 -10 Drive A (Osc. Axle Lock) 5000 (345) 7500 (517) 6 -10 Drive B (Osc.
PAGE 158
SECTION 3 - 1CHASSIS & 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 3-60.
PAGE 159
SECTION 3 - 1CHASSIS & 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 3-60.
PAGE 160
SECTION 3 - 1CHASSIS & TURNTABLE 3.25 COLD WEATHER PACKAGE 6. 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. As an option, a cold weather package is available to allow the machine to be operated in lower temperatures. The package consists of battery heaters, a hydraulic tank heater, Exxon Univis hydraulic oil, and diesel fuel conditioner. See Figure 3-61., Cold Weather Package.
PAGE 161
SECTION 3 - 1CHASSIS & TURNTABLE HYDRAULIC OIL TANK HEATER CABLE BATTERY HEATER CABLE BATTERY HEATER CABLE BATTERY REF AUX PUMP BATTERY HEATER BATTERY HEATER VIEW A-A A B A B TANK HEATER VIEW B-B Figure 3-61.
PAGE 162
SECTION 3 - 1CHASSIS & TURNTABLE Changing the Oil Filter WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING. DO NOT LET USED OIL RUN INTO THE SOIL; COLLECT THE USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF THE USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS. 1. Drain the oil. 2. Close the oil drain valve. 3. 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.
PAGE 163
SECTION 3 - 1CHASSIS & TURNTABLE 6. Manually screw in the new filter until the gasket is flush. 7. Tighten the fuel filter cartridge with a final half-turn. 8. Open the fuel shut-off valve. 9. Check for leaks. Cleaning the Fuel Strainer 7. Tighten the filter another half-turn. 8. Check the oil level. 9. Check the oil pressure. 10. Check the oil filter cartridge and make sure there are no leaks.
PAGE 164
SECTION 3 - 1CHASSIS & TURNTABLE Removal NOTE: The hood support weighs approximately 134 lbs. (61 kg). 1. Disconnect the battery. 2. Use a tie strap as shown below to secure the hood support when the hood is being removed. 6. When all of the bolts are removed, lift the hood support away from the machine. 3. Remove the bolts and clamps that secure the engine hood assembly to the hood support. 4. Carefully lift the engine hood assembly away from the machine.
PAGE 165
SECTION 3 - 1CHASSIS & TURNTABLE 1. 2. 3. 4. Hood Hood Support Gas Spring Bolt 5. 6. 7. 8. Washer Clamp Hinge Engine Tray Figure 3-63.
PAGE 166
SECTION 3 - 1CHASSIS & TURNTABLE NOTE: The engine assembly weighs approximately 1275 lbs. (579 kg). 8. Pull the pump assembly away from the engine. 9. Using a ratchet strap, support the pump in a position that will keep the pump from interfering with engine removal. 13. Carefully lift the engine assembly away from the machine. 10. Disconnect all fuel lines from the engine. Cap all open hoses to prevent fuel leakage. 11.
PAGE 167
SECTION 3 - 1CHASSIS & TURNTABLE Installation 1. Using an adequate lifting device, support the weight of the engine assembly and position it in place on the machine. Install the engine pivot pin. NOTE: The engine assembly weighs approximately 1275 lbs. (579 kg) 4. Lift the hood support back into position. Install the bolts and washers that secure the hood support to the hinges. Re-connect the gas springs to the hood support NOTE: The hood support weighs approximately 134 lbs. (61 kg) . 2.
PAGE 168
SECTION 3 - 1CHASSIS & TURNTABLE 5. Use a tie strap as shown below to secure the hood support when the hood is being installed. 3.27 DEUTZ EMR 2 (S/N 87575 TO PRESENT) NOTE: S/N’s 85693 & 85910 also incorporated EMR2. 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. 6. Carefully lift the engine hood assembly onto the hood support.
PAGE 169
SECTION 3 - 1CHASSIS & TURNTABLE The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp home) functions. In order to switch the engine off, the EMR2 is switched in a de-energized fashion over the ignition switch. A strong spring in the actuator presses the control rod in the deenergized condition into the zero position.
PAGE 170
Figure 3-65.
PAGE 171
Figure 3-66.
PAGE 172
Figure 3-67.
PAGE 173
Figure 3-68.
PAGE 174
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-69.
PAGE 175
SECTION 3 - 1CHASSIS & TURNTABLE Figure 3-70.
PAGE 176
Figure 3-71.
PAGE 177
Figure 3-72.
PAGE 178
Figure 3-73.
PAGE 179
Figure 3-74.
PAGE 180
Figure 3-75.
PAGE 181
SECTION 3 - 1CHASSIS & TURNTABLE 3.28 BIO FUEL IN DEUTZ ENGINES General Use of bio fuels is permitted for the compact engines made by DEUTZ. Distillate fuels with residue oil percentages or mixed fuels may not be used in DEUTZ compact engines. 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 182
SECTION 3 - 1CHASSIS & 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 183
SECTION 3 - 1CHASSIS & TURNTABLE 3.29 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 3-76.) then: 2nd Page of Diagnostic Information for a Given Fault (See Figure 3-77.
PAGE 184
SECTION 3 - 1CHASSIS & TURNTABLE DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Yes Troubleshooting flow chart No Figure 3-77.
PAGE 185
SECTION 3 - 1CHASSIS & 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 C
PAGE 186
SECTION 3 - 1CHASSIS & 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) HO
PAGE 187
SECTION 3 - 1CHASSIS & 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 188
SECTION 3 - 1CHASSIS & TURNTABLE DTC 116- ECT Higher Than Expected Stage 1 TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor Diagnostic Aids • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have caused "ECT Higher Than Expected 1.
PAGE 189
SECTION 3 - 1CHASSIS & 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 190
SECTION 3 - 1CHASSIS & 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 191
SECTION 3 - 1CHASSIS & 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 192
SECTION 3 - 1CHASSIS & TURNTABLE 3-144 – JLG Lift – 3121171
PAGE 193
SECTION 3 - 1CHASSIS & 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,
PAGE 194
SECTION 3 - 1CHASSIS & TURNTABLE 3-146 – JLG Lift – 3121171
PAGE 195
SECTION 3 - 1CHASSIS & 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 196
SECTION 3 - 1CHASSIS & TURNTABLE 3-148 – JLG Lift – 3121171
PAGE 197
SECTION 3 - 1CHASSIS & 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.
PAGE 198
SECTION 3 - 1CHASSIS & 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.
PAGE 199
SECTION 3 - 1CHASSIS & 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 remai
PAGE 200
SECTION 3 - 1CHASSIS & 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
PAGE 201
SECTION 3 - 1CHASSIS & 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
PAGE 202
SECTION 3 - 1CHASSIS & 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.
PAGE 203
SECTION 3 - 1CHASSIS & TURNTABLE DTC 524- Oil Pressure Low 19 BLACK/GREEN 2 1 BLUE • Engine Oil Pressure • Check Condition- Key on, Engine on • Fault Condition- Engine oil pressure lower than expected while engine has been running for a minimum amount of time while engine speed is above some limit as defined in the diagnostic calibration For systems that use a transducer, this fault sets if the engine oil pressure is less than x psia and engine speed is greater than y RPM after the engine has been runn
PAGE 204
SECTION 3 - 1CHASSIS & 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 Doe
PAGE 205
SECTION 3 - 1CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low BLACK RED/TAN • System voltage to ECM • Check Condition- Key on, Engine on • Fault Condition- Battery voltage to ECM less than x volts while the engine is operating at y RPM or greater as defined in the diagnostic calibration • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle The battery voltage powers the ECM and must
PAGE 206
SECTION 3 - 1CHASSIS & TURNTABLE 3-158 – JLG Lift – 3121171
PAGE 207
SECTION 3 - 1CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High BLACK RED/TAN • System voltage to ECM • Check Condition- Key on, Engine Cranking or Running • Fault Condition- Battery voltage to ECM greater than x volts while the engine is running as defined in the diagnostic calibration • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle The battery voltage powers the ECM and must
PAGE 208
SECTION 3 - 1CHASSIS & TURNTABLE 3-160 – JLG Lift – 3121171
PAGE 209
SECTION 3 - 1CHASSIS & 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.
PAGE 210
SECTION 3 - 1CHASSIS & TURNTABLE 3-162 – JLG Lift – 3121171
PAGE 211
SECTION 3 - 1CHASSIS & 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
PAGE 212
SECTION 3 - 1CHASSIS & TURNTABLE 3-164 – JLG Lift – 3121171
PAGE 213
SECTION 3 - 1CHASSIS & 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.
PAGE 214
SECTION 3 - 1CHASSIS & TURNTABLE 3-166 – JLG Lift – 3121171
PAGE 215
SECTION 3 - 1CHASSIS & 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.
PAGE 216
SECTION 3 - 1CHASSIS & 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.
PAGE 217
SECTION 3 - 1CHASSIS & 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) 3121171 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 218
SECTION 3 - 1CHASSIS & 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) 3-170 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 219
SECTION 3 - 1CHASSIS & 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 3121171 – JLG Lift – 3-171
PAGE 220
SECTION 3 - 1CHASSIS & 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) 3-172 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 221
SECTION 3 - 1CHASSIS & 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 3121171 – JLG Lift – 3-173
PAGE 222
SECTION 3 - 1CHASSIS & 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) 3-174 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 223
SECTION 3 - 1CHASSIS & 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 3121171 – JLG Lift – 3-175
PAGE 224
SECTION 3 - 1CHASSIS & 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) 3-176 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 225
SECTION 3 - 1CHASSIS & 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 3121171 – JLG Lift – 3-177
PAGE 226
SECTION 3 - 1CHASSIS & 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.
PAGE 227
SECTION 3 - 1CHASSIS & 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, s
PAGE 228
SECTION 3 - 1CHASSIS & 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, sou
PAGE 229
SECTION 3 - 1CHASSIS & 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.
PAGE 230
SECTION 3 - 1CHASSIS & TURNTABLE 3-182 – JLG Lift – 3121171
PAGE 231
SECTION 3 - 1CHASSIS & 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.
PAGE 232
SECTION 3 - 1CHASSIS & 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.
PAGE 233
SECTION 3 - 1CHASSIS & 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.
PAGE 234
SECTION 3 - 1CHASSIS & TURNTABLE 3-186 – JLG Lift – 3121171
PAGE 235
SECTION 3 - 1CHASSIS & 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.
PAGE 236
SECTION 3 - 1CHASSIS & 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.
PAGE 237
SECTION 3 - 1CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT INDEX 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 pressu
PAGE 238
SECTION 3 - 1CHASSIS & TURNTABLE 3.30 AUXILIARY POWER SYSTEM 3.31 COUNTERWEIGHT 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 and controlled boom angle (see Section 4.11, Controlled Boom Angle System).
PAGE 239
SECTION 3 - 1CHASSIS & TURNTABLE A B A. Part Number\Actual Weight Stamping B. Apply Loctite #271 to Bolt Threads and to Threads in Counterweight. Torque to 400 ft. lbs. (542 Nm). Typical Four Places. Figure 3-78.
PAGE 240
SECTION 3 - 1CHASSIS & TURNTABLE NOTES: 3-192 – JLG Lift – 3121171
PAGE 241
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM CONTROL ENABLE SYSTEM The platform controls make use of a time dependent enable circuit to limit the time availability of "live" or enabled controls. To operate any directional function, the footswitch must be depressed before activation of the function. When the footswitch is depressed, the controls are enabled and the operator has 7 seconds to operate any function.
PAGE 242
SECTION 4 - BOOM & PLATFORM 4.5 JIB STOW SYSTEM This machine is equipped with a full function side swing rotator that is mechanically limited to 55 degree rotation to the left and electrically limited to 70 degrees to the right through the use of a positive action limit switch mounted on the rotator assembly. The machines stowed length can be reduced to facilitate transportation on standard trailers by swinging the jib further to the right using the hydraulic power of the side swing rotator.
PAGE 243
SECTION 4 - BOOM & PLATFORM 4.7 TOWER PATH CONTROL SYSTEM 4.8 AUTOMATIC MAIN BOOM CONTROL SYSTEM (see Figure 4-1., Tower Path vs. Main Boom Angle) The Tower Path Control System uses the envelope control sensors to enhance the control of the tower boom for increased user efficiency and is used as an integral part of the envelope control system (see Section 4.6, Envelope Control System). Both the ground and platform control panels use one function switch to control the tower.
PAGE 244
SECTION 4 - BOOM & PLATFORM TOWER PATH FOR MAIN BOOM ANGLES BELOW 15 DEGREES TOWER PATH FOR MAIN BOOM ANGLES ABOVE 55 DEGREES Figure 4-1. Tower Path vs.
PAGE 245
SECTION 4 - BOOM & PLATFORM MAIN BOOM FULLY EXTENDED MACHINE WILL TIP OVER IN DIRECTION OF ARROWS IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE TOWER BOOM FULLY LOWERED TO FULLY RAISED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-2.
PAGE 246
SECTION 4 - BOOM & PLATFORM JIB ELEVATED MACHINE WILL TIP OVER IN DIRECTION OF ARROW IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE MAIN BOOM FULLY ELEVATED TOWER BOOM FULLY LOWERED TO FULLY RAISED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-3.
PAGE 247
SECTION 4 - BOOM & PLATFORM JIB ELEVATED MACHINE WILL TIP OVER IN DIRECTION OF ARROW IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE MAIN BOOM FULLY ELEVATED TOWER BOOM FULLY LOWERED TO FULLY RAISED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-4.
