Service and Maintenance Manual Model 24RS P/N - 3121287 September 12, 2013
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION REVISON LOG Original Issue A-2 - September 12, 2013 – JLG Lift – 3121287
TABLE OF CONTENTS SECTION NO. SECTION A B C SECTION 1.1 1.2 1.1 SECTION 2.1 2.2 2.3 2.4 2.5 2.6 3121287 TITLE PAGE NO. A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 ii TITLE PAGE NO. 3 - CHASSIS & TURNTABLE Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 SECTION 5.1 5.2 5.3 5.4 5.5 3121287 TITLE PAGE NO. 4 - BOOM & PLATFORM Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. SECTION 6.1 6.2 6.3 6.4 SECTION 7.1 7.2 7.3 iv TITLE PAGE NO. 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 analyzer Menu Structure. . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 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. 4-1. 4-2. 3121287 TITLE PAGE NO. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 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. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 5-43. 5-44. vi TITLE PAGE NO. Powertrack Hosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 5-45. 5-46. 5-47. 5-48. 5-49. 5-50. 5-51. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 3121287 TITLE PAGE NO. Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Pads . . . . .
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 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 4-1 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 6-1 6-2 6-3 6-4 6-5 6-6 viii TITLE PAGE NO. Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Capacities Operating Specifications Table 1-3. Capacities Table 1-1. Operating Specifications Capacity: Unrestricted: ANSI ANSI Export Maximum Travel Grade, stowed Position (Gradeability) Maximum Travel Grade, stowed Position (Side Slope) Hydraulic Oil Tank (to Full Level) 500 lbs. (227 kg) 500 lbs. (227 kg) Elevated Drive Speed 0.75 mph (1.2 kph) System Voltage *Drive hubs should be one half full of lubricant.
SECTION 1 - SPECIFICATIONS Tires Hydraulic Oil Table 1-6. Hydraulic Oil Table 1-4. Tires Size Hydraulic System Operating Temperature Range 39 x 15-22.5 Maximum Tire Load 13,100 lbs. (5942 kg) Type Foam Filled Engine Data Table 1-5. Deutz D2011 Type Number of Cylinders Liquid Cooled 3.7in. (94 mm) Stroke 4.4 in. (112 mm) Total Displacement 189.6 cu. in. (3.1 L) Compression Ratio 19.
SECTION 1 - SPECIFICATIONS Major Component Weights 1.2 FUNCTION SPEEDS Notes: DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance. 2. Stop watch should be started with the function movement, not with actuation of the joystick or switch. 3.
SECTION 1 - SPECIFICATIONS Table 1-8. Machine Orientation When Performing Speed Test Drive; (Max Speed) 1-4 Test should be done on a smooth, level surface. Start approximately 7.6m (25 ft) from starting point so the unit is at a maximum speed when starting the test. Results should be recorded for a 61m (200ft) course. Drive forward, "High Speed", record time Drive Reverse, "High Speed", record time Drive; (Max Torque) (Above Horizontal) Test should be done on a smooth, level surface.
SECTION 1 - SPECIFICATIONS Table 1-9. Function Speeds Adjustment Default Function Ranges Setting Table 1-9.
SECTION 1 - SPECIFICATIONS Figure 1-1.
SECTION 1 - SPECIFICATIONS 1.1 2. Swing Gearbox OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-10. Lubrication Specifications. KEY SPECIFICATIONS BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. HO FILL Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424. DRAIN EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L-2105.
SECTION 1 - SPECIFICATIONS 4. Hydraulic Tank Return Filter and Breather 6. Wheel Drive Hub FILL PORT OIL SHOULD BE TO THIS HEIGHT 15° Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - For breather element, remove wing nut and cover to replace. Under certain conditions, it may be necessary to replace both elements on a more frequent basis. Lube Point(s) - Level/Fill Plug Capacity - 20.5 oz. (0.
SECTION 1 - SPECIFICATIONS Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. 8. Fuel Filter/Water Separator 11. Main Valve Filter Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 9. Air Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. 12. Optional Fuel Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 10.
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.
SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
SECTION 2 - GENERAL SECTION 2. GENERAL these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures. 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE Annual Machine Inspection General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operation and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL 2. Component Disassembly and Reassembly When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
SECTION 2 - GENERAL 2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage.
SECTION 2 - GENERAL 4. Cylinder Drift 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 0.0030 0.08 b.
SECTION 2 - GENERAL NOTE: Reference the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. Table 2-3.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL 1001151189-A Figure 2-1. Hydraulic Oil Operation Chart 1001151190-A Figure 2-2.
SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121287
SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows: 3.1 TIRES AND WHEELS Tire Replacement JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model.
SECTION 3 - CHASSIS & TURNTABLE 3.2 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) indicates to the operator conditions that could make the direction of movement of the chassis different than the direction of movement of the drive/ steer control handle in the platform. The system indicates to the operator the need to match the black and white directional arrows on the platform control panel to the arrows on the chassis.
SECTION 3 - CHASSIS & TURNTABLE 3.4 STEER CYLINDER Installation Removal 1. Place the machine on a firm, level surface. 2. Place a container under the frame to catch hydraulic oil. 3. Tag and disconnect the hydraulic lines from the steer cylinder. 4. Remove the bolts, keeper pins, and retaining pins securing the tie rod links to the steer cylinder rod ends. 5. Remove the bolts securing the steer cylinder to the frame and remove the steer cylinder from the machine. 1.
SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE HUB 4. Remove the bolts securing the drive motor to the hub and carefully pull the motor away from the drive hub, taking care not to kink or put stress on the hydraulic hoses. 5. Place a container under the drive brake to catch hydraulic oil. 6. Tag and disconnect the hydraulic lines running to the drive brake. Removal 1. Place the machine on a firm, level surface. 2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
SECTION 3 - CHASSIS & TURNTABLE Installation 1. Position the hub onto the axle or spindle. 2. Coat the retaining bolts with JLG Threadlocker P/N 0100019 and secure the hub in place with the bolts. Torque the bolts to 190 ft.lbs. (260 Nm). 3. Connect the hydraulic lines running to the drive brake as tagged during Removal. 4. Align the splines of the drive motor shaft with the splines in the drive brake and secure in place with the retaining bolts. Torque the bolts to 37 ft.lbs. (51 Nm). 5.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-7.
SECTION 3 - CHASSIS & TURNTABLE 9. Remove cardan shaft from the splines of output shaft. Cleaning Wash all parts (except seals) in a weak solvent on carbon base and then degreased. Measuring And Replacement Measure all parts and compare their actual dimensions with the nominal ones given in the technical documentation. Replace any parts with scratches or burrs that could cause leakage or damage with new ones. Use new seals and washers when reassembling the motor.