PAGE 248
SECTION 4 - BOOM & PLATFORM 4.9 ELECTRICAL RETRIEVAL SYSTEM The Electrical Retrieval System provides a backup means of retrieving an elevated boom in the event of a failure of any sensor used in the envelope control system (see Section 4.6, Envelope Control System). Although the system is continuously monitored for its viability, it is not active until a failure of the envelope control system is detected. The system uses a load cell pin to attach the tower lift cylinder to the turntable.
PAGE 249
SECTION 4 - BOOM & PLATFORM approached. The control system indicates to the operator this automatic introduction of slow down by flashing the creep light on the platform display panel. This feature applies to both platform and ground controls, however, no indication is made on the ground control panel. NOTE: For more detailed information concerning system adjustment and operation, refer to Section 6 - JLG Control System. 4.
PAGE 250
SECTION 4 - BOOM & PLATFORM 4.16 ELECTRONIC PLATFORM LEVELING 4.17 MAIN BOOM The Electronic Platform Leveling System uses two tilt sensors (mounted on either side of the pivot weldment), a control valve (mounted to the platform support), a level cylinder, and the platform control module (mounted in the platform control box) to automatically measure and control the incline of the platform with respect to gravity. This system is active while operating drive, telescope, lift or swing.
PAGE 251
SECTION 4 - BOOM & PLATFORM 8. Remove the cover from the top of the main boom to gain access to the telescope cylinder attaching hardware. 9. Remove the bolt, keeper pin, and retaining pin securing the barrel end of the telescope cylinder to the main boom base section. 11. If necessary, remove the shoulder screws, retaining rings, and pin that secures the rod end of the telescope cylinder to the main boom fly section and remove the telescope cylinder from the fly section. 12.
PAGE 252
SECTION 4 - BOOM & PLATFORM 13. If necessary, remove the shoulder screws, retaining ring, and pin that secures the barrel end of the level cylinder to the main boom fly section and remove the level cylinder from the fly section. nose and secure in place with the pivot pin, keeper pin, and bolt. 3. If removed during assembly, install the telescope cylinder into the fly section.
PAGE 253
SECTION 4 - BOOM & PLATFORM 4. Install the bolt, keeper pin, and retaining pin that secures the barrel end of the telescope cylinder to the main boom base section. 6. Install the jib/platform assembly onto the boom. 7. Extend the fly section enough to attach an adequate lifting device for removing the fly section. 8. Install the bolts, keeper pins, and pivot pins that secure the jib rotator support to the nose of the fly section. 5. Install the cover to the top of the main boom. 9.
PAGE 254
4-14 – JLG Lift – See Figure 4-6., Main Boom Assembly - Sheet 2 of 4 Figure 4-5. Main Boom Assembly - Sheet 1 of 4 See Figure 4-6.
PAGE 255
Figure 4-6. Main Boom Assembly - Sheet 2 of 4 1. Loctite #242 2. Washer 3. Bolt 4. Shim 5. Wear Pad 6. Screw 7. Main Tele Cyl. 8. Bolt 9. Shoulder Screw 10. Pin 11. Tele Exhaust Hose 12. Tele Extend Hose 13.
PAGE 256
4-16 Figure 4-7.
PAGE 257
1. 2. 3. 4. Pivot Assembly Upper Front Wear Pad Shim Bolt 5. 6. 7. 8. Bolt 9. Shoulder Screw 13. Bolt 17. Upper Jib Link Level Cylinder Pin 10. Level Cylinder 14. Jib Rotator 18. Platform Rotator Tele Cylinder Pin 11. Side Wear Pad 15. Lower Jib Link 19. Level Link Pin Retaining Ring 12. Shim 16. Jib Cylinder 20. Retaining Ring Figure 4-8. Main Boom Assembly - Sheet 4 of 4 21. 22. 23. 24. Fly Boom Section 25.
PAGE 258
SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Check torque on the bolts every 150 hours of operation. Ft-Lbs. Nm A 85 115 B 420 672 C 480 650 D 85 115 E 190 260 Figure 4-9.
PAGE 259
SECTION 4 - BOOM & PLATFORM 4.18 TOWER BOOM Installation and Assembly NOTE: To ease assembly of the tower base boom to the machine, have the base section slightly tilted downward towards the pivot pin bushings. 1. Use an overhead crane or other suitable lifting device, and maneuver the tower boom base section in place. Install the pivot pin. Install the keeper pin and apply Loctite #271 to the retaining bolt. Torque the bolt to 285 ft. lbs. (386 Nm). 4.
PAGE 260
SECTION 4 - BOOM & PLATFORM 0801370-C Figure 4-10.
PAGE 261
SECTION 4 - BOOM & PLATFORM 0801370-C 1. 2. 3. 4. 5. Tower Fly Tower Mid Tower Base Front Upper Wear Pad Wear Pad Shim 6. 7. 8. 9. Bolt Washer Front Side Wear Pad Wear Pad Shim 10. 11. 12. 13. Screw Shoulder Bolt Snap Ring Retaining Pin 14. 15. 16. 17. Front Lower Wear Pad Wear Pad Shim Bolt Washer Figure 4-11.
PAGE 262
SECTION 4 - BOOM & PLATFORM 0801370-C 1. 2. 3. 4. 4-22 Upper Rear Wear Pad 5. Rear Side Wear Pad 9. Keeper Shim Wear Pad Shim 6. Wear Pad Shim 10. Bolt Bolt 7. Screw 11. Tower Tele Cylinder Washer 8. Trunnion Keeper Block 12. Bottom Rear Wear Pad Figure 4-12. Tower Boom Assembly - Sheet 3 of 3 – JLG Lift – 13. 14. 15. 16.
PAGE 263
SECTION 4 - BOOM & PLATFORM Ft-Lbs. Nm A 85 115 B 35 47.5 Figure 4-13.
PAGE 264
SECTION 4 - BOOM & PLATFORM Ft-Lbs. Nm A 85 115 B 35 47.5 Figure 4-14.
PAGE 265
SECTION 4 - BOOM & PLATFORM BOLT, KEEPER PIN DETAIL A PIVOT PIN DETAIL E DETAIL A DETAIL D See Figure 4-18., Boom & Cylinder Installation - Sheet 4 of 4 DETAIL C DETAIL B 0272979-H Figure 4-15.
PAGE 266
SECTION 4 - BOOM & PLATFORM LOAD SENSING PIN TOWER LIFT CYLINDER BOLT, KEEPER PIN SCREW PIVOT PIN BOLT, KEEPER PIN PIVOT PIN MAIN LIFT CYLINDER 0272979-H Figure 4-16.
PAGE 267
SECTION 4 - BOOM & PLATFORM See Figure 4-23., Pin Clamp Detail 0272979-H 1. 2. 3. 4. 5. 6. Upper Link Retaining Ring Bolt Keeper Pin Lower Link 7. 8. 9. 10. 11. 12. Pin Keeper Bolt Pin Bolt Keeper Figure 4-17.
PAGE 268
SECTION 4 - BOOM & PLATFORM NOTE: If space is available install one thrust washer on each side of the boom assembly between the tower fly boom section and the main base boom section. If space only allows for the use of one thrust washer, install it on the same side as the proximity sensor. (Same as the left side or powertrack side of the machine.) THRUSTWASHER THRUSTWASHER 0272979-H Figure 4-18.
PAGE 269
SECTION 4 - BOOM & PLATFORM Bolt # Ft-Lbs. Nm 1 675 915 2 285 386 3 190 260 4 600 813 5 200 271 0272979 H Figure 4-19.
PAGE 270
SECTION 4 - BOOM & PLATFORM 0272979 H Figure 4-20.
PAGE 271
SECTION 4 - BOOM & PLATFORM Bolt # Ft-Lbs. Nm 1 675 915 2 285 386 3 190 260 4 600 813 5 200 271 0272979 H Figure 4-21.
PAGE 272
SECTION 4 - BOOM & PLATFORM 0273513 E 1. 2. 3. A B C Bar Blade Plate Apply Loctite #242 & torque to 85 ft.lbs. (115 Nm) Apply Loctite #242 & torque to 35 ft.lbs. (47 Nm) Adjust all blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate Figure 4-22.
PAGE 273
SECTION 4 - BOOM & PLATFORM 9. Align the telescope cylinder trunnions. Install the keepers and shims. Secure them in place with the retaining bolts. 10. Install the upper and lower length sensors. 6. Install the tower mid section into the tower base section. Install the wear pads in the tower base section. NOTE: Keep the tower fly section out of the tower mid section enough to allow for installation of the telescope cylinder retaining pin. 7. Install the tower fly section into the tower mid section.
PAGE 274
SECTION 4 - BOOM & PLATFORM 14. Install the pivot pin. Install the keeper pin and apply Loctite #271 to the retaining bolt. Torque the bolt to 285 ft.lbs. (386Nm). NOTE: The lower link weighs approximately 659 lbs. (299 kg). 13. Insert a pin through the hole in the lower link so that a lifting strap can be used to position the link in the tower fly section. NOTE: The main lift cylinder weighs approximately 785 lbs. (356 kg). The upper link weighs approximately 412 lbs. (187 kg). 15.
PAGE 275
SECTION 4 - BOOM & PLATFORM 16. Install the pivot pin. Install the keeper pin and apply Loctite #271 to the retaining bolt. Torque the bolt to 675 ft. lbs. (915 Nm). Pin Clamp Installation Procedure 1. Install the main boom pivot pin and loosely install the cross bolt and nut. 2. Install the pin clamp bar. Clamp the bolts and washers. Tighten the clamp bolts enough to hold the pin clamp in position for the following steps (5 ft. lbs. [7 Nm] maximum). 3. Install the jack screws and jam nuts.
PAGE 276
SECTION 4 - BOOM & PLATFORM #242 #242 #242 #242 #242 #242 #242 #242 #271 #271 #242 #242 #242 #242 Figure 4-24.
PAGE 277
SECTION 4 - BOOM & PLATFORM Figure 4-25.
PAGE 278
SECTION 4 - BOOM & PLATFORM Figure 4-26.
PAGE 279
SECTION 4 - BOOM & PLATFORM Figure 4-27.
PAGE 280
SECTION 4 - BOOM & PLATFORM Figure 4-28.
PAGE 281
SECTION 4 - BOOM & PLATFORM Table 4-1. Hose/Cable Pull Chart Letter Dim. X Description In. Cm.
PAGE 282
SECTION 4 - BOOM & PLATFORM USING CINCH STRAPS, MAKE THREE SEPARATE BUNDLES AS FOLLOWS: 1. MAIN TELESCOPE EXTEND, RETRACT & PLATFORM RETURN HOSES. 2. PLATFORM SUPPLY AND (3) MAIN LIFT CYLINDER HOSES. 3. ALL OTHER CABLES & AIR LINE THAT ARE ROUTED THROUGH MAIN BOOM CLAMP. SEE DETAIL E ADJUST PUSHTUBE POSITION SO THERE IS 0.250 ± 0.125 in. (0.635 ± 0.317 cm) CLEARANCE BETWEEN PUSH TUBE AND POWERTRACK ROLLER AT THIS LOCATION STRAPS ARE TO BE LOCATED AT 6.000 ± 1.000 (15.2 ± 2.5 cm) & 16.000 ± 1.000 in.
PAGE 283
SECTION 4 - BOOM & PLATFORM SEE DETAIL D ROUTE HOSES THROUGH CARRIER TUBES AS SHOWN ABOVE PLATFORM SUPPLY MAIN LIFT CYL. MAIN TELE CYL. AIR LINE PLATFORM RETURN GENERATOR CABLE OR WELD LEAD MAIN LIFT CYL. MAIN TELESCOPE CYL. ELECTRICAL CABLE MAIN LIFT CYL. CABLE DETAIL D 0273360-E Figure 4-31.
PAGE 284
SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. Tower Lift Cylinder Angle Sensor (1) Load Pin(1) Tower Angle Sensors (2) Tower Length Sensors (2) Tower Transport Length Switch (1) Main Boom Angle Sensor (2) 7. Main Boom Transport Length Switch (2) 8. Dual Capacity Length Switch (2) 9. Main Boom Transport Angle Switch (1) 10. Jib Stow Switch (1) 11. Dual Capacity Jib Position Switch (1) Figure 4-32.
PAGE 285
SECTION 4 - BOOM & PLATFORM SEE DUAL CAPACITY LENGTH SWITCH & MAIN BOOM TRANSPORT LENGTH SWITCH DETAILS Figure 4-35. SEE LEVEL SENSOR & JIB SWITCH DETAILS Figure 4-37. IMPORTANT: THE CONTROL SYSTEM MUST BE RECALIBRATED AT THE CONCLUSION OF ASSEMBLY OR REPLACEMENT OF ANY SENSOR. SEE TOWER BOOM LENGTH SENSOR & TOWER BOOM ANGLE SENSOR DETAILS Figure 4-38. SEE ROTARY ANGLE SENSOR DETAILS & ANGLE SWITCH DETAIL Figure 4-40. SEE TOWER LIFT CYLINDER ANGLE SENSOR DETAIL Figure 4-34.
PAGE 286
SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. 7. Sensor Cover Washer Ring Bolt Sensor Arm Sensor Switch Lift Cylinder TOWER LIFT CYLINDER ANGLE SENSOR DETAIL SENSOR COVER REMOVED FOR CLARITY SECTION A-A SEE TOWER LIFT CYLINDER ANGLE SENSOR DETAIL 0273121-M Figure 4-34.
PAGE 287
SECTION 4 - BOOM & PLATFORM MAIN BOOM TRANSPORT LENGTH SWITCH DETAIL 2X 90° ROUTE SWITCH HARNESS AROUND COVER MOUNT AS SHOWN ENSURE THAT MAIN BOOM TRANSPORT LENGTH SWITCH LEVERS AND HEADS ARE ORIENTED AS SHOWN TO AVOID DAMAGE: SWITCH LEVER TRAVEL LIMIT MUST BE EQUAL IN BOTH DIRECTIONS.
PAGE 288
SECTION 4 - BOOM & PLATFORM TOWER BOOM TRANSPORT LENGTH SWITCH DETAIL LEVER FULLY EXTENDED 90° TO AVOID DAMAGE: SWITCH LEVER TRAVEL LIMIT MUST BE EQUAL IN BOTH DIRECTIONS. ORIENT SWITCH LEVER AT SPLINE INDEX LOCATION CLOSEST TO 90° 0273121-M Figure 4-36.
PAGE 289
SECTION 4 - BOOM & PLATFORM SEE PUSH NUT DETAIL PUSH NUT PUSH NUT DETAIL LEVEL SENSOR DETAIL SENSOR MOUNT SENSOR COVER TYPICAL ON LEFT & RIGHT SIDE OF BOOM MOUNTING BOLT JIB STOW SWITCH TO ACTIVATE WHEN JIB ROTATES 70° TOWARDS RIGHT SIDE OF MACHINE FROM CENTER POSITION THE JIB SWITCH MOUNT TO ACHIEVE 0.000" - 0.030" (0.00mm - 0.
PAGE 290
SECTION 4 - BOOM & PLATFORM LOWER SENSOR DETAIL NOTE: LENGTH SENSOR COVER NOT SHOWN FOR CLARITY UPPER SENSOR DETAIL ATTACH LATCH HOOK TO RING ON FLY BOOM AS SHOWN TYPICAL ON UPPER & LOWER SENSORS SEE UPPER SENSOR DETAIL TOWER BOOM ANGLE SENSOR DETAIL TOWER BOOM LENGTH SENSOR DETAIL SEE LOWER SENSOR DETAIL 0273121-M Figure 4-38.
PAGE 291
SECTION 4 - BOOM & PLATFORM HOSE LOOP NOTE: ROUTE 3/4" TELE CYL EXTEND HOSE THROUGH HOSE LOOP ROUTE ALL SENSOR HARNESSES WITH 3/4" TELE CYL EXTEND HOSE BUT DO NOT ROUTE THE SENSOR HARNESSES THROUGH THE HOSE LOOP ROUTE REMAINING TELE CYL HOSES WITH 3/4" TELE CYL EXTEND HOSE, BUT DO NOT ROUTE THE REMAING HOSES THROUGH THE HOSE LOOP.
PAGE 292
SECTION 4 - BOOM & PLATFORM REPOSITION SWITCH HEAD AND LEVER AS SHOWN ON LIMIT SWITCH LEVER IN-LINE WITH SWITCH BODY TYPICAL LEFT & RIGHT SIDES OF BOOM ALIGN TIMING MARKS ON SHAFT WITH LABELED LETTERS (L or R) EACH SENSOR MUST CORRESPOND WITH SIDE OF BOOM ON WHICH IT IS MOUNTED SEE ROTARY SENSOR DETAIL ROTARY SENSOR DETAIL TYPICAL LEFT & RIGHT SIDES OF BOOM (LEFT SIDE OF BOOM SHOWN) 0273121-M Figure 4-40.
PAGE 293
SECTION 4 - BOOM & PLATFORM ADJUST PROXIMITY SENSOR TO BE FLUSH ±0.015 (0.396 mm) WITH BOTTOM OF COUNTERBORE IN SENSOR MOUNT DETAIL C MAIN BASE BOOM PIVOT DOUBLER PROXIMITY SENSOR PROXIMITY SENSOR MOUNT 0.075 ± 0.030 (1.90 ± 0.76 mm) ADJUST SENSOR MOUNT TO HAVE 0.075 ± 0.030 (1.90 ± 0.76 mm) CLEARANCE TO PIVOT DOUBLER WHEN BOOMS ARE IN STOWED POSITION PROXIMITY SENSOR PROXIMITY SENSOR MOUNT SLIDE COUPLING ONTO SWITCH UNTIL IT BOTTOMS OUT TORQUE CLAMP SCREW TO 8 in.lbs. (0.
PAGE 294
SECTION 4 - BOOM & PLATFORM 4.19 MAIN BOOM TRANSPORT ANGLE SWITCH and See Figure 4-35., Boom Sensor Locations - Dual Capacity, Length, & Main Boom Transport and Figure 4-42., Main Boom Transport Angle Switch Wiring The Main Boom Transport Angle Switch is located on the left side of the tower fly boom underneath the cover. This switch is used as a backup for the rotary angle sensors and trips (activates) when the main boom is approximately 15° above the tower boom.
PAGE 295
SECTION 4 - BOOM & PLATFORM Analyzer Readings and The analyzer reading for these switches can be found in the Diagnostics menu under Transport Data. In the Transport position, the screen should read: Possible Faults 1. Stuck Switch • 8/4 Fault Code • MAIN BOOM TRN AGL SW/SENSOR DISAGREEMENT Analyzer message. and 2. Wire Broken/Disconnected • 8/4 Code Fault Code • MAIN BOOM TRN AGL SW FAILED Analyzer message 4.20 TOWER TRANSPORT LENGTH SWITCH See Figure 4-35.
PAGE 296
SECTION 4 - BOOM & PLATFORM and and In the OUT of Transport position, the screen should read: Possible Faults 1. Stuck Switch • 8/4 Fault Code • TWR LEN SW/SENSOR DISAGREEMENT Analyzer message. 2.
PAGE 297
SECTION 4 - BOOM & PLATFORM 4.21 MAIN BOOM TRANSPORT LENGTH SWITCHES In Transport - Switch #2 on cam: See Figure 4-35., Boom Sensor Locations - Dual Capacity, Length, & Main Boom Transport and Figure 4-44., Main Boom Transport Length Switch Wiring The Transport Length Switches are located on the right side of the Main Base boom underneath the cover. These switches run on cams mounted to the upper fly boom to determine if the main boom is telescoped within or beyond the transport position.
PAGE 298
SECTION 4 - BOOM & PLATFORM 4.22 DUAL CAPACITY SWITCHES Out of Transport - Switch #2 off cam: See Figure 4-35., Boom Sensor Locations - Dual Capacity, Length, & Main Boom Transport and Figure 4-45., Dual Capacity Switch Wiring The Dual Capacity Switches are located on the left side of the Main Base boom underneath the cover. The Dual Capacity Switches along with the Main Boom Transport Length Switches run on a series of cams mounted on the fly boom to determine the length of the main boom.
PAGE 299
SECTION 4 - BOOM & PLATFORM Switch #2 on cam: Switch #2 off cam: Switch #1 on cam: Possible Faults 1. Stuck Switch • 8/4 Fault Code • CAP LEN SW DISAGREEMENT* Analyzer message *This fault will not show up until telescope is activated. 2.
PAGE 300
SECTION 4 - BOOM & PLATFORM IN TRANSPORT: 12 volts on red (2-70-6) 12 volts on white (49-122) 9 volts on black (49-123) OUT OF TRANSPORT: 12 volts on red (2-70-6) 9 volts on white (49-122) 12 volts on black (49-123) Figure 4-42. Main Boom Transport Angle Switch Wiring IN TRANSPORT: 9 volts on red 12 volts on white 12 volts on black OUT OF TRANSPORT: 12 volts on red 12 volts on white 9 volts on black Figure 4-43.
PAGE 301
SECTION 4 - BOOM & PLATFORM #1 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT #2 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT SIDE OF THE MAIN BOOM (TOP SWITCH). THIS SWITCH IS IN THE N.C. SIDE OF MAIN BOOM (BOTTOM SWITCH). THIS SWITCH IS OPEN POSITION WHEN THE MAIN BOOM IS FULLY RETRACTED. WHEN THE MAIN BOOM IS FULLY RETRACTED.
PAGE 302
SECTION 4 - BOOM & PLATFORM 4.23 TOWER TELESCOPE CYLINDER 5. Position the Platform/Ground select switch to the Ground position. Removal 1. Place the machine on a firm, level surface with the axles fully extended or the turntable centered between the rear wheels. 2. Select lift up and raise the tower boom until it is in a horizontal position. NOTE: The main boom must be elevated approximately 12 inches (30 cm) above the boom rest but no more than 15° above the tower to prevent damage to the machine.
PAGE 303
SECTION 4 - BOOM & PLATFORM 6. Plug the analyzer into the connector inside the Ground control box. THE SERVICE MODE MENU WILL BE SELECTABLE AT THE TOP LEVEL OF THE ANALYZER MENU STRUCTURE. “SERVICE MODE” WILL BE DISPLAYED ON THE TOP LINE OF THE ANALYZER WITH THE CURRENT SUB-MENU SELECTION ON THE BOTTOM LINE. THE SUB-MENUS WILL SCROLL WITH THE LEFT AND RIGHT ARROW KEYS. 11. Scroll through the analyzer menu until "SERVICE MODE" is displayed. Press the ENTER key. 12.
PAGE 304
SECTION 4 - BOOM & PLATFORM 13. Press ENTER. The analyzer will read: If the main boom angle sensors are calibrated and working properly the control system will verify the main boom angle readings are between +0.0 and +15.0 (ref tower boom). If they are calibrated and working properly and outside the angle limits, the analyzer will read: NOTE: The main boom must be elevated approximately 12 inches (30 cm) above the boom rest but no more than 15° above the tower to prevent damage to the machine.
PAGE 305
SECTION 4 - BOOM & PLATFORM 16. Enter code 95268. The analyzer will read: BEFORE CONTINUING WITH THIS PROCEDURE, DOUBLE CHECK ALL SUPPORTING DEVICES AND MID BOOM RESTRAINING CHAIN. 19. Extend the tower fly section no more than necessary to gain access to the telescope cylinder retaining pin (about 5.5 ft. [1.7 m]). When access is gained to the telescope cylinder retaining pin, remove the four shoulder bolts and two snap rings that hold it in place and remove the telescope cylinder retaining pin.
PAGE 306
SECTION 4 - BOOM & PLATFORM 21. Disconnect the length sensor cables from the tower boom fly section. 22. Tag and disconnect the electrical lines going to the upper and lower tower boom length sensors. 26. Place blocking under the tower telescope cylinder to prevent it from dropping suddenly and begin pulling the cylinder out of the boom using an adequate lifting device. Reposition the blocks and lifting straps as needed to prevent the cylinder from dropping suddenly and to keep it balanced.
PAGE 307
SECTION 4 - BOOM & PLATFORM 4. Connect the length sensor cables to the tower boom fly section. 7. Secure the angle sensors to the boom section with the retaining bolts and washers. At the rear of the tower boom, connect the wires going to the angle sensors as tagged during removal. 8. If necessary, refer to Removal and use the analyzer Service Mode to cycle the cylinder in and out several times to purge air from the cylinder. 5. Install the length sensors and mounting brackets.
PAGE 308
SECTION 4 - BOOM & PLATFORM 4.24 TOWER LIFT CYLINDER 4. If the Boom Control System allows tower telescope, skip to step 18. If not, continue with step 6. Removal 5. Plug the analyzer into the connector inside the Ground control box. 1. Place the machine on a firm, level surface with the axles fully extended or the turntable centered between the rear wheels. 2. Select lift up and raise the tower boom until it is in a horizontal position.
PAGE 309
SECTION 4 - BOOM & PLATFORM 7. The analyzer screen should read: 11. Scroll through the menu until "TWR LIFT ONLY?" is displayed as shown below. 12. Press ENTER. The analyzer will read: 8. Use the arrow button to reach ACCESS LEVEL 2. Press the ENTER key. 9. Enter Code 33271 to get into Access Level 1 mode. NOTE: The service mode will only be displayed on the analyzer when in access level 1 in the ground mode and be hidden while in access level 2.
PAGE 310
SECTION 4 - BOOM & PLATFORM 13. Press the ENTER key. The control system will perform the following checks: 15. After the successful completion of the checks, the analyzer will read: The axles must be extended or the DOS (Direction of Steering) switch must indicate the turntable is between the rear tires, otherwise the analyzer will read: 16. Enter code 74466. The analyzer will read: 14.
PAGE 311
SECTION 4 - BOOM & PLATFORM 17. Press the ENTER key to acknowledge the stability control is turned off. The analyzer should read: 22. At the rod end of the cylinder, remove the retaining bolt and pivot pin that secures that end of the cylinder to the tower boom. 23. At the barrel end of the cylinder, remove the sensor cover to gain access to the sensor. Remove the angle sensor, sensor arm, and sensor pin. 18.
PAGE 312
SECTION 4 - BOOM & PLATFORM 25. Disconnect the wiring harness from the strain relief connector at the opposite side of the load sensing pin. 26. Use the Load Pin Removal Tool (JLG P/N 4846765) to prevent the pin from being damaged, and use a hammer to remove the pin. To make the tool refer to Figure 4-49., Load Pin Removal Tool, JLG P/N 4846765. If the Load Pin Removal Tool is not available, use an arbor of the proper size (as shown below).