SECTION 3 - CHASSIS & TURNTABLE 9. Lubricate the roll-gerotor set surface and place on it the channel plate. 10. Lubricate and install 2 psc. Balls in channel plate ball grooves. 11. Align mark on valve drive with a hole in the outer rim of the Valve Plate. Turn Valve Plate clockwise (as shown below) until splines in the two parts engage /rotation about 15°/. Plate counter clockwise (as shown below) until splines in the two parts engage.
SECTION 3 - CHASSIS & TURNTABLE 4. Place the balance plate (set) inside the end cover with the pin orientated to fall in with the hole of its bottom. Use a plastic hammer. 2. Connect the hydraulic lines to the drive motor as tagged during removal. Torque the fittings to 60 ft.lbs. (82 Nm). Lubricate spacer and install in the balance plate hole.
SECTION 3 - CHASSIS & TURNTABLE 7. 3.7 SWING DRIVE HUB Remove the O-ring (99) between the motor control valve (32) and motor (31). Discard O-ring. Disassembly MOTOR DISASSEMBLY See Figure 3-8. 1. Place the unit on a work bench with the motor end up. 2. Remove the two magnetic pipe plugs (1P) and drain the oil out of the gearbox. NOTE: Record the condition and volume of the oil. 3. Remove hydraulic tubing assembly (35) by loosening fittings on both ends of tube with a wrench. 4.
SECTION 3 - CHASSIS & TURNTABLE 1P Pipe Plug 6 Brake Housing 21 Bolts 22 Lock Washer 23 O-ring/pipe Plug 30 31 32 35 99 Elbow Motor Counter Balance Valve Hydraulic Tube Assembly O-rings Figure 3-9.
SECTION 3 - CHASSIS & TURNTABLE INPUT BRAKE DISASSEMBLY 6 Brake Housing 8A Brake Piston 8D O-ring 8E O-ring/back Up Ring 8F O-ring 8H O-ring/back Up Ring 8J Brake Rotor 8K Brake Stator 8L Spring 8M Pressure Plate 8N Internal Retaining Ring Figure 3-10. Input Brake Disassembly 1. Insert and tighten the 0.250-20 UNC socket head capscrews through the pressure plate (8M) and into the brake piston (8A) to compress the springs and relieve pressure on the retaining ring (8N). 5. Remove the 0.
SECTION 3 - CHASSIS & TURNTABLE MAIN DISASSEMBLY 1A Output Shaft 1G Housing 1P Pipe Plug 2 Internal Gear 4 Ring Gear 5 O-ring 5A O-ring 6 Brake Housing 8 Sun Gear 11 Thrust Washer 12 Bolts 13 Dowel Pin 44 Internal Retaining Ring Figure 3-11. Main Disassembly 9. SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS. 10. 1. Remove the sun gear (8) with retaining ring (44) inside. 2. With the unit resting on the output shaft (pinion) (1A), remove the bolts (12) from the brake housing (6). 3.
SECTION 3 - CHASSIS & TURNTABLE HOUSING-SHAFT DISASSEMBLY 1A Output Shaft 1B Lip Seal 1C Tapered Bearing Cup 1D Tapered Bearing Cone 1E Tapered Bearing Cup 1F Tapered Bearing Cone 1G Housing 1H Tanged Washer 1I Lock Tanged-washer 1J Bearing Nut 1K Retaining Ring Figure 3-12. Housing Shaft Disassembly 1. Set the unit on a work bench so the housing (1G) flange is down. Remove the retaining ring (1K) from the output shaft (1A). 3. Bend the tang on the lock tanged-washer (1I) out of the locknut (1J).
SECTION 3 - CHASSIS & TURNTABLE CARRIER DISASSEMBLY 3A 3B 3C 3D Carrier Tanged Washer Bearing Needle Thrust Spacer 3E Planet Shafts 3F Cluster Gear 3G Roll Pin Figure 3-13. Carrier Disassembly 1. Drive the planet shaft (3E) out of the carrier pin holes forcing the roll pin (3G) to sheer off. 4. Using a hammer and punch, drive the pieces of the roll pin (3G) out of the planet shaft (3E) and carrier (3A). 2. Hold on to the planet gear (3F) and push the planet shaft (3E) out of the carrier (3A).
SECTION 3 - CHASSIS & TURNTABLE Tightening and Torquing Bolts Assembly If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure the bolts are not tightened beyond their specified torque. The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle. CARRIER SUBASSEMBLY 1. Apply a liberal coat of grease to the bore of the cluster gear (3F). This will enable the needle rollers (3C) to be held in place during assembly. 2.
SECTION 3 - CHASSIS & TURNTABLE 3A 3B 3C 3D Carrier Tanged Washer Bearing Needle Thrust Spacer 3E Planet Shafts 3F Cluster Gear 3G Roll Pin Figure 3-14.
SECTION 3 - CHASSIS & TURNTABLE HOUSING-SHAFT SUBASSEMBLY 1A Output Shaft 1B Lip Seal 1C Tapered Bearing Cup 1D Tapered Bearing Cone 1E Tapered Bearing Cup 1F Tapered Bearing Cone 1G Housing 1H Tanged Washer 1I Lock Tanged-washer 1J Bearing Nut 1K Retaining Ring Figure 3-15. Housing Shaft Subassembly NOTE: Spray a light film of oil on all component parts during assembly. Spray a generous amount of oil on bearings during installation. 1.
SECTION 3 - CHASSIS & TURNTABLE 9. Press on the small end of the bearing cone (1D), being careful not to contact the bearing cage, until the bearing cone (1D) seats on the shoulder of the output shaft (1A). Use Tool T145741. 16. Ensure there is end play on the hub-output shaft. 17. Roll the housing (1G) in each direction to insure bearing are seated and then measure housing initial rolling torque using rolling torque adapter tool. 10. Place the bearing cone (1F) onto the output shaft (1A). 18. 11.
SECTION 3 - CHASSIS & TURNTABLE MAIN ASSEMBLY 1A Output Shaft 1G Housing 1P Pipe Plug 2 Internal Gear 4 Ring Gear 6 Brake Housing 8 Sun Gear 5 O-ring 5A O-ring 11 12 13 44 Thrust Washer Bolts Dowel Pin Internal Retaining Ring Figure 3-16. Main Assembly 1. Slightly tap the internal gear (2) with the spline side down onto the output shaft (1A) splines to ensure the internal gear (2) is properly seated. 2. Grease and install the o-ring (5) onto the housing (1G) oring groove. 3.
SECTION 3 - CHASSIS & TURNTABLE 5. Place ring gear (4) in to large end of cluster gear to secure timing. 11. Pull one cover bolt (12) and place into the bolt hole and repeat for the remaining bolts. 6. Remove carrier sub-assembly and ring gear (4) from the table and assemble into the Internal gear (2) being careful to keep the ring gear, or sun gear, in mesh with the cluster gears. 12. Torque the bolts (12) in a star pattern 23-27 ft-lbs (2.5-3 Nm). 13.