PAGE 313
SECTION 4 - BOOM & PLATFORM Pin Harness P/N 4922826 Cross harness ends and cable tie to filter box as shown Orient harness with Deutsch connector routed over filter box Position harness with filter box supported by turntable access hole as shown Figure 4-48.
PAGE 314
SECTION 4 - BOOM & PLATFORM 5. Secure the pin in place with the retaining pin and retaining pin bolt on the other end. Torque the bolt to 285 ft.lbs. (386 Nm). 7. Cycle the cylinder in and out several times to purge air from the cylinder. If necessary, refer to Removal and use the analyzer Service Mode. 8. At the rod end of the cylinder, install the retaining bolt and pivot pin that secures that end of the cylinder to the tower boom. It may be necessary to use the analyzer Service Mode to align the pin.
PAGE 315
SECTION 4 - BOOM & PLATFORM Figure 4-49.
PAGE 316
SECTION 4 - BOOM & PLATFORM 4.25 MAIN LIFT CYLINDER 7. The analyzer screen should read: Removal 1. Place the machine on a firm, level surface with the axles fully extended or the turntable centered between the rear wheels. The tower boom must also be fully lowered and retracted. 2. Connect the JLG Control System Analyzer to the connector at the ground control box. 3. Start the engine. 4. Position the Platform/Ground select switch to the Ground position. 8. Use the arrow button to reach ACCESS LEVEL 2.
PAGE 317
SECTION 4 - BOOM & PLATFORM 10. Scroll through the analyzer menu until SERVICE MODE is displayed. Press the ENTER key. 12. Press the ENTER key. The control system will perform several tests to make sure the machine is in the proper position. If the axles are not extended or the turntable is not centered between the rear wheels, the screen will read: 11. Scroll through the menu until the "MAIN LIFT?" is displayed as shown below.
PAGE 318
SECTION 4 - BOOM & PLATFORM If the tower boom length sensors are calibrated and operating properly, the control system will verify the tower boom length readings are less than 6 in. (15.2 cm). If the tower boom length is not within the limits, the screen will read: 13. When the machine passes all the configuration checks, the screen will read: 4-78 14. Enter code 55050. The analyzer will read: WHEN THE STABILITY CONTROL IS OFF THE MACHINE WILL TIP IF USED INCORRECTLY. 15.
PAGE 319
SECTION 4 - BOOM & PLATFORM 16. If the main boom angle sensors are calibrated and operating properly, the control system will now allow main lift up/down below main boom angles of +65°. 17. Activate main lift and elevate the boom enough to gain access to remove the main lift cylinder. 18. Use a crane or other suitable supporting device to support the weight of the main boom assembly. Installation 1. Using an adequate lifting device, position the main lift cylinder in place on the machine.
PAGE 320
SECTION 4 - BOOM & PLATFORM 4.26 MAIN BOOM TELESCOPE CYLINDER 8. The analyzer screen should read: Removal 1. Place the machine on a firm, level surface with the axles fully extended or the turntable centered between the rear wheels. The tower boom must also be fully lowered and retracted. 2. Connect the JLG Control System Analyzer to the connector at the ground control box. 3. Start the engine. 4. Position the Platform/Ground select switch to the Ground position. 9.
PAGE 321
SECTION 4 - BOOM & PLATFORM 11. Scroll through the analyzer menu until SERVICE MODE is displayed. Press the ENTER key. 13. Press ENTER. The control system will perform several tests to make sure the machine is in the proper position. If the axles are not extended or the turntable is not centered between the rear wheels, the screen will read: 12.
PAGE 322
SECTION 4 - BOOM & PLATFORM If the tower boom length sensors are calibrated and operating properly, the control system will verify the tower boom length is less than 6 in. (15.2 cm). If the tower boom is outside the length limit, the screen will read: 14. When the machine passes all the configuration checks, the screen will read: 15. Enter code 69286. The analyzer will read: WHEN THE STABILITY CONTROL IS OFF THE MACHINE WILL TIP IF USED INCORRECTLY. 16.
PAGE 323
SECTION 4 - BOOM & PLATFORM 18. Telescope the main boom out until the retaining pin at the end of the telescope cylinder rod can be accessed. 19. Place blocking or boom supports under the main boom to support it. 20. Place blocking under the main lift cylinder to support it. 21. Place blocking under the lower link to support it. 23. Remove the bolts securing the rear boom cover and remove the cover. 24.
PAGE 324
SECTION 4 - BOOM & PLATFORM 27. Support the upper link using a nylon strap or blocking. Remove the bolt, keeper, and pin securing the upper link to the base boom. Carefully lower the upper link enough to allow the telescope cylinder to be removed. Installation NOTE: The telescope cylinder weighs approximately 663 lbs. (300 kg). 1. Carefully install the telescope cylinder into the rear of the main boom.
PAGE 325
SECTION 4 - BOOM & PLATFORM 5. Install the shoulder screws, retaining rings, and pin securing the end of the telescope cylinder. It may be necessary to use the analyzer Service Mode to align the pin. 6. Carefully raise the upper link into position. Install the bolt, keeper, and pin securing the upper link to the base boom. 7. Install the rear boom cover and secure it in place with the retaining bolts. 8. Remove all blocking used during the Removal procedure. 9.
PAGE 326
SECTION 4 - BOOM & PLATFORM 4.27 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.
PAGE 327
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.
PAGE 328
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.
PAGE 329
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.
PAGE 330
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.
PAGE 331
Figure 4-50.
PAGE 332
4-92 JOIN LEFT LEVEL SENSOR HARNESS WITH HOSE BUNDLE HERE – JLG Lift – PLATFORM RETURN Figure 4-51. Main Boom Powertrack Installation - Sheet 2 of 3 OPTIONAL AIRLINE/WELD LEAD/ 7500W GENERATOR CABLE CONTROL CABLE AC CABLE PLATFORM SUPPLY (1.000) LOCATE END 1.0 ± 0.5 PAST HOSE LOOP AS SHOWN LOCATE (2) TIES 1.0 ± 0.
PAGE 333
3121171 – JLG Lift – DIM "X" 30.5 cm 30.5 cm 183 cm 183 cm 30.5 cm 30.5 cm 30.5 cm 12" 12" 72" 72" 12" 12" 12" DESCRIPTION LEVEL UP HOSE (PORT L1) LEVEL DOWN HOSE (PORT L2) SWING RIGHT HOSE (PORT S1) SWING LEFT HOSE (PORT S2) 64" 64" 62" 62" N JIB LIFT UP HOSE (PORT J1) 60" O JIB LIFT DOWN HOSE (PORT J2) 60" P PLATFORM SUPPLY (PORT P) 58" Q TANK (PORT T) 55" NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm) Figure 4-52.
PAGE 334
SECTION 4 - BOOM & PLATFORM Switch States / Boom Length Regions Dual Cap. Switch #1 Dual Cap. Switch #2 Control System Conclusion of Dual Cap.
PAGE 335
SECTION 4 - BOOM & PLATFORM 4.29 ELECTRONIC PLATFORM LEVELING Normal Operation NOTE: For more detailed information concerning system adjustment and operation, refer to Section 6 - JLG Control System. Description Electronic platform leveling replaces the conventional hydraulic method of platform leveling. To control electronic platform leveling the platform is equipped with a pair of tilt sensors, one primary and one secondary, mounted to the non-rotating portion of the platform rotator.
PAGE 336
SECTION 4 - BOOM & PLATFORM 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. These zones are as follows: 1. Lift up 2. Lift down During the power-up procedure, function enable, in both Platform and Ground Mode, is delayed during the 1.5 second startup lamp test. During this 1.
PAGE 337
SECTION 4 - BOOM & PLATFORM 4.30 TOWER BOOM DRIFT TEST 5. While still in the DIAGNOSTICS/BOOM SENSORS NEVER DIAGNOSE A SUSPECTED TOWER BOOM LIFT CYLINDER DRIFT BY FULLY ELEVATING THE BOOMS. MACHINE TIPOVER COULD OCCUR. menu using the left arrow record the displayed value of the TOWER ANGLE 1 and TOWER ANGLE 2. Press the escape press the left arrow DO NOT LEAVE THE MACHINE UNATTENDED AT ANY TIME DURING THE TEST. 1.
PAGE 338
SECTION 4 - BOOM & PLATFORM JIB BOOM NOTE: UPPER BOOM AND JIB BOOM ARE FULLY ELEVATED, UPPER TELESCOPE BOOM IS FULLY RETRACTED. LOWER BOOM IS ELEVATED TO 10°. UPPER (MAIN) BOOM 10.0° TOWER BOOM Figure 4-52.
PAGE 339
SECTION 4 - BOOM & PLATFORM 4.31 ROTARY ACTUATOR Required Tools Theory of Operation The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03).
PAGE 340
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 4-53.
PAGE 341
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 4-54.
PAGE 342
SECTION 4 - BOOM & PLATFORM Disassembly 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out the entire pin. 1. Remove the capscrews (113) over end cap lock pins (109). 2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/ 16” (4.76mm). 4. Install the end cap (4) removal tools provided with the Helac seal kit. 5. Using a metal bar, or something similar, unscrew the end cap (4) by turning it counter clockwise. 3.
PAGE 343
SECTION 4 - BOOM & PLATFORM 6. Remove the end cap (4) and set aside for later inspection. 8. Every actuator has timing marks for proper engagement. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assembly.
PAGE 344
SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet. 11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O.D. gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2). 12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged. 4-104 13.
PAGE 345
SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove. 19. Remove the piston O.D. seal (202). 20. Remove the piston I.D. seal (200). You may now proceed to the inspection process. 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2).
PAGE 346
SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thickness (not less than 0.123” or 3.12 mm). 1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth. Assembly 2. Inspect the thrust washers (304) for rough or worn edges and surfaces.
PAGE 347
SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end cap (4). 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion. 3. Install the wiper seal (304.1/green 0-ring) into it’s groove on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304). 5. Install the wear guide (302) on the end cap (4) and shaft (2). 6.
PAGE 348
SECTION 4 - BOOM & PLATFORM Each T-seal has 2 back-up rings (see drawing for orientation). Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion. Make sure the wedged ends overlap correctly. Repeat this step for the outer seal (202). 4-108 – JLG Lift – 7. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore. 8.
PAGE 349
SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) you can see if your timing marks are lining up. When they do, tap the piston (3) in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out. 11. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (2) with the gear teeth on the inside of the piston (3).
PAGE 350
SECTION 4 - BOOM & PLATFORM 14. Coat the threads on the end of the shaft with antiseize grease to prevent galling. 17. Tighten the end cap (4). In most cases the original holes for the lock pins will line up. 15. Install the 0-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4). 18. Place the lock pins (109) provided in the Helac seal kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole. 16.
PAGE 351
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 4-55., 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 352
SECTION 4 - BOOM & PLATFORM Figure 4-55.
PAGE 353
SECTION 4 - BOOM & PLATFORM Bleeding After Installation NOTE: Bleeding will be necessary if excessive backlash is displayed after the actuator is installed. To do this, bleeder valves must be installed in the actuator at the locations shown below. The following steps are recommended when a minimum of two gallons (8 liters) is purged. 1. Connect a 5 foot (1.5 m) long 3/16" inside diameter, 5/16" outside diameter clear vinyl drain tube to each of the two bleeder valves.
PAGE 354
SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A,B,D E C,D A B C D E Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque to 480 ft. lbs. (650 Nm) Check torque every 150 hours of operation Torque to 75 ft. lbs. (102 Nm) Figure 4-57.
PAGE 355
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 356
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 357
SECTION 5 - HYDRAULICS 5.2 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fixture. NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
PAGE 358
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Loctite #242 (Not Shown) Locking Primer (Not Shown) Loctite #RC 609 (Not Shown) Capscrew Tapered Bushing Head 7. 8. 9. 10. 11. 12. Barrel Rod Piston Not Used Wear Ring Back-Up Ring 13. 14. 15. 16. 17. 18. Back-Up Ring O-Ring O-Ring Rod Wiper Seal Wear Ring 19. 20. 21. 22. 23. T-Seal Washer Ring Bolt Holding Valve O-Ring Plug Figure 5-3.
PAGE 359
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Piston Bushing Head 6. 7. 8. 9. 10. Counterbalance Valve Loctite #242 (Not Shown) Locking Primer (Not Shown) Loctite #RC 609 (Not Shown) Bolt 11. 12. 13. 14. 15. Bearing O-ring Plug Socket Head 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 * Torque 30 to 35 ft.lbs. (41 to 48 Nm) Figure 5-4.
PAGE 360
SECTION 5 - HYDRAULICS 7 10 28 13 12 6 5 19 29 27 16 17 17 18 23 20 20 22 19 27 9 26 25 11 21 24 15 8 4 1684343-D 1. 2. 3. 4. 5. 6. Loctite #242 (Not Shown) Loctite #271 (Not Shown) Locking Primer (Not Shown) Rod Link Capscrew Tapered Bushing 7. 8. 9. 10. 11. 12. Bearing Bushing Head Barrel Rod O-Ring Plug 13. 14. 15. 16. 17. 18. O-Ring Plug Not Used Roll Pin Piston Wear Ring Back-Up Ring 19. 20. 21. 22. 23. 24. Lock Ring Backup Ring Washer Ring O-Ring O-Ring Capscrew 25. 26.
PAGE 361
SECTION 5 - HYDRAULICS 7 30 12 6 28 5 19 29 27 13 16 27 19 20 22 20 24 23 17 17 18 26 9 25 21 11 15 8 4 1684430-B 1. 2. 3. 4. 5. 6. Loctite #242 (Not Shown) Loctite #271 (Not Shown) Primer #7471 Rod End Block Capscrew Tapered Bushing 7. 8. 9. 10. 11. 12. Bearing Bushing Head Barrel Rod O-Ring Plug 13. 14. 15. 16. 17. 18. O-Ring Plug Not Used Roll Pin Piston Wear Ring Back-Up Ring 19. 20. 21. 22. 23. 24. Guidelock Backup Ring Washer Ring O-Ring O-Ring Capscrew 25. 26. 27. 28. 29.
PAGE 362
SECTION 5 - HYDRAULICS 10 16* 11 6 10 17* 10 18** 10 7 11 12 4 102 13 105 102 3 101 108 104 109 109 104 103 106 9 107 15 5 8 * Torque 30-35 ft.lbs. (40.5-47.5 Nm) Max ** Torque 45-50 ft.lbs. (61-68 Nm) Max 1. 2. 3. 4. 5. 6. Loctite #242 Locking Primer Capscrew Tapered Bushing Bushing Bushing 7. 8. 9. 10. 11. 12. Barrel Rod Head O-ring Plug O-ring Plug O-ring Plug 13. 14. 15. 16. 17. 18.
PAGE 363
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Loctite #242 Capscrew Tapered Bushing Barrel Head 6. Rod 6A. Bushing 7. O-Ring Plug 8. O-Ring Plug 9. 10. 11. 12. Not Used Piston Washer Ring Capscrew 13. Capscrew 14. Valve Block 101.Lock Ring 102.Wear Ring 103.Backup Ring 104.Wear Ring 105.Backup Ring 106.O-Ring 107.O-Ring 108.Hydrolock 109.Wiper Ring 110.Rod Seal Figure 5-8.
PAGE 364
SECTION 5 - HYDRAULICS 7 13 13 1A 1A 1 13 11 8** 13 14 3 11 104 6 105 12* 106 109 101 110 101 103 102 5 4 107 16*,108 2 9 10 2A 2A * Prior to S/N 79667 ** Torque to 20 ft.lbs. (27 Nm) Max 1684173-D 1. Barrel 1A. Bushing 2. Rod 2A. Bushing 3. Piston 4. Head 5. 6. 7. 8. 9. 10. Spacer Tapered Bushing Counterbalance Cartridge Check Valve Cartridge Washer Ring Capscrew 11. 12. 13. 14. 15. 16. Capscrew Setscrew O-ring Plug O-ring Plug Loctite #242 Loctite #RC 609 101. Wear Ring 102.
PAGE 365
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Rod Head Piston Nut Loctite #222 (not shown) 7. 8. 9. 10. 11. 12. Not Used Rod End Bushing Barrel End Bushing Not Used Wiper Rod Seal 13. 14. 15. 16. 17. 18. Wear Ring Piston Seal Wear Ring O-ring Back Up Ring O-ring Figure 5-10.
PAGE 366
SECTION 5 - HYDRAULICS 1. Loctite #242 7. Barrel 2. Locking Primer 8. Rod 3. Capscrew 9. Head 4. Screw 10. Rod 5. Screw 10A. Bushing 6. Tapered Bushing 11. Fitting * Torque to 30 ft. lbs. (40.6 Nm) 12. 13. 14. 15. 16. 17. Fitting Fitting Plug Plug Wear Pad Piston 18. 19. 20. 21. 22. 23. Bracket Capscrew Capscrew Spacer Spacer Valve 23A. Valve 23B. Valve 23C. Valve 101.Backup Ring 102.Backup Ring 103.Wear Ring 104.O-Ring 105.O-Ring 106.Seal 107.Rod Wiper 108.Wear Ring 109. Seal Figure 5-11.
PAGE 367
SECTION 5 - HYDRAULICS 1. Loctite #242 6. Head 2. Capscrew 7. Barrel 3. Bolt 7A. Bushing 8. Rod 4. Bolt 5. Tapered Bushing 8A. Bushing * Torque to 50 ft. lbs. (68 Nm) 9. 10. 11. 12. 13. O-Ring Plug O-Ring Plug Wear Pad Piston Bracket 14. 15. 16. 17. 18. Foot Plate Capscrew Capscrew Spacer Valve 101.Wear Ring 102.Backup Ring 103.Backup Ring 104.Wear Ring 105.O-Ring 106.O-Ring 107.Seal 108.Rod Wiper 109.Seal Figure 5-12.
PAGE 368
SECTION 5 - HYDRAULICS R.010 MIN R.010 MIN 7X R.020 SECTION .010 A-A 32 MAX SURFACE FINISH (2 SURFACES) 2.740 .010 2.020 2.995 .010 2.593 2.905 .010 .060 .010 A A 1.125 .030 2X 8.000 9.000 15 .030 2 4.500 HEAD INSTALLATION SLEEVE JLG P/N 1001107143 .060 .060 2X .005/.015 X 45 2.130 .010 2.015 2X R.010 .010 .005 PISTON INSTALL SLEEVE JLG P/N 1001107145 Figure 5-13.
PAGE 369
SECTION 5 - HYDRAULICS 2.250 .125 1.755 .010 2.020 .010 R.030 MAX 1.250 .250 3.000 STK 3X .030/.100 X 45 GO (PISTON) GAUGE JLG P/N 1001107146 3.875 3.357 .125 .010 R.030 MAX 2.020 1.250 .250 .010 3.000 STK .030/.100 X 45 GO (PISTON) GAUGE JLG P/N 1001107147 Figure 5-14.
PAGE 370
SECTION 5 - HYDRAULICS 32 MAX SURFACE FINISH (3 SURFACES) 4.965 4.770 .010 2X .010 4.874 .020 2X 15 6X R.020 MIN 3.000 2 .060 HEAD INSTALL SLEEVE JLG P/N 1001107000 5.000 .060 2X .005/.015 X 45 4.650 .010 4.515 2X R.010 .010 .005 PISTON INSTALL SLEEVE JLG P/N 1001107001 3.000 .125 2.438 .010 4.520 .010 R.030 MAX 1.250 .250 5.000 STK .030/.100 X 45 GO (PISTON) GAUGE JLG P/N 1001107002 Figure 5-15.
PAGE 371
SECTION 5 - HYDRAULICS 32 MAX SURFACE FINISH (3 SURFACES) 3.965 3.770 .010 3.874 .010 .020 2X 15 6X R.020 MIN 3.000 2 .060 HEAD INSTALL SLEEVE JLG P/N 1001106846 3.500 .060 2X .060/.100 X 45 3.625 .010 3.015 2X R.125 .010 .030 PISTON INSTALL SLEEVE JLG P/N 1001106847 2.000 .125 1.688 .010 3.020 .010 R.030 MAX 1.250 .250 4.500 STK GO (PISTON) GAUGE (Tower Lift Cylinder Only) .030/.100 X 45 JLG P/N 1001106848 Figure 5-16.
PAGE 372
SECTION 5 - HYDRAULICS EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 5-18. Tapered Bushing Removal 14. Screw the piston CCW, by hand, and remove the piston from cylinder rod. 15.
PAGE 373
SECTION 5 - HYDRAULICS 4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. 5. Inspect threaded portion of barrel for damage. Dress threads as necessary. a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation. 6.
PAGE 374
SECTION 5 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove. Figure 5-21.
PAGE 375
SECTION 5 - HYDRAULICS 3. Place a new “o”ring and back-up seal in the applicable outside diameter groove of the cylinder head. NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(See magnified insert in Figure 5-24.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other. Figure 5-23. Installation of Head Seal Kit 4.
PAGE 376
SECTION 5 - HYDRAULICS 10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing. b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-1) 11.
PAGE 377
SECTION 5 - HYDRAULICS 20. Secure the cylinder head gland using the washer ring and socket head bolts. (See Table 5-1, Cylinder Head and Tapered Bushing Torque Specifications and Table 5-2, Holding Valve Torque Specifications) Table 5-1. Cylinder Head and Tapered Bushing Torque Specifications Description 22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable.
PAGE 378
SECTION 5 - HYDRAULICS 5.3 COUNTERBALANCE VALVE CHECK 7. After applying the torque to the valve, examine the valve for hydraulic oil leaks. If the valve leaks, replace the counterbalance valve, see Step #10. If the valve does not leak, proceed to Step #13. 1. Position the machine on a firm level surface. 2. Ensure the tower boom and main booms are on their respective boom rests. 8. To replace the counterbalance valve: 3.
PAGE 379
SECTION 5 - HYDRAULICS 5.4 HYDRAULIC TANK The hydraulic tank has a capacity of 53.3 gallons (201.7 liters) and includes the hydraulic return filter and two suction strainers. It is normal for the oil level to appear low when the boom is raised and should only be checked with the machine on level ground and with the boom fully retracted and lowered.
PAGE 380
SECTION 5 - HYDRAULICS 5.5 HYDRAULIC RETURN FILTER Check the hydraulic return filter indicator with the hydraulic oil at normal operating temperature and the engine running. Replace the filter element before the indicator reaches the red filter restricted area or every 300 hours, whichever comes first. A - Red = Filter Restricted; Filter Bypassed B - Green = Filter Good; Not Restricted Figure 5-29.
PAGE 381
SECTION 5 - HYDRAULICS 2 4 3 1 5 1. 2. 3. 4. 5. Return Filter Vented Fill Cap Sight/Temperature Gauge Filter Mounting Bracket Magnetic Drain Plug Figure 5-31.
PAGE 382
SECTION 5 - HYDRAULICS A. B. C. D. E. Front Steer Valve/Axle Extend Traction Valve Rear Steer Valve/Axle Extend Chassis Module Controller Junction Manifold Valve Figure 5-32.
PAGE 383
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Level Up Rotate Right Level Down Rotate Left 5. 6. 7. 8. Jib Down Jib Swing Left Jib Up Jib Swing Right 9. 10. 11. 12. Platform Dump Level Up Relief Jib Up/Down Relief Level Down Relief 13. 14. 15. 16. Main Pressure Check Port Level Up Test Port Level Down Test Port Jib Up/Down Test Port Figure 5-33.
PAGE 384
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Level Up Rotate Right Level Down Rotate Left 5. 6. 7. 8. Jib Down Jib Swing Left Jib Up Jib Swing Right 9. 10. 11. 12. Platform Dump Level Up Relief Jib Up/Down Relief Level Down Relief 13. 14. 15. 16. Main Pressure Check Port Level Up Test Port Level Down Test Port Jib Up/Down Test Port Figure 5-34.
PAGE 385
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Tower Lift Tower Tele Main Lift Main Tele Exhaust Port Main Tele Exhaust Check 6. 7. 8. 9. 10. Swing Right Relief Main Tele Extend Relief Main Tele Extend Check Main Tele Retract Check Swing Differential Sensing 11. 12. 13. 14. 15. Main Tele Extend Port Main Tele Retract Port Main Tele Differential Sensing Main Tele Retract Relief Aux Port to Main Lift 16. Temperature Switch 17. Port to Platform Valve Figure 5-35.
PAGE 386
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Main Tele Exhaust Check Swing Right Test Port Main Tele Extend Test Port Main Tele Retract Test Port Pressure Switch 6. 7. 8. 9. 10. Main Lift Solenoid Pressure from Aux Pump Return (Swivel) Pressure from Function Pump Tower Tele Solenoid 11. 12. 13. 14. 15. Main Pressure Port Tower Lift Solenoid Main Dump Solenoid Swing Check Valve Proportional Swing Valve 16. Swing Left Test Port 17. Swing Left Relief Figure 5-36.
PAGE 387
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Load Sense Port PVG Enable Solenoid Valve Swing Left Port Swing Right Port Main Tele Extend Solenoid 6. 7. 8. 9. 10. Main Tele Proportional Valve Main Tele Retract Solenoid Aux Port to Tower Lift Main Pressure Check Swing Check Figure 5-37.
PAGE 388
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Pressure Adjustment Main Lift Extend Shock Valve Main Lift Section Tower Lift Retract Shock Valve Tower Lift Section 6. 7. 8. 9. 10. Tower Telescope Section Tower Telescope Retract Shock Valve Tower Telescope Extend Shock Valve Tower Lift Extend Shock Valve Main Lift Retract Shock Valve Figure 5-38.
PAGE 389
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Pressure Port LS Port Main Lift B Port Tower Lift B Port 5. 6. 7. 8. Tower Telescope B Port Tower Telescope A Port Tower Lift A Port Main Lift A Port Figure 5-39.
PAGE 390
SECTION 5 - HYDRAULICS 1. 2. 4. 5. 6. Inlet Compensator Plug Plug Washer Housing 7. 8. 9. 10. 11. Orifice Plug Plug Spring Cone 12. 13. 14. 15. 16. Spool O-ring Plug Filter Seat 17. 18. 19. 20. 21. Thrust Pad Spring O-ring Adjusting Screw Plug 22. 23. 24. 25. 26. Plug Seal Screw Plug Pilot Supply 27. Relief Valve 28. Conversion Kit Figure 5-40.
PAGE 391
SECTION 5 - HYDRAULICS 6 25 ± 3 Nm (221 ± 27 in.lb.) 6 20 ± 3 Nm (177 ± 27 in.lb.) 6 8 ± 1 Nm (71 ± 9 in.lb.) 24 45 ± 5 Nm (398 ± 44 in.lb.) 4 ± 1 Nm (35 ± 9 in.lb.) 8 ± 1 Nm (71 ± 9 in.lb.) 4 35 ± 3 Nm (308 ± 27 in.lb.) 6 2.5 4 ± 1 Nm (35 ± 9 in.lb.) 2.5 6 35 ± 3 Nm (308 ± 27 in.lb.) 3 4 ± 1 Nm (35 ± 9 in.lb.) Figure 5-41.