SECTION 3 - CHASSIS & TURNTABLE INPUT BRAKE ASSEMBLY 6 Brake Housing 8A Brake Piston 8D O-ring 8E O-ring/back Up Ring 8F O-ring 8H O-ring/back Up Ring 8J Brake Rotor 8K Brake Stator 8L Spring 8M Pressure Plate 8N Internal Retaining Ring Figure 3-18. Input Brake Assembly 1. Starting with a stator (8K), alternately stack and install stators (8K) into lobes or splines of the brake housing (6) and rotors (8J) (internal splines) onto splines of the sun gear (8). 4.
SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to the illustration below for installing o-rings (8D), (8F) and backup rings (8E), (8H). 6. 12. Lightly grease cylinder walls of the brake housing (6) and install the brake piston (8A) into the brake housing (6). If necessary, place T-134711 on top of the brake and lightly tap until the brake piston (8A) contacts the brake disk stack. 7. Insert 8 Springs (8L) into the brake piston (8A) spring holes. 8.
SECTION 3 - CHASSIS & TURNTABLE 1P Pipe Plug 6 Brake Housing 21 Bolts 22 Lock Washer 23 O-ring/pipe Plug 30 31 32 35 99 Elbow Motor Counter Balance Valve Hydraulic Tube Assembly O-rings Figure 3-20. Motor Control Valve 17. 18. Install the motor control valve (32) onto the motor (31) using bolts (21) and washers (22). Torque the bolts 18-20 ft-lbs. Ensure the holes in the motor control valve (32) are aligned with holes in the motor (31). Install the elbow fitting (30) into the brake housing (6).
SECTION 3 - CHASSIS & TURNTABLE Figure 3-21. Swing Drive Assembly and increase the pressure until the brake releases. The brake is released when you are able to rotate the tool. Brake Test Before performing the Brake Test, remove the motor, tubing and elbow as per Motor disassembly instructions. To perform a brake check, install a hydraulic hand pump with pressure gauge into brake port in Brake Housing using a 7/16-20 threaded fitting. Place the Roll Test Tool (Figure 3-22.) into the sun gear (8).
SECTION 3 - CHASSIS & TURNTABLE Brake Chart, check to see if it has the proper number of springs using the Spring Checking Procedure. Increase to maximum pressure (refer to Table 3-3, Swing Brake Chart) and hold at that pressure for one minute. If the brake does not leak or lose pressure, the unit has passed the brake test. If the brake loses pressure, attempt to repair the leak using the leak repair procedure at end of this procedure. springs.
SECTION 3 - CHASSIS & TURNTABLE BREAK LEAK REPAIR PROCEDURE Install two flat socket head capscrews 0.250-20 UNC, ½" length into holes in brake piston evenly. tighten bolts in steps evenly to ensure that the pressure plate (8M) does not get wedged into brake cylinder. Carefully remove retaining ring from brake housing. Remove the brake piston from brake housing. Check o-rings, backup rings, and brake cavity in brake housing for damage.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-23. Bearing Cone Press Tool -T144566 Figure 3-24.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-25.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-26.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-27. Bearing Cup Pressing Tool - T155291 Figure 3-28.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-29.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-30. Swing Drive Test Plate Tool - T187845 spot. Refer to Figure 3-36., Swing Bearing Installation. 3.8 PROCEDURE FOR SETTING SWING GEAR BACKLASH 1. Set backlash 0.254 to 0.381 mm (0.10 to 0.15 in.) using the following procedure. 2. Place the shim (JLG P/N 1001140563) between the swing drive pinion and the swing bearing on the high Swing Drive not shown for clarity. NOTE: The high spot will be marked with yellow paint.
SECTION 3 - CHASSIS & TURNTABLE 3. Apply JLG threadlocker P/N 0100019 to the pivot bolt and torque to 280 Nm (206.5 lbs.ft.). 6. Tighten the jack bolt until the pinion is snug against the shim and bearing and then loosen the jack bolt. 4. If engaged, remove the turntable lock pin. 7. Torque the jack bolt to 68 Nm (50 ft.lbs.). 5. Apply JLG threadlocker P/N 0100019 to the other swing drive mounting bolts and torque to 40 Nm (30 ft.lbs.).
SECTION 3 - CHASSIS & TURNTABLE 8. Apply JLG threadlocker P/N 0100019 to the threads where the jam nut will be and tighten the jam nut. 10. Torque the M20 bolts on the right side of the swing drive to 550 Nm (405 ft.lbs.). 9. Torque the M16 bolts on the left of the swing drive to 280 Nm (206.5 lbs.ft.). 11. Remove the shim and discard. 3.9 SWING BEARING Wear Tolerance 1. From the underside of the machine, with the main boom positioned as shown in Figure 3-32.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-31.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-32.
Figure 3-33.
SECTION 3 - CHASSIS & TURNTABLE 5. Turntable/Swing Bearing Removal 1. Place the machine on a firm, level surface. 2. Set the swing lock. 3. Remove the front hood assemblies. Attach a magnet or other lifting device to support the weight of the hoods and remove the bolts that secure them to the turntable. Remove the bolts securing the swing drive to the turntable. Attach an adequate lifting device to the swing drive and remove it from the machine.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-34.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-35.
SECTION 3 - CHASSIS & TURNTABLE 9. Attach chains or slings to the lifting lugs to support the weight of the turntable. 10. Remove the bearing bolts securing the turntable to the bearing. 11. Lift the turntable off of the chassis. 12. Place the turntable assembly on adequate blocking. 13. Remove the outer race bearing bolts from the underside of the frame. 14. Install lifting eyes into the swing bearing for removal. NOTE: The swing bearing weighs approximately 132 lbs. (60 kg). 15.
SECTION 3 - CHASSIS & TURNTABLE 280 Nm (206.5 lbs.ft.) in the pattern shown in Figure 337., Swing Bearing Torque Sequence. Installation 1. Install lifting eyes into the swing bearing for installation. NOTE: The swing bearing weighs approximately 132 lbs. (60 kg). 2. Attach an adequate lifting device to the swing bearing and place it onto the mounting holes on the frame. Refer to Figure 3-36., Swing Bearing Installation for proper bearing alignment. 3. Apply JLG Threadlocker Part No.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-36.
SECTION 3 - CHASSIS & TURNTABLE 10. Connect the hoses to the drive pump as tagged during removal. Swing Bearing Torque Values 1. Outer Race - 280 Nm (206.5 ft.lbs.) w/JLG Threadlocker P/N 0100019. 2. Inner Race - 280 Nm (206.5 ft.lbs.) w/JLG Threadlocker P/ N 0100019. 3. See Swing Bearing Torquing Sequence. CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS THEREAFTER. 11. Install the swing drive and adjust the backlash.