PAGE 392
SECTION 5 - HYDRAULICS 1. 2. 4. 5. Compensator Valve Housing Thrust Pad Spring 6. 7. 8. 9. O-ring Adjusting Screw Plug Plug 10. 11. 12. 13. Check Valve Shuttle Shuttle Pipe 14. 15. 16. 17. O-ring Screw Washer Plug 18. 19. 20. 21. PVLP O-Ring PVLA valve PVLA Plug 22. Relief Valve Figure 5-42.
PAGE 393
SECTION 5 - HYDRAULICS 6 40 ± 3 Nm (354 ± 27 in.lb.) 40 ± 3 Nm (354 ± 27 in.lb.) 13 6 10 ± 1 Nm (88.5 ± 9 in.lb.) 10 35 ± 3 Nm (308 ± 27 in.lb.) 6 Figure 5-43.
PAGE 394
SECTION 5 - HYDRAULICS 22 + 3,-0 Nm (195 + 44, -0 in.lb.) 13 1. 2. 3. 4. 5. 6. 7. Nut Washer Stay Bolt O-ring O-ring O-ring O-ring Figure 5-44.
PAGE 395
SECTION 5 - HYDRAULICS A. B. C. D. 5.2 Ohm ± 5% 7.2 Ohm 8.7 Ohm ± 5% 4.7 Ohm ± 5% Figure 5-45.
PAGE 396
SECTION 5 - HYDRAULICS Ft-Lbs. Nm A 14 19 B 20-25 27-34 C 8-10 10-15 D 30-35 41-47 E 90-100 122-136 Coil Nuts 4-6 5-8 Figure 5-46.
PAGE 397
SECTION 5 - HYDRAULICS Ft-Lbs. Nm A 354 in.lbs. 40 B 20-25 27-34 C 35-40 47-54 D 50 68 E 90-100 122-136 Coil Nuts 4-6 5-8 Figure 5-47.
PAGE 398
SECTION 5 - HYDRAULICS A Ft-Lbs. Nm 195 in.lbs. 22 B 50 68 C 50-55 68-75 D 8-10 10-15 E 90-100 122-136 Coil Nuts 4-6 5-8 Figure 5-48.
PAGE 399
SECTION 5 - HYDRAULICS 5.6 ENABLE VALVES 7. Tag and disconnect the electrical harness from each enable valve solenoid. Removal 8. Remove the existing hardware securing the enable valves to the turntable and remove the three enable valves. 1. Make sure the machine is on a firm level surface. 2. Extend the axles until the axle locked light is illuminated. Installation 3. Position the machine with the booms on suitable boom rests. 1.
PAGE 400
SECTION 5 - HYDRAULICS Air Purge Procedure for Non-Calibrated Machines Air Purge Procedure for Calibrated Machines 1. Loosen the hoses on Port #2 (side) of Tower Lift and Tower Telescope enable valves. This is not necessary on Main Lift Enable Valve because the orientation of the valve allows the air to escape. 1. Loosen the hoses on Port #2 (side) of Tower Lift and Tower Telescope enable valves. It is not necessary on Main Lift Enable Valve because the orientation of the valve allows the air to escape.
PAGE 401
SECTION 5 - HYDRAULICS 5.7 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. stand by adjustment is the outside adjustment, closest to the turntable.
PAGE 402
SECTION 5 - HYDRAULICS HIGH PRESSURE RELIEF - 3200 PSI (220.6 BAR) 1. Install a high pressure gauge at the MP1 port of the main valve block. SAUER PUMP 5. Loosen the jam nut at the setscrew with the 17 mm wrench. Using a 3 mm allen wrench, adjust clockwise to increase, or counterclockwise to decrease. 6. After adjusting the pressure, tighten the jam nut and the cover nut. This is the maximum relief pressure for all the functions governed by this pump. 2.
PAGE 403
SECTION 5 - HYDRAULICS 5. Install high pressure gauge at "M14". 5. Install high pressure relief at "M2". 6. Activate swing left. 6. Activate main telescope retract. 7. Swing left relief is located to the left of "M14". The adjustment is below the outer cap. Turn CW to increase pressure. 7. Main telescope retract is on top surface of valve directly behind "M2". The adjustment is below the outer plug. Turn CW to increase pressure. 8. Remove turntable lock pin. 8. Reconnect hoses.
PAGE 404
SECTION 5 - HYDRAULICS b. Pull out the Emergency Stop switch and start the engine. c. The analyzer screen should read: 2. In this level, enter the "service mode" menu then scroll left or right to "set pressure" submenu as shown below. d. Use the arrow button to reach ACCESS LEVEL 2. Press the ENTER key. 3. Set Pressures - allows function of selected submenu with enable valve closed (to set pressure settings of functions that should not/cannot not be independently operated) e.
PAGE 405
SECTION 5 - HYDRAULICS 5. When the operator enters access code 146005, "SET PRESSURES" will be displayed on the top line and current sub-menu on the bottom line. The submenus will scroll with the left and right arrow keys. top line and "VALVE FAULT" on the bottom line as shown below. 6. Pressure setting sub-menus will include the following: • "MAIN LIFT?" • "TWR LIFT?" • "TWR TELE?" 7.
PAGE 406
SECTION 5 - HYDRAULICS Adjustments Made at the Frame Valve Bank AXLE EXTEND AND RETRACT, FRONT AND REAR 2500 PSI (172.3 BAR) 2. Install the Analyzer in the platform control box and scroll menu’s to Access Level 2 and insert password (33271) to get into Access Level 1. 1. To extend the axles, drive the machine back and forth until extended. A machine that cannot be driven must be jacked up. 2.
PAGE 407
SECTION 5 - HYDRAULICS Figure 5-50.
PAGE 408
SECTION 5 - HYDRAULICS 4. Remove the circular covers at the side or square cover at the top to gain access to the axle/steer valves. 6. Remove the pressure gauge from MS2 port and install on the MS1 port, which is on the right side of the front axle/steer valve, closest to the right front wheel spindle. Position the steer switch to activate the left front steer cylinder until the rod is in the fully retracted position and hold the switch for a few seconds after the rod has stopped.
PAGE 409
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 410
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 411
SECTION 5 - HYDRAULICS 5.8 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 412
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.
PAGE 413
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 414
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 415
SECTION 5 - HYDRAULICS NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are available in 0.3, 0.5, and 1.0 mm thickness. Hydraulic Centering of Control Modules PREPARATION FOR ADJUSTMENT When control modules are exchanged or replaced, it is generally necessary to center the new module. This is done by running the pump with gauges installed at ports X1, X2, MA, and MB Release the jam nut and turn the adjustment screw on top of the control module valve body.
PAGE 416
SECTION 5 - HYDRAULICS 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). Loosen screws with metric allen wrench. Pump Size Allen Wrench 28 8 mm 2. Loosen jam screw (ref. item 2). 3.
PAGE 417
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 418
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. 5. Oil Level Inspection a. Inspect oil level in the reservoir daily. b. If "topping off" is required, use only the same Mobilfluid #424, Product #52233-4. c. Do Not Mix Fluids.
PAGE 419
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 420
SECTION 5 - HYDRAULICS 1. Torque 50 ft lbs (222 Nm) w/Loctite 242 2. Torque 35 ft lbs (156 Nm) w/Loctite 242 3. Function Pump 4. Left Side Drive Forward 5. Right Side Drive Forward 6. Right Side Drive Pump 7. Right Side Drive Reverse 8. Left Side Drive Pump 9. Left Side Drive Reverse NOTE: Drive Coils are approximately 5.5 ohms. Figure 5-51.
PAGE 421
SECTION 5 - HYDRAULICS 5.9 FUNCTION PUMP Figure 5-52. 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 422
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 423
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.
PAGE 424
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. 5-70 13. Disassemble the plug.
PAGE 425
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 426
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 427
SECTION 5 - HYDRAULICS 3. Pumps clockwise driven must have a position of the valve plate 4 degrees out of center in the same direction decentered like drive direction. Adjustments TAPER ROLLER BEARING INITIAL TENSION Cast Iron pump housing must have initial tension of the bearings: 0 to 0.05 mm. 4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees decentered in the ccw position.
PAGE 428
SECTION 5 - HYDRAULICS Figure 5-53. Function Pump, Pressure and Flow Control - Sheet 1 Figure 5-54.
PAGE 429
SECTION 5 - HYDRAULICS Figure 5-55. 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 430
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 431
SECTION 5 - HYDRAULICS 5.10 DRIVE & FUNCTION PUMP START UP PROCEDURES Start-Up Procedure The machine 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 432
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 433
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION settings for smooth control of: acceleration, deceleration, creep, min speed, and max.-speed for all boom, drive, and steering functions. WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATE THE TILT SENSOR.
PAGE 434
SECTION 6 - JLG CONTROL SYSTEM 6.2 CANBUS COMMUNICATIONS CANbus: CAN (Control Area Network) is a two wire differential serial link between the Platform Module, Ground Module, Boom Length Angle Module and the Chassis Module providing bi-directional communications. Two-wire: One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal; both wires ”float” (2.5v) when no signal is being sent.
PAGE 435
SECTION 6 - JLG CONTROL SYSTEM Figure 6-2.
PAGE 436
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING ACCEL ACCELERATE LEN LENGTH ACT ACTIVE LIM LIMIT A/D ANALOG DIGITAL CONVERTER COUNT LVL LEVEL AMB.
PAGE 437
SECTION 6 - JLG CONTROL SYSTEM 6.3 CALIBRATION INSTRUCTIONS Table 6-2. Reasons for Re-Calibration 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.
PAGE 438
6-6 (See Figure 6-5.) (See Figure 6-6.) (See Figure 6-7.) – JLG Lift – Figure 6-3. Analyzer Flow Chart NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration. (See Figure 6-4.
PAGE 439
3121171 – JLG Lift – Figure 6-4. Analyzer Flow Chart - Personalities (Software Version 7.X) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
PAGE 440
Figure 6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
PAGE 441
3121171 – JLG Lift – CALIBRATIONS: DRIVE CALIBRATE DRIVE? CALIBRATIONS: BOOM SENSORS POSITION 1: CHECK SYSTEM? CALIBRATIONS: STEER CALIBRATE STEER? CALIBRATIONS: TILT SENSOR POSITION 1: CHECK SYSTEM? DEUTZ SETUP: SETUP 4 DEUTZ SETUP: SETUP 3 DEUTZ SETUP: SETUP 2 DEUTZ SETUP: SETUP 1 CALIBRATIONS: DEUTZ SETUP: CALIBRATE BOOM VALVES? CALIBRATIONS: BOOM VALVES CALIBRATIONS: NONE AVAILABLE CALIBRATIONS: UNLOCK BOOM CALIBRATE UNLOCK BOOM? CALIBRATE LEVEL DOWN CRACKPOINT? CALIBRATIONS: LEVEL DOW
PAGE 442
6-10 – JLG Lift – Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
PAGE 443
3121171 – JLG Lift – Figure 6-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 2 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
PAGE 444
6-12 – JLG Lift – Figure 6-9. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 3 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
PAGE 445
Figure 6-10.
PAGE 446
SECTION 6 - JLG CONTROL SYSTEM J4 GREY 8 PIN J1 GREY 12 PIN PIN 1 J2 BLACK 12 PIN PIN 1 J3 GREEN 12 PIN PIN 1 PIN 1 J5 BROWN 12 PIN Figure 6-11.
PAGE 447
SECTION 6 - JLG CONTROL SYSTEM Figure 6-12.
PAGE 448
SECTION 6 - JLG CONTROL SYSTEM Figure 6-13.
PAGE 449
SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-14.
PAGE 450
SECTION 6 - JLG CONTROL SYSTEM 6.4 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER The top level menus are as follows: HELP DIAGNOSTICS SYSTEM TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS (view only) 1. Connect the cable supplied with the analyzer, to the controller module located in the platform box or at the controller module in the ground control box and connect the remaining end of the cable to the analyzer.
PAGE 451
SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password. Use the UP or DOWN arrow key to enter the second digit of the password which is 33271. Continue using the arrow keys until all the remaining digits of the password is shown.
PAGE 452
SECTION 6 - JLG CONTROL SYSTEM 6.7 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER 6.8 MACHINE SETUP Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2 = LIFT DOWN PERSONALITIES: DRIVE ACCEL 1.0s There will be a minimum and maximum for the value to ensure efficient operation.
PAGE 453
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. 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 454
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Configuration Digit GLOW PLUG: 5 STARTER LOCKOUT: 6 ENGINE SHUTDOWN: 7 TILT: 8 Number Description 0 NO GLOW PLUGS: No glow plugs installed. 1 AIR INTAKE: Glow plugs installed in the air intake on the manifold. 2 IN-CYLINDER: Glow plugs installed in each cylinder. 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
PAGE 455
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Configuration Digit GEN SET/WELDER: 10 GEN SET CUTOUT: 11* 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 456
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Configuration Digit Number Description FUNCTION CUTOUT: 14* 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 457
SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
PAGE 458
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE Section 6.9 FOR MACHINE ORIENTATION WHENSETTING SPEEDS) DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.
PAGE 459
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Speeds SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.
PAGE 460
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Speeds TOWER TELESCOPE: ACCEL X.Xs Displays/adjusts tower telescope acceleration 1.0 to 1.0 sec 1.0 DECEL X.Xs Displays/adjusts tower telescope deceleration 0.5 to 0.5 sec 0.5 MIN IN XX% Displays/adjusts minimum tower telescope in speed. Same as Creep speed 1 to 1% 1 MAX IN XXX% Displays/adjusts maximum tower telescope in speed 60 to 60% 60 MIN OUT XX% Displays/adjusts minimum tower telescope out speed.
PAGE 461
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Speeds JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5 MIN LEFT XX% Displays/adjusts minimum jib left speed. Same as Creep speed 0 to 65% 40 MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 MIN RIGHT XX% Displays/adjusts minimum jib right speed.
PAGE 462
SECTION 6 - JLG CONTROL SYSTEM 6.9 MACHINE ORIENTATION WHEN SETTING SPEEDS Test Notes MAIN BOOM LIFT UP: From platform control, lowest elevation up to maximum elevation, main boom retracted, tower boom on boom rest. MAIN BOOM LIFT DOWN: From platform control, maximum elevation down to minimum elevation, main boom retracted, tower boom on boom rest. TOWER BOOM LIFT UP: From platform control, lowest elevation up to maximum elevation, main boom retracted and horizontal.
PAGE 463
SECTION 6 - JLG CONTROL SYSTEM 6.10 SYSTEM TEST The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Test from the Platform 1. Position the Platform/Ground select switch to the Platform position. 3. Before proceeding, ensure that the switches on the platform console are in the following positions: a. Drive speed switch is in the Middle position. (Turtle Icon) b. 4WS switch is in the Middle position.
PAGE 464
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 6-15., 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 465
Figure 6-15.
PAGE 466
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 6-16.
PAGE 467
Figure 6-16.
PAGE 468
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer RUNNING 6-36 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 469
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. 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 470
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TEST ALL INPUTS? TESTS COMPLETE 6-38 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 471
SECTION 6 - JLG CONTROL SYSTEM 6.11 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 472
SECTION 6 - JLG CONTROL SYSTEM 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 473
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 474
SECTION 6 - JLG CONTROL SYSTEM 6.12 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 475
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 476
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 477
SECTION 6 - JLG CONTROL SYSTEM 6.13 CALIBRATING BOOM 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 keys to reach CALIBRATIONS. Hit Enter. 3. Pull out the Emergency Stop switch.
PAGE 478
SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach Boom Valves. The screen will read: 9. Hit Enter. The screen will read: 6-46 10. Hit Enter. The screen will read: 11. If the main lift wiring and hosing is properly installed and not damaged, hit enter.
PAGE 479
SECTION 6 - JLG CONTROL SYSTEM 12. If the tower lift wiring and hosing is properly installed and not damaged, hit enter. The screen will read: 14. The control system will next calibrate the LIFT, TWR LIFT, and TWR TELE valves. This can be confirmed by watching the LED’s on the respective valves as they are being calibrated. When the valves are calibrated, the screen will read: 13. If the tower telescope wiring and hosing is properly installed and not damaged, hit enter.
PAGE 480
SECTION 6 - JLG CONTROL SYSTEM 6.14 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS Platform Leveling Fault Warning There are three possible level valve driver errors, short to battery, short to ground, and open circuit. The JLG Control System takes a snapshot of the two sensor values and records the difference once on each power up. The Control system allows a ±5 degree difference from those values.
PAGE 481
SECTION 6 - JLG CONTROL SYSTEM CAN Errors 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. In both cases above the following will occur: 1. The Electronic Leveling System Fault Lamp will flash (to indicate that there is a leveling fault). 2. The platform alarm will sound. 3. A system fault will be logged. 4.
PAGE 482
SECTION 6 - JLG CONTROL SYSTEM 6.15 CALIBRATING PLATFORM LEVEL 4. The analyzer screen should read: STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 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.
PAGE 483
SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector inside the Ground control box. 10. Using the UP/DOWN arrows, adjust the following personalities to 100%. Basket Rotate Basket Level Jib U/D (if configured) Start up the machine and exercise each above platform function (from the ground) eight (8) to ten (10) times for 5 seconds in each direction. 11. Return the personality settings back to the values as shown in the Personality Ranges/Defaults table in Section 6 - JLG Control System.
PAGE 484
SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and start the engine. 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.
PAGE 485
SECTION 6 - JLG CONTROL SYSTEM 2. Position the Platform/Ground select switch to the Ground position. 5. The analyzer screen should read: 3. Plug the analyzer into the connector inside the Ground control box. 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 9. Use the arrow keys to reach the TILT SENSOR. The screen should read: 4. Pull out the Emergency Stop switch and start the engine.
PAGE 486
SECTION 6 - JLG CONTROL SYSTEM 6.17 BOOM SENSOR CALIBRATION 10. Press ENTER. 11. When prompted, swing turntable 180° to opposite end of chassis. To begin calibration of the boom sensors, the following conditions must be met: 12. Press ENTER.
PAGE 487
SECTION 6 - JLG CONTROL SYSTEM • During calibration if the main boom becomes extended the Control System will abort the calibration sequence and the analyzer will display “CAL FAILED” and “MAIN EXTENDED”. Continue to display “CAL FAILED” and follow the electrical retrieval system sequence for positions of backward stability concern until all transport positions are met or the power is cycled. Refer to Section 4.9, Electrical Retrieval System. Step 1 - Position 1 1.
PAGE 488
SECTION 6 - JLG CONTROL SYSTEM • “CAL STEERING” If there is a fault in the configuration process “CAL FAILED” and “MAIN ANGL1 FAULT” or “MAIN ANGL2 FAULT” will be displayed. The Control System will then record right main boom min angle, left main boom min angle, retracted tower length 1 (upper), retracted tower length 2 (lower) and low cylinder angle. The main boom min angle will be set at –4.2 (ref tower). The low cylinder angle will be set to 1.0. The tower retracted length will be set at 305.4” (775.
PAGE 489
SECTION 6 - JLG CONTROL SYSTEM reading at which the main boom transport angle limit switch is tripped (see position 6 for use of this value). The analyzer will display “CAL FAILED” and “MAIN ANGL FAULT” if the uncalibrated main boom angle sensors read more than 30 (ref tower) before the main boom transport angle limit switch is tripped. Step 3 - Position 3 2.
PAGE 490
SECTION 6 - JLG CONTROL SYSTEM 2. After the pressing the ENTER key , the analyzer will display “CALIBRATING…”on the bottom line and Control System will record left tower angle 3, right tower angle 3, and chassis tilt sensor values. The Control System must see a change in the drive orientation switch or “CAL FAILED” and “DRIVE ORNT SW” will be displayed. If the change in right sensor readings is more than 1.0 from the change in left sensor readings, “CAL FAILED” and “TWR ANGL FAILED” will be displayed.
PAGE 491
SECTION 6 - JLG CONTROL SYSTEM the enable valves on and turn on the Main Control Valve and turn on the Tower Lift PVG valve at a 20% down command and monitor the Main Lift angle for decreasing movement of more than 0.2 deg, Tower Lift angle for decreasing movement of more than 0.2 deg and Tower Telescope length decreasing movement of more than 0.5" (1.27 cm) for 60 seconds.
PAGE 492
SECTION 6 - JLG CONTROL SYSTEM Telescope tower out to max length 3. If the “CHECK BOOM…” test passes the analyzer will display “CALIBRATING…”on the bottom line and record tower extended length 1 (upper) and tower extended length 2 (lower). The tower extended length will be set at 669.4”. The length 1 sensor and the length 2 sensor must be in the proper range or “CAL FAILED” and “TWR LEN1 FAULT” or “TWR LEN2 FAULT” will be displayed.
PAGE 493
SECTION 6 - JLG CONTROL SYSTEM Step 7 - Position 7 1. After completing the previous step, the analyzer will read: The Control System will disable all functions except auto platform level and main lift up. The Control System will energize tower tele out with the main lift up command. The analyzer will display “CAL FAILED” and “TWR NOT OUT” if movement of either tower length sensors is detected. The Control System will disable all functions except auto platform level and tower tele in.
PAGE 494
SECTION 6 - JLG CONTROL SYSTEM Step 8 - Position 8 1. After completing the previous step, the analyzer will read: 2. After pressing the ENTER key , the Control System will verify the measured length of the tower boom matches the expected length of 305.4” +/0.5”, otherwise, the analyzer will display “CAL FAILED” on the top line and “TWR IN TO MIN” on the bottom line each time the ENTER key is pressed and the measured length does not match the expected length.
PAGE 495
SECTION 6 - JLG CONTROL SYSTEM trol System will fail calibration and the analyzer will display “PIN ANGLE FAULT”. Step 9 - Position 9 1. After completing the previous step, the analyzer will read: The Control System will disallow all functions except auto platform level and swing. 2. After pressing the ENTER key , the Control System will verify the measured angle of the tower cylinder matches the target angle of 74.6 +/-0.
PAGE 496
SECTION 6 - JLG CONTROL SYSTEM Step 10 - Position 10 1. After completing the previous step, the analyzer will read: Lift main down to stop 2. After pressing the ENTER key , the analyzer will display “CALIBRATING…”on the bottom line and Control System will calculate load pin cal resultant force 9. The Control System must see a change in the drive orientation switch or “CAL FAILED” and “DRIVE ORNT SW” will be displayed.
PAGE 497
SECTION 6 - JLG CONTROL SYSTEM crack point at which the control system detects movement of the main boom angle sensors (if required). 2. After pressing the ENTER key , the Control System will verify the angle of the main boom matches the target angle of 15.0 +/- 3.
PAGE 498
SECTION 6 - JLG CONTROL SYSTEM 6.18 BOOM CONTROL SYSTEM (BCS) VIOLATION • the turntable is centered between the rear tires • Ground Mode is selected NOTE: The Unlock Boom Calibration procedure must be performed whenever the boom sensor calibration procedure is completed.
PAGE 499
SECTION 6 - JLG CONTROL SYSTEM 2. After the operator presses the ENTER key , the Control System will verify that the BCS is in the Normal state: 3.
PAGE 500
SECTION 6 - JLG CONTROL SYSTEM 5.
PAGE 501
SECTION 6 - JLG CONTROL SYSTEM 6. Once “CHECKING BOOM…” is started, the control system will wait 2 seconds and then capture the position of the Main Boom to Tower, Tower Cylinder Angle and Tower Length. The control system then will command the Main Lift, Tower Lift and Tower Telescope PVG valves to 40%, engage the Main Control and PVG enable valves and command the Engine to 1800 RPM for 20 seconds. The control system will monitor for the Main Lift and Tower Lift angles increasing by more then 0.
PAGE 502
SECTION 6 - JLG CONTROL SYSTEM 7. After the 20 seconds has elapsed the control system will command the engine back to idle, shut off the commands to the PVG valves, disengage the Main Control and PVG enable valves and turn on the Main Lift, Tower Lift and Tower Telescope Enable valves and monitor the Main Lift and Tower Lift angles for decreasing movement of more then 0.2 deg and Tower Telescope length decreasing movement of more then 0.5” for 60 seconds.
PAGE 503
SECTION 6 - JLG CONTROL SYSTEM 8. After the 60 seconds has elapsed the control system will Leave the Enable valves on and turn on the Main Control Valve and turn on the Tower Lift PVG valve at a 20% down command and monitor the Main Lift and Tower Lift angles for decreasing movement of more then 0.2 deg and Tower Telescope length decreasing movement of more then 0.5” for 60 seconds.
PAGE 504
SECTION 6 - JLG CONTROL SYSTEM 9. Once the “CHECKING BOOM…” testing is complete and the test passes the control system will clear the Tower Event log and clear the “BCS VIOLATION – BOOM LOCKED” fault flag. The screen will read: 11. Once the Main boom transport angle switch indicates it is below elevation the Analyzer will display “TWR DWN TO STOP”. 12. Once the Tower Boom is below elevation the Analyzer will display “TEST COMPLETE”. 10.
PAGE 505
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 001 00 1 EVERYTHING OK The normal help message in Platform Mode. 002 00 2 GROUND MODE OK The normal help message in Ground Mode. 0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" while the vehicle is out of transport position.
PAGE 506
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed - 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. 2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with Footswitch open. 2215 22 15 D/S JOY.
PAGE 507
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected before engine start. 237 23 7 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed during power-up. Fault Message Fault Description 250 25 0 <<< FUNCTION PREVENTED >>> 259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE The model selection has EMS been changed.
PAGE 508
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 330 33 0 <<< GROUND OUTPUT DRIVER >>> 331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake Valve. 332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the Brake Valve. 3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the Ground Alarm.
PAGE 509
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the Alternator 3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the Auxiliary Power Pump Relay. 3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the Auxiliary Power Pump Relay. 3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the Auxiliary Power Pump Relay.
PAGE 510
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to - Ground Alarm equipped the Ground Alarm. vehicles only. 3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground - Generator / Welder to the Generator Relay. equipped vehicles only. 3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to - Generator / Welder the Generator Relay.
PAGE 511
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Rotate Right Valve. 3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT 3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Rotate Right Valve.
PAGE 512
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33135 33 135 33136 33 33137 Fault Description Check PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the Platform Control Valve. - Electronic leveling system equipped vehicles only. 136 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground - 1250AJP only. to the Main Lift APU Valve.
PAGE 513
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to - Gravity Lift Down equipped the Lift Down Auxiliary vehicles only. Valve. 33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the Lift Down Auxiliary Valve. 33156 33 156 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground - 1250AJP only. to the Tower Lift APU Valve.