SECTION 3 - CHASSIS & TURNTABLE NOTE: The Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-37. Swing Bearing Torque Sequence 3.10 CHASSIS TILT INDICATOR SYSTEM The Chassis Tilt Indicator System measures the relationship of turntable angle as compared to level ground. The system uses a tilt sensor to measure this. The tilt sensor is an integral part of the ground module and has two settings; 5.0° (depending on market) and 6.0° degrees.
SECTION 3 - CHASSIS & TURNTABLE 3.11 COLD START SYSTEM 3.12 ENGINE OPERATING STATES The JLG Control System monitors the engine coolant and ambient temperature to determine cylinder preheating requirements. If the coolant temperature is below 65° C when control power is turned on, the glow plugs will be automatically activated for a period of time based on the ambient temperature up to a maximum of 20 seconds. During this preheat period, the glow plug indicators on the control consoles will flash.
SECTION 3 - CHASSIS & TURNTABLE 3.13 ENGINE START CONDITIONS 3.14 ENGINE RPM LEVELS Engine starting is controlled by the Ground Module. The Ground Module will allow the starter to be engaged and keep the starter energized if all of the following conditions are satisfied. 1. NOTE: The RPM levels are set in the Analyzer Personalities menu. Table 3-4. Engine RPM Levels The Start Switch is selected. a. Ground Mode is active with Ground Module input J4-4 energized or b.
SECTION 3 - CHASSIS & TURNTABLE Mid Engine RPM 3.15 ENGINE CONTROLS Mid Engine RPM occurs when all of the following conditions exist; 1. The Engine State is Engine Running. 2. The operator is not shutting down the engine. 3. The control system is not commanding a higher engine RPM (Multi-function or High Engine). 4. The control system is not calling for Generator RPM. 5.
SECTION 3 - CHASSIS & TURNTABLE Glow Plugs Ambient Air Temperature Sensor The diesel engine has glow plugs, controlled by the ground module to assist in cold starting. The Ground Module calculates the length of time the glow plugs are energized prior to startup based upon ambient temperature, engine coolant temperature, and battery voltage. Refer to Table 3-5, Glow Plug Conditions. The ambient air temperature sensor is integrated within the Ground Module.
SECTION 3 - CHASSIS & TURNTABLE b. Disconnect the supply line coming from the hydraulic tank. 2. Coat the mounting bolts with Loctite #242 and use the bolts and washers to attach the auxiliary pump to the turntable. Torque the bolts to 40 ft.lbs. (55 Nm). 3. Connect the hydraulic lines to the motor as tagged during removal. a. Torque the hydraulic line running to the main control valve to 13 ft.lbs. (18 Nm). 3.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-40.
Figure 3-41.
Figure 3-42.
Figure 3-43.
Figure 3-44.
SECTION 3 - CHASSIS & TURNTABLE 3.17 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-45., Counterweight Bolt Torque. NOTE: The left counterweight weighs approximately 937.6 ± 30.8 lbs. (425.3 ± 14 kg) and the right counterweight weighs approximately 937.2 ± 30.8 lbs. (425.1 ±14 kg). Actual weight is stamped on the counterweight. Figure 3-45.
SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-62 – JLG Lift – 3121287
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM CONTROL ENABLE SYSTEM Extend Function The platform controls use a time dependent enable circuit to limit the time availability of “live” or enabled controls. When the footswitch is depressed, the controls are enabled and the operator has 7 seconds to operate any control. The controls will remain enabled as long as the operator continues to use any function and will remain enabled 7 seconds after the last function has been used.
SECTION 4 - BOOM & PLATFORM 4.7 EMERGENCY DESCENT SYSTEM 2. Pull the telescope cylinder rod out and turn the trunnion plate at the end of the rod 90 degrees so it will clear the attachment fittings on the boom base section. 3. Remove the bolts, washers, wear pads, and shims from the front of the boom base section. 4. Remove the upper rear wear pads from the boom fly section. 5. Pull the boom fly section and telescope cylinder from the boom base section as an assembly. 6.
SECTION 4 - BOOM & PLATFORM 7. 8. 9. Remove the snap rings and pin that secure the telescope cylinder to the boom fly section. Assembly 1. If removed, install the wear pads to the telescope cylinder wear pad mounts. Apply JLG Threadlocker P/N 0100011 to the bolts and torque to 40.5 ft.lbs. (55 Nm) with the exception of the side pads on the lower telescope cylinder wear pad mount which are torqued to 20.5 ft.lbs. (28 Nm). 2. Install the rear lower wear pads onto the boom fly section.
SECTION 4 - BOOM & PLATFORM 5. Position the telescope cylinder into the boom fly section. Secure the barrel end in place with the retaining pin and snap rings. 6. Install the upper telescope cylinder supports in the boom fly section. Apply JLG Threadlocker P/N 0100011 to the bolts and torque to 40.5 ft.lbs. (55 Nm). 7. Install the upper wear pad mount onto the telescope cylinder. Apply JLG Threadlocker P/N 0100011 to the bolts and torque to 40.5 ft.lbs. (55 Nm). 8.
SECTION 4 - BOOM & PLATFORM 4.10 LOWER BOOM 6. Remove the pin securing the lift cylinder to the upright. Remove the lift cylinder. 7. Remove the rear upper pin that secures the lower boom section to the upright. Lift the lower boom section slightly and place a block under the lower boom section for support. Remove the pin securing the timing link to the boom upright and remove the timing link. 8. Remove the pin securing the lower boom section to the upright. Remove the lower boom section.
SECTION 4 - BOOM & PLATFORM Assembly 4. Install the timing link and secure in place with the attaching hardware. 5. Rest the timing link against the upright and the lower boom against the tension link. NOTE: Note: Make sure the upright is supported at all times by an adequate lifting device. 1. 2. Use a block to allow the upright to sit level during the assembly process. Refer to Figure 4-1., Block to Set the Upright On. Set the upright on the block.
SECTION 4 - BOOM & PLATFORM 8. Attach an adequate lifting device to the lower boom assembly and install it in the turntable. 9. Secure the lower boom to the turntable with the attaching hardware. 22±0 150±0 BLOCK TO SET THE UPRIGHT ON Figure 4-1.
SECTION 4 - BOOM & PLATFORM Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
SECTION 4 - BOOM & PLATFORM Figure 4-6. Boom Proximity Sensor 2. 4.11 TELESCOPE CYLINDER Drive the pivot pin out. It may be necessary to toggle the basket level switch to get the pin loose. Removal 1. 4-12 Remove the bolt and keeper pin that secure the upper master cylinder pivot pin (barrel end) to the main boom.
SECTION 4 - BOOM & PLATFORM Figure 4-7.