PAGE 514
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Rotate Left Valve. 33177 33 177 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the JIB Rotate Left Valve. 33178 33 178 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Right Valve.
PAGE 515
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 33306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing Left Valve. 33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the Main Telescope Flow Control Valve. 33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the Main Telescope Flow Control Valve.
PAGE 516
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 434 43 4 435 43 437 Fault Description Check 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. 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sensor reading is < 0.1V. - Deutz engine only. 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
PAGE 517
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 454 45 4 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply voltage is high. - 1250AJP only. 455 45 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply voltage is high. - 1250AJP only. 456 45 6 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG - 1250AJP only. Valve supply voltage is high.
PAGE 518
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 4524 45 24 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG - 1250AJP only. Valve command is improper. 4525 45 25 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has timed out. - 1250AJP only. 4526 45 26 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has timed out. - 1250AJP only.
PAGE 519
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 660 66 0 <<< COMMUNICATION >>> 662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost. 666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN communication lost. - ECM equipped engine only. 667 66 7 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communication lost. - 1250AJP only.
PAGE 520
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED 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 521
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence Fault Message 8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 - Electronic leveling system reverence voltage is outequipped vehicles only. side acceptable range (4.9 to 5.1 volts). 8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 - Electronic leveling system reverence voltage is outequipped vehicles only.
PAGE 522
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 communications lost. - Envelope Control equipped vehicles only. 8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 communications lost. - Envelope Control equipped vehicles only. 8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out - Envelope Control equipped of range.
PAGE 523
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8426 84 26 TOWER LENGTH SENSOR #2 - OUT OF RANGE HIGH Tower Boom Angle Sensor - Envelope Control equipped #2 out of range high. vehicles only. -1250 8427 84 27 TOWER LENGTH SENSOR #2 - OUT OF RANGE LOW Tower Boom Angle Sensor - Envelope Control equipped #2 out of range low. vehicles only.
PAGE 524
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8441 84 41 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COM- The Tower Cylinder Angle - Envelope Control equipped MAND Sensor is changing without vehicles only. a tower lift command. -1250 8442 84 42 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is bad. - Envelope Control equipped vehicles only.
PAGE 525
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 8482 84 82 8483 84 8484 Fault Description Check TOWER ENVELOPE MASSIVELY ENCROACHED 8482 TOWER ENVELOPE MASSIVELY ENCROACHED - Tower has exceeded the maximum tower path stop line. 1250 Only 8482 TOWER ENVELOPE MASSIVELY ENCROACHED - Tower has exceeded the maximum tower path stop line.
PAGE 526
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 859 85 9 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT There is a disagreement between the Load Pin and the Tower Lift cylinder Angle. 8510 85 10 LOAD PIN - FORCE VALUES NOT CHANGING The Load Pin is not chang- -1250 ing. 8511 85 11 LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE Load pin force did not change enough for the tower angle movement.
PAGE 527
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 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 528
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 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. 8627 86 27 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not responding to steer commands.
PAGE 529
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 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. 9914 99 14 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software requires an updated. 9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain calibration has been lost.
PAGE 530
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 9928 99 28 ENVELOPE CONTROL DISABLED Envelope Control has been - Envelope Control equipped disabled by the user from vehicles only. Access Level 0. 9929 99 29 MOMENT CONTROL DISABLED Moment Control has been disabled by the user from Access Level 0. - Envelope Control equipped vehicles only. 9930 99 30 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been calibrated.
PAGE 531
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart DTC Flash Code Sequence 9975 99 75 LOAD PIN NOT CALIBRATED The Load Pin has not been -1250 calibrated. 9979 99 79 FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER Temporary fault for the telematics project. The model needs to be a 600S or 1350S if not this fault will be generated and Platform controls will be prevented. This fault was to insure that the software will only work for these two models.
PAGE 532
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Analyzer Diagnostics Menu Menu: Submenu: Selection: Description: DIAGNOSTICS: SYSTEM: 6-100 GM BATTERY (XX.XX) V Displays battery voltage at ground module PM BATTERY (XX.XX) V Displays battery voltage at platform module AMB.
PAGE 533
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Analyzer Diagnostics Menu Menu: Submenu: Selection: Description: SOFT O/R (CL or OP) Displays the OPEN or CLOSED condition of the soft touch over ride switch GENSET/WELDER (CL or OP) Displays the OPEN or CLOSED condition of the GENSET/WELDER switch LIGHTS (CL or OP) Displays the OPEN or CLOSED condition of the LIGHTS switch BSK TILT1 (X.X) Displays the status of basket tilt sensor #1 BSK TILT2 (X.
PAGE 534
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 535
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Analyzer Diagnostics Menu Menu: Submenu: Selection: Description: ENVELOPE SENSORS: 3121171 TWR LEN1 (X.X)" Displays the measured value of tower length sensor #1 TWR LEN2 (X.X)" Displays the measured value of tower length sensor #2 TWR ANGL1 (XX.X) Displays the measured value of tower angle sensor #1 TWR ANGL2 (XX.X) Displays the measured value of tower angle sensor #2 CYL ANGL (XX.
PAGE 536
SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Analyzer Diagnostics Menu Menu: Submenu: Selection: Description: MA1 CAL L (X) Displays the lowest main angle #1 value recorded during calibration MA2 CAL L (X) Displays the lowest main angle #2 value recorded during calibration MA1 CAL H (X) Displays the highest main angle #1 value recorded during calibration MA2 CAL H (X) Displays the highest main angle #2 value recorded during calibration TRIP ANG (X.
PAGE 537
SECTION 6 - JLG CONTROL SYSTEM Table 6-7.
PAGE 538
SECTION 6 - JLG CONTROL SYSTEM Figure 6-17. CANbus Connections Diagram 6.19 CANBUS TROUBLESHOOTING The PLATFORM MODULE and the CHASSIS MODULE have ”Terminator Resistors” located inside the modules, these resistors squelch high speed signal reflections in the CANbus transmission lines. The value of the terminators is determined by wire properties, this includes the type of insulation and geometry, combined to determine the perfect value for bus termination.
PAGE 539
SECTION 6 - JLG CONTROL SYSTEM B A PLATFORM MODULE CANbus Link C Figure 6-18.
PAGE 540
SECTION 6 - JLG CONTROL SYSTEM Remove Ground Module J7 plug and measure the A & B pin of the T fitting. This should measure approximately 60 Ohms for a complete CANbus Circuit. Boom Length & Angle Module CANbus Link Ground Module J7 (Black) plug Platform Module J7 (Black) plug Figure 6-19.
PAGE 541
SECTION 6 - JLG CONTROL SYSTEM "BEFORE" Slip Ring Connection "AFTER" Slip Ring Connection Figure 6-20.
PAGE 542
SECTION 6 - JLG CONTROL SYSTEM Chassis Module J1 (Gray) Plug Chassis Module CANbus Link Figure 6-21.
PAGE 543
Figure 6-22.
PAGE 544
SECTION 6 - JLG CONTROL SYSTEM CANbus Communication Failure 4. The analyzer screen should read: If a problem in the CANbus system is suspected, use the following step-by-step procedure to verify which part of the CANbus communication system has failed. CANBUS LINK FROM THE PLATFORM MODULE LOST 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 5. Press enter twice to reach Logged Help. The screen will read: 3.
PAGE 545
SECTION 6 - JLG CONTROL SYSTEM 7. If the CANbus link from the platform module is lost, you will see the Ground Module SW version, Ground Module HW version, Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version or the Platform Module HW version. The Analyzer screen will read: 8. Hit the right arrow button once.
PAGE 546
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED SPEC YES NO 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
PAGE 547
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED 9 Disconnect the Chassis Module deutsche plug at the ”T’ fitting below the Boom Length & Angle Module. Perform an ohms check at the ”A” and ”B” sockets of the deutsche plug. Inspect the shield wire ”C” for shorts.
PAGE 548
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE GROUND MODULE LOST 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. Press enter twice to reach Logged Help. The screen will read: 3. Pull out the Emergency Stop switch. 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter.
PAGE 549
SECTION 6 - JLG CONTROL SYSTEM 7. If the CANbus link from the ground module is lost, you will see the Ground Module SW version, Ground Module HW version, Ground Module SN, BM SW version, Chassis SW version, Platform Module SN, but you will not see the Platform Module SW version or the Platform Module HW version. The Analyzer screen will read: 3121171 – JLG Lift – 8. Hit the right arrow button once.
PAGE 550
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE BOOM LENGTH & ANGLE MODULE (BLAM) LOST 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. Press enter twice to reach Logged Help. The screen will read: 3. Pull out the Emergency Stop switch. 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter.
PAGE 551
SECTION 6 - JLG CONTROL SYSTEM 7. If the CANbus link from the Boom Length & Angle Module is lost, you will see the Platform Module SW version, Platform Module HW Rev, Platform Module SN, Ground Module SW version, Ground Module HW Revision, Ground Module SN, Chassis SW version, but you will not see the Boom Length & Angle Module SW revision.
PAGE 552
SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Troubleshooting: BLAM Can Communications Lost STEP ACTION REQUIRED SPEC YES NO 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
PAGE 553
SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE CHASSIS MODULE LOST 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. Press enter twice to reach Logged Help. The screen will read: 3. Pull out the Emergency Stop switch. 6. Hit ESC to get back to the HELP screen and then use the arrow button to reach VERSIONS. Hit Enter.
PAGE 554
SECTION 6 - JLG CONTROL SYSTEM 7. If the CANbus link from the Chassis Module is lost, you will NOT see the Platform Module SW version, Platform Module HW rev, Platform Module SN, Chassis SW version, Boom Length & Angle Module SW version, but you WILL see the Ground Module SW version, Ground Module HW rev, and the Ground Module SN. The analyzer screen will read: 9. Hit the right arrow button once. The screen will read: 10. Hit the right arrow button once. The screen will read: 8.
PAGE 555
SECTION 6 - JLG CONTROL SYSTEM 11. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS LOST NOTE: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault Code 6-6) basically means all communication linked from the Ground Module to the Chassis Module is lost.
PAGE 556
SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Troubleshooting: Chassis Can Communications Lost STEP ACTION REQUIRED SPEC YES NO 1 Install the Analyzer at the ground station, scroll to the ”Diagnostics” sub level menu, press ”enter” then scroll to the ”Versions” menu item press ”enter” and view the screen, reference the Diagnostics / Version Chart to assist you in determining which module has lost it’s communication link.
PAGE 557
SECTION 6 - JLG CONTROL SYSTEM Load Moment Pin Troubleshooting necessary, refer to Section 4 for information concerning replacement of the Load Moment Pin. The following Troubleshooting Charts outline diagnostic measures to be taken to diagnose problems within the Load Moment Pin portion of the JLG Control System. If Table 6-11.
PAGE 558
SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range STEP FAULT CODE/SYMPTOM REPAIR YES NO Check to see if the platform is overloaded in the vertical position. Check the rated capacity requirement. Remove excess weight Go to step 2 2 Check to see if any additional accessories have been added to the platform without proper calibration. Perform the Boom Sensor calibration process.
PAGE 559
SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range STEP FAULT CODE/SYMPTOM REPAIR YES NO Check to see if the platform is overloaded in the vertical position. Check the rated capacity requirement. Remove excess weight Go to step 2 2 Check to see if any additional accessories have been added to the platform without proper calibration. Perform the Boom Sensor calibration process.
PAGE 560
SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-128 – JLG Lift – 3121171
PAGE 561
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL 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. 7.
PAGE 562
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 563
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement • 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. This procedure applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with external seals. 1.
PAGE 564
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet.
PAGE 565
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
PAGE 566
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. 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 567
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11.
PAGE 568
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 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4.
PAGE 569
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A B C C Figure 7-14. HD/HDP Contact Installation Figure 7-16. 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 570
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18.
PAGE 571
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 0274670 D Figure 7-19.
PAGE 572
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20.
PAGE 573
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 0274670 D Figure 7-21.
PAGE 574
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22.
PAGE 575
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 0274670 D Figure 7-23.
PAGE 576
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 0274670 D Figure 7-24.
PAGE 577
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally.
PAGE 578
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-25.
PAGE 579
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26.
PAGE 580
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27.
PAGE 581
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 1001119861 B Figure 7-28.
PAGE 582
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-29.
PAGE 583
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 2 Figure 7-30.
PAGE 584
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-31.
PAGE 585
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 3 Figure 7-32.
PAGE 586
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 Figure 7-33.
PAGE 587
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 4 Figure 7-34.
PAGE 588
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 Figure 7-35.
PAGE 589
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 5 Figure 7-36.
PAGE 590
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 6 Figure 7-37.
PAGE 591
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 6 Figure 7-38.
PAGE 592
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 7 Figure 7-39.
PAGE 593
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001119861 B SHEET 7 Figure 7-40.
PAGE 594
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 8 Figure 7-41.
PAGE 595
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 8 1001119861 B Figure 7-42.
PAGE 596
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-43.
PAGE 597
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110761 C Figure 7-44.
PAGE 598
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-45.
PAGE 599
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110761 C Figure 7-46.
PAGE 600
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-47.
PAGE 601
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110761 C Figure 7-48.
PAGE 602
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-49.
PAGE 603
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110761 C Figure 7-50.
PAGE 604
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-44 – JLG Lift – 3121171
PAGE 605
PAGE 606
3121171 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.