SECTION 4 - BOOM & PLATFORM 3. 4. 5. 4-14 Remove the bolt and keeper pin that secure the lower master cylinder pivot pin (rod end) to the upright. 6. Telescope out enough for the telescope cylinder attachment ears clear the attachment fittings on the boom base section. Reinstall the attachment blocks and telescope in to gain access to the wear pad mount bracket. 7. Remove the bolts securing the upper wear pad mount bracket to the telescope cylinder and remove the mount bracket. 8.
SECTION 4 - BOOM & PLATFORM 9. Remove the bolts securing the telescope cylinder upper supports and remove the supports. 11. Remove the snap ring from the pin at the barrel end of the cylinder and drive the pin out. 10. Tag and disconnect the hydraulic hoses from the telescope cylinder. Cap or plug all openings. 12. Attach an adequate lifting strap to the rear of the telescope cylinder and pull the cylinder out of the boom, adjusting the strap as necessary to balance the weight of the cylinder.
SECTION 4 - BOOM & PLATFORM Installation 1. 2. 4-16 3. Install the upper telescope cylinder supports. 4. Install the hoses on the telescope cylinder as tagged during removal. Operate the retract function to bring the cylinder rod into place. Install the attach blocks and shims to secure the cylinder rod in place. Insert the cylinder into the boom. Install the snap ring on the retaining pin for the barrel end of the telescope cylinder.
SECTION 4 - BOOM & PLATFORM 5. Install the wear pad mount bracket on the top of the of the telescope cylinder. 6. Install the wear pad mount on the bottom of the telescope cylinder. Activate the telescope function to gain room to install the bracket. Place the bracket into the boom and then assemble the wear pad to the bracket inside the boom. Flip the assembly up into place and attach to the cylinder rod. secure the pivot pin in place with the keeper pin and retaining bolt. Torque the bolt to 40 ft.
SECTION 4 - BOOM & PLATFORM Figure 4-8., Hose Adjustment - Figure 1 below). 4. Adjust the pull lengths at position “A” (See Figure 4-9., Hose Adjustment - Figure 2). With the pull lengths set, tighten the hose clamp at position “A” until hoses are tight and unable to be moved. Figure 4-8. Hose Adjustment - Figure 1 3. Pull the hoses and cables through the push tube in the same order as the carrier tube and power track. Figure 4-9. Hose Adjustment - Figure 2 5.
SECTION 4 - BOOM & PLATFORM tighten the hose clamp at position “B” until hoses are tight and unable to be moved. Figure 4-10. Hose Adjustment - Figure 3 6. Pull excess loop of hydraulic hose through a window between the links in the power track at location “C” (Figure 4-11., Hose Adjustment - Figure 4). Ensure there is an excess loop at location “D”. (See Figure 4-12., Hose Adjustment - Figure 4) Figure 4-11.
SECTION 4 - BOOM & PLATFORM Figure 4-12. Hose Adjustment - Figure 4 7. Attach all hydraulic hoses and cables and start up the machine. Raise the boom a minimum of 5 degrees above horizontal (See Figure 4-13., Hose Adjustment Figure 5). Figure 4-13. Hose Adjustment - Figure 5 8. d. Rotate the platform completely in the opposite direction After each step below, hold the function switch for an additional 5 sec. This will ensure the component has reached full stroke and pressurized the hose. e.
SECTION 4 - BOOM & PLATFORM power track. Adjust the loop of hoses between the power track and carrier tube (See Figure 4-13., Hose Adjustment - Figure 5) so that the minimum distance between the carrier tube and hoses match the dimension shown below. 11. Tighten hose clamp at location “D” (Figure 4-11., Hose Adjustment - Figure 4) until hoses are tight and unable to be moved.
SECTION 4 - BOOM & PLATFORM Figure 4-14.
SECTION 4 - BOOM & PLATFORM 4.13 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. When the footswitch is depressed, the controls are enabled and the operator has 7 seconds to operate any control. The controls will remain enabled as long as the operator continues to use any function and will remain enabled 7 seconds after the last function has been used.
SECTION 4 - BOOM & PLATFORM NOTES: 4-24 – JLG Lift – 3121287
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated. 3. Turn the o-ring on the other side of the fitting and repeat the previous step, ensuring the entire o-ring is coated with hydraulic oil.
SECTION 5 - HYDRAULICS Dip Method Spray Method NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. This method requires a pump or trigger spray bottle. The following is needed to correctly oil the o-ring in this manner: 1. Fill the spray bottle with hydraulic oil. 2. Hold the fitting over a suitable catch can. 3. Spray the entire o-ring surface with a medium coat of oil.
SECTION 5 - HYDRAULICS ASSEMBLY 5.2 HYDRAULIC CYLINDERS Platform Slave Level Cylinder DISASSEMBLY 1. Remove the lockwire. 1. Install seals on the components. 2. Install the head and piston onto the rod. 3. Screw the locknut onto the rod. 4. Install the rod into the barrel. 5. Install the lockwire to retain the head. Figure 5-1. Slave Level Head Assembly 2. Remove the cylinder rod (with piston, head, and locknut) from the barrel. 3. Unscrew the locknut from rod. Figure 5-2.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Piston Head Lock Wire 6. 7. 8. 9. 10. Locknut Bearing Rod Seal Piston Seal Wiper 11. 12. 13. 14. 15. Wear Ring Wear Ring O-ring O-ring O-ring 16. Backup Ring 17. Cartridge Valve 18. Cartridge Valve Figure 5-3.
SECTION 5 - HYDRAULICS ASSEMBLY Master Cylinder DISASSEMBLY 1. Remove the lockwire. 1. Install seals on the components. 2. Install the gland and piston to the rod. 3. Screw the locknut on the rod. 4. Install the rod weldment to the tube weldment. 5. Install the lockwire to retain the gland. Figure 5-4. Master Cylinder Head Assembly 2. Remove the rod (with piston, head, and locknut) from the tube weldment. 3. Unscrew the locknut from rod weldment. Figure 5-5.
SECTION 5 - HYDRAULICS 1001132375-C 1. 2. 3. 4. 5. Rod Wiper Seal Rod Seal O-ring Backup Ring 6. 7. 8. 9. 10. Gland Tube Weldment Piston Piston Seal Wear Ring 11. 12. 13. 14. 15. Locknut Bearing O-ring Wear Ring Lock Wire Figure 5-6.
SECTION 5 - HYDRAULICS ASSEMBLY Steer Cylinder DISASSEMBLY 1. Unscrew the heads from both ends. 1. Install seals on the components. 2. Screw the piston on the rod. 3. Put the steel ball in the thread hole, and screw the hexagon socket set screw . 4. Torque the piston and rod together, then install them to the tube weldment.. 5. Install the glands on both ends. Figure 5-7. Steer Cylinder Head Assembly 2. Remove the piston rod from the tube weldment. 3.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Rod Head Wiper Seal Retaining Ring 5. 6. 7. 8. Rod Seal Wear Ring O-ring Backup Ring 9. 10. 11. 12. Piston Wear Ring Setscrew Ball 13. 14. 15. 16. Piston Seal O-ring Barrel Bearing Figure 5-9.
SECTION 5 - HYDRAULICS ASSEMBLY Lift Cylinder DISASSEMBLY 1. Unscrew the head from the barrel. 1. Install seals on the components. 2. Install the head, stop collar, and piston on the rod. 3. Screw the hex nut on the rod, put the steel ball in the thread hole, and screw in the setscrew. 4. Install the rod to the barrel. 5. Torque the head. Figure 5-10. Lift Cylinder Head Assembly 2. Remove the cylinder rod (with piston, gland and hex nut) from the barrel. 3.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Nut Setscrew Ball Piston Wear Ring 6. 7. 8. 9. 10. Piston Seal O-ring Spacer Rod Barrel 11. 12. 13. 14. 15. Head Backup Ring O-ring Cushion Ring Wear Ring 16. 17. 18. 19. 20. Rod Seal Wiper O-ring O-ring Retaining Ring 21. Cartridge Valve 22. Cartridge Valve 23. Not Used 24. Cartridge Valve 25. Not Used 26. Bushing Figure 5-12.
SECTION 5 - HYDRAULICS Telescope Cylinder 5. Pull the rod cover from the rod assembly. 6. Remove the seals from the pistons. 7. Remove the seals from the rod cover. DISASSEMBLY 1. 2. Remove the valve assembly. Unscrew the 1st rod cover and pull the 1st and 2nd rod assembly from the cylinder barrel. 3. Unscrew the 2nd rod cover and pull the 2nd rod assembly from the 1st rod assembly. 4. Unscrew the setscrew and piston from the rod assembly. 3121287 ASSEMBLY – JLG Lift – 1.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod #1 Rod#2 Head #1 Wiper 6. 7. 8. 9. 10. Rod Seal Backup Ring Wear Ring O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Head #2 Wiper Rod Seal Backup Ring 16. 17. 18. 19. 20. Wear Ring O-ring Backup Ring O-ring Piston #1 21. 22. 23. 24. 25. Piston Seal Wear Ring O-ring Piston #2 Piston Seal 26. 27. 28. 29. 30. Wear Ring O-ring O-ring Backup Ring Piston #2 31. Valve 32. Bolt 33. Lockwasher Figure 5-13.
SECTION 5 - HYDRAULICS Torque 50-55 lb.ft. (68-75 Nm) Torque 8-12 lb.ft. (11-16 Nm) Torque 8-12 lb.ft. (11-16 Nm) Torque 4-4.5 lb.ft. (5-6 Nm) Torque 4-4.5 lb.ft. (5-6 Nm) Torque 8-12 lb.ft. (11-16 Nm) Torque to 16 lb.ft. (22 Nm) Torque 4-4.5 lb.ft. (5-6 Nm) Torque 75-80 lb.ft. (102-108 Nm) 1. 2. 3. 4. 5. Torque 8-12 lb.ft. (11-16 Nm) Valve Block Assembly Counterbalance Valve Counterbalance Valve Shuttle Valve O-ring 6. 7. 8. 9. 10. 3/8 Plug 1/4 Plug Roll Pin Bolt Lockwasher Figure 5-14.
SECTION 5 - HYDRAULICS Figure 5-15.
SECTION 5 - HYDRAULICS Figure 5-16.
SECTION 5 - HYDRAULICS Figure 5-17.
SECTION 5 - HYDRAULICS Figure 5-18.
SECTION 5 - HYDRAULICS Figure 5-19.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Breather Assembly Wing Nut Cover Fitler Filter Element Return Filter Assembly Bolt Washer Cover Gasket Spacer Spring Filter Element Fill Cap Level Sight Window Main Valve Filter Inner Baffle Drain Plug Figure 5-20.
SECTION 5 - HYDRAULICS Figure 5-21.
SECTION 5 - HYDRAULICS Torque 25 lb.ft. (34 Nm) Torque 98- 102 lb.ft. (133-138 Nm) Torque 18- 23.5 lb.ft. (24-32 Nm) Torque 20 lb.ft. (27 Nm) 4W/2W VALVE Torque 20 lb.ft. (27 Nm) BRAKE VALVE Torque 25 lb.ft. (34 Nm) Torque 50 lb.ft. (67 Nm) Torque 4- 5 lb.ft. (5.5-6.5 Nm) 8.8 Ω Torque 4- 5 lb.ft. (5.5-6.5 Nm) 8.8 Ω Torque 98- 102 lb.ft. (133-138 Nm) Torque 35 lb.ft. (47.5 Nm) Torque 98- 102 lb.ft. (133-138 Nm) Torque 35 lb.ft. (47.5 Nm) Figure 5-22.
SECTION 5 - HYDRAULICS Figure 5-23.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Breather Assembly Wing Nut Cover Fitler Filter Element Return Filter Assembly Bolt Washer Cover Gasket Spacer Spring Filter Element Fill Cap Level Sight Window Main Valve Filter Inner Baffle Drain Plug Figure 5-24.
SECTION 5 - HYDRAULICS Finger Tight Torque to 8 lb.ft. (11 Nm) Figure 5-25.
SECTION 5 - HYDRAULICS MAIN VALVE FILTER CHARGE FILTER Figure 5-26.
Figure 5-27.
Figure 5-28.
Figure 5-29.
Figure 5-30.
Figure 5-31.
SECTION 5 - HYDRAULICS 5.3 SAUER DANFOSS PUMP 9. When the gauge begins to register charge pressure, enable and start engine. Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at all line connections and listen for cavitation. Check for proper fluid level in reservoir. 10.
SECTION 5 - HYDRAULICS Troubleshooting Table 5-1. Electrical Troubleshooting Item Description Action Control operates pump in one direction only. Control coil failure Measure resistance at coil pins. Resistance should be 14.20 Ω (24V) or 3.66 Ω (12V) at 20°C [70°F]. Replace coil. No pump function No power to controller Restore power to controller. Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, reconnect wires.
SECTION 5 - HYDRAULICS Table 5-3. Transmission Operates Normally in One Direction Only Item Description Action Open bypass valves. Open bypass causes one or both directions to be inopera- Close/repair bypass function. tive. Input to pump control. Input to control module is operating improperly. Check control input and repair or replace as necessary. Control orifices Control orifice(s) are blocked. Clean control orifices. Control screens Control screen(s) are blocked.
SECTION 5 - HYDRAULICS Table 5-5. System Noise or Vibration Item Description Action Reservoir oil level Low oil level leads to cavitation. Fill reservoir. Aeration of the oil/pump inlet vacuum Air in system decreases efficiency of units and controls. Air in system is indicated by excessive noise in pump, foaming in oil, and hot oil. Find location where air is entering into the system and repair. Check that inlet line is not restricted and is proper size.
SECTION 5 - HYDRAULICS General Adjustment Practices Charge Pressure Relief Valve Adjustment This section offers instruction on inspection and adjustment of pump components. Read through the entire topic before beginning a service activity. Refer to Pressure measurements, for location of gauge ports and suggested gauge size. Refer to Figure 5-32., Charge Pressure Adjustment. 1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3.
SECTION 5 - HYDRAULICS Figure 5-32. Charge Pressure Adjustment NOTE: If you change pressure limiter settings, you must also change the HPRV valve to maintain proper PL function. Pressure Limiter Adjustments Lock motor output shaft to adjust the pressure limiter setting. Lock the vehicle’s brakes or rigidly fix the work function so it cannot rotate. NOTE: Ensure charge pressure is properly set before checking pressure limiter. 1.
SECTION 5 - HYDRAULICS Figure 5-34. Pressure Limiter Valve Adjustment Table 5-9. Pressure Limiter Settings 2. Start the prime mover and operate at normal speed. 3. Use a 17mm wrench to loosen the locking nut (L024). 4. Activate the control input until pressure in the high side of the system loop stops rising. This pressure is the PL setting. 430 NOTE: The model code on the serial plate gives the factory setting of the PL (Pressure Limiter). The PL setting is referenced to charge pressure.
SECTION 5 - HYDRAULICS 1. Engaging the Bypass Function Loosen the locking nut. Use this procedure to bypass the pump to allow moving the vehicle/machine short distances when you cannot start the prime mover. 1. 1. To open the HPRVs (L150), rotate three revolutions counter clockwise using a 22mm hex wrench. Do not rotate more than 3 revolutions, leakage will result. Figure 5-35. Engaging the Bypass Function Figure 5-36. Displacement Limiter Adjustment 2.
SECTION 5 - HYDRAULICS Control Neutral Adjustment NOTE: Adjustment of the EDC is very sensitive. Be sure to hold the hex wrench steady while loosening the locknut. Total adjustment is less than 120 degrees. All functions of the Electric Displacement Control (EDC) are preset at the factory. Adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to replace the control or coils.
SECTION 5 - HYDRAULICS NOTE: A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is usually not possible. Mechanical Neutral Adjustment SERVO ADJUSTMENT Figure 5-38. Neutral Adjustment (Bottom View) 5-40 – JLG Lift – 1. Run prime mover at 1800 min¯¹(rpm). 2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges. Ensure the differential between M4 and M5 is less than 1.5 bar [22 psi]. 3.
SECTION 5 - HYDRAULICS 7. Remove all gauges and replace gauge port plugs. Figure 5-39. Servo Adjustment SERVO ADJUSTMENT SIDE M4 pressure differential is 3 bar [43 psi]. The system pressure differential must be below 1.5 bar [22 psi]. Repeat test on solenoid C2 side. 1. Run prime mover at 1800 rpm. 2. If using a PWM signal to set mechanical neutral, start with the electronic control testing tool off (no current to either solenoid). Check to be sure the servo pressure differential is less than 1.
SECTION 5 - HYDRAULICS electrical connections when using straps or chains to support the pump. INSPECTION 1. Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component. 2. Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the control module when installing control. INSPECTION 1.
SECTION 5 - HYDRAULICS Control Solenoids Figure 5-41. Control Module Removal/Installation REMOVAL 1. Disconnect electrical connection and remove the three cap screws (D050) using a 4 mm internal hex wrench. 2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring. 3. If necessary, remove the coil using a 12 point 26 mm socket. 3. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 N•m [3.7 lbf•ft]. 4.
SECTION 5 - HYDRAULICS Shaft Seal, Roller Bearing and Shaft Replacement the work surface so the shaft is pointing to the side. The shaft assembly is serviceable without disassembling the pump. Orient the pump on Figure 5-42. Shaft Assembly REMOVAL 1. Unwind the spiral ring (J300) from the housing to release the shaft/seal/bearing subassembly. 2. Pry on the lip of the seal carrier (J275) to dislodge it from the pump. Remove the seal carrier. Remove and discard O-ring (J260).
SECTION 5 - HYDRAULICS Charge Pump If the pump has an auxiliary pump attached, remove the auxiliary pump and connecting shaft before removing the auxiliary pad. REMOVAL 1. Position pump so end cover or auxiliary pad is on top. 2. If necessary, remove auxiliary pump (not shown), or shipping cover (K300) and pad seal (K250) as shown on following page. 3. Remove end cover/auxiliary pad screws (K400) using a 8 mm internal hex wrench. NOTE: Ensure proper torque on aux pad screws (K400).
SECTION 5 - HYDRAULICS 6. Install the thrust washer (K500). Coated side goes toward charge pump coupling (K200). 7. Install a new cover gasket. (K150). If removed, install guide pins (K450). 8. Install the auxiliary pad or charge pump cover and cap screws. Using a 8mm internal hex wrench, torque the cap screws (K400) to 92 N•m [68 lbf•ft]. Torque in sequence below. Table 5-11.
SECTION 5 - HYDRAULICS Charge Pressure Relief Valve Pressure Limiter Valve Replacement Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to repair the internal components of the valve. Torque to 52 N•m [38 lbf•ft] See Charge pressure relief valve adjustment, page 30, for adjustment instructions. Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual components. See Pressure limiter adjustment, page 31, for adjustment instructions.
SECTION 5 - HYDRAULICS Table 5-12. Fastener Size and Torque Chart Item Fastener Wrench Size Torque D015 Neutral adjust screw 4 mm internal hex NA D050 Coil mounting bolt 4 mm internal hex 8 N•m [9 lbf•ft] D060 Neutral adjust locking nut 13 mm 10 N•m [7 lbf•ft] D250 Electric control mounting bolt 5 mm internal hex 13 N•m [10 lbf•ft] E350 Servo cylinder locking bolt 11 mm 14.5 N•m [11 lbf•ft] K350 A pad Shipping cover mounting bolt 17 mm 8.7 N•m [6.
SECTION 5 - HYDRAULICS Figure 5-50.
SECTION 5 - HYDRAULICS Figure 5-51.
SECTION 5 - HYDRAULICS 4. 5.4 HYDRAULIC DRIVE PUMP PRE-FILL PROCEDURE The case of the hydraulic drive pump, MUST be pre-filled before starting the engine. Failure to do so can cause premature failure of the pump. 1. Fill the hydraulic reservoir. 2. Determine if the hydraulic oil tank sight level gauge is higher than other hydraulic components. a. Locate a case access port on the hydraulic drive pump. Preferably one located at or near the top or upper sides of the pump. b.
SECTION 5 - HYDRAULICS 4. 5. 5-52 P2 MAIN RELIEF VALVE. Pressure gauge at the MP2 port. Locate the Platform level up relief valve located on the top of the manifold, right above port 4. Loosen the jam nut and screw the adjustment clockwise, until it bottoms out. You may need to keep loosening the jam nut until the adjustment is bottomed out. Locate the P2 Main relief valve next to the MP2 port. Adjust counter clockwise 3 full turns. Activate level up to the end of stroke and hold.
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM The JLG designed Control System is a 12 volt based motor control unit installed on the boom lift. 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Introduction The JLG Control System provides simplicity in viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep and max.-speed for all boom, drive, and steering functions.
SECTION 6 - JLG CONTROL SYSTEM The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubleshooting. Optional equipment includes a beacon light, function cutout, and ground alarm. These options may be added later but some must be programmed into the controller when installed.
SECTION 6 - JLG CONTROL SYSTEM 6.3 USING THE HAND HELD ANALYZER Using the Analyzer With the machine power on and the analyzer connected properly, the analyzer will display the following: To Connect the JLG Control System Analyzer 1. Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer.
SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: The top level menus are as follows: HELP DIAGNOSTICS SYSTEM TEST OPERATOR ACCESS PERSONALITIES MACHINE SETUP CALIBRATIONS (Service Access only) SYSTEM DATALOG VERSIONS ENGINE OPER CONTROLS If you press ENTER, at the HELP: PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen.
SECTION 6 - JLG CONTROL SYSTEM Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit of the password, 3. 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.
SECTION 6 - JLG CONTROL SYSTEM There are two settings that JLG strongly recommends that you do not change.
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION ABBREVIATION MEANING MEANING ACCELERATE GND ACTIVE GRN GREEN A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE AMB.
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION ROT. MEANING ROTATE RT RIGHT S/C SHORT CIRCUIT SEL SELECTOR SN SERIAL NUMBER SPD SPEED STOW STOWED STOWD SW STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ.
3121287 LOG: (xxx) x: xxxxxxxxxxx HELP: EVERYTHING OK MENU: HELP: PRESS ENTER MENU: DIAGNOSTICS ACCESS LEVEL: CODE XXXXX SYSTEM TEST: ACTIVATE ? MENU: PERSONALITIES Figure 6-2.
6-10 – JLG Lift – DRIVE MID ENGINE CREEP 850mA DRIVE MAX TORQUE CREEP 725mA DRIVE ME ELEV MAX 900mA DRIVE MT ELEV MAX 790mA DRIVE MID ENGINE MAX 1135mA DRIVE MAX TORQUE MAX 1100mA STEER CREEP RIGHT 50% STEER CREEP LEFT 50% DRIVE ME/MT ACCEL 300mA/s DRIVE ME/MT MIN 640mA STEER MAX LEFT 80% DRIVE MAX SPEED MAX 1500mA STEER MAX RIGHT 80% STEER MIN LEFT 35% DRIVE MAX SPEED MIN 640mA DRIVE TO STOP DECEL 1075 mA/s STEER DECEL 0.
3121287 NO MODEL 340AJ MODEL MENU: MACHINE SETUP GLOW PLUGS – JLG Lift – NO YES NO YES METRIC IMPERIAL LOAD SYSTEM DISABLED ENABLED NO BOOM CUTOUT DRIVE CUTOUT DRIVE CUT E&T TILT 5 DEGREES 4 DEGREES 3 DEGREES 4 DEGREES + CUT 3 DEGREES + CUT NO DRIVE DESCENT MOTION GROUND ALARM ONE RESTART ENGINE STOP FUEL CUTOUT FUNCTION CUTOUT ENGINE SHUTDOWN NO WARN ONLY CUTOUT PLATFORM CUTOUT ALL SPECIAL 1 DISABLED ENABLED START LOCKOUT Figure 6-4.
6-12 – JLG Lift – DRV ORIENT STATE CONFIRM / REQUIRED DRV ORIENT TT SW OPEN-INLINE/ CLOSED-DOS DRIVE MODE MAX SPEED/MAX TORQUE /MID ENGINE TRACTION LOCK OUTPUT ON /OFF BRAKES STATUS LOCKED/ RELEASED STEER OUTPUT LEFT/RIGHT XXX % STEER DEMAND LEFT/RIGHT XXX % DRIVE FDBK mA XXXXmA DRIVE OUT mA FORWARD / REVERSE XXXXmA DRIVE OUTPUT FORWARD / REVERSE XXX % DRIVE DEMAND FORWARD / REVERSE XXX % DRIVE/STEER CRIBBING MODE DISABLED /ENABLED CRIBBING MODE SW CLOSED/OPEN DRV ORNT OVR SW CLOSED/OPEN TE
3121287 * * – JLG Lift – GENSET /WELDER SW OPEN/CLOSED H&T LIGHTS SW OPEN/CLOSED FUEL SELECT SW OPEN/CLOSED HORN SW OPEN/CLOSED CREEP SW OPEN/CLOSED MAX TORQUE SW OPEN/CLOSED MAX SPEED SW OPEN/CLOSED PLAT ROT RGHT SW OPEN/CLOSED PLAT ROT LEFT SW OPEN/CLOSED PLAT LEVEL DN SW OPEN/CLOSED PLAT LEVEL UP SW OPEN/CLOSED JIB LIFT DN SW OPEN/CLOSED JIB LIFT UP SW OPEN/CLOSED TELE OUT SW OPEN/CLOSED * From Sheet 1 PLATFORM LOAD CELL4: XXX.XKG 2 PLATFORM LOAD CELL3: XXX.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-7.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-8.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-9.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-10.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-11.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-12.
SECTION 6 - JLG CONTROL SYSTEM 6.4 SYSTEM FAULT MESSAGES The Help Message display on the JLG Analyzer provides diagnostic feedback to explain vehicle operation and interlocks.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programing Information Configuration Label/Digit Number Description Default Number The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programing Information Description Default Number Configuration Label/Digit Number FUEL CUTOUT: 8* 1 ONE RESTART: One restart with limited run time when near Empty. 2 ENGINE STOP: No starting permitted when near Empty.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programing Information Configuration Label/Digit Number Description H & T LIGHTS: 15* 1 NO: No head and tail lights installed. 2 YES: Head and tail lights installed. 1 NO: No broken cable switch installed. 2 YES: Broken cable switch installed. 1 NO: No load sensor installed. 2 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programing Information Configuration Label/Digit Number Description Default Number * Certain market selections will alter default setting. LEVELING MODE: 22* 1 ALL FUNCTIONS: Platform level with all functions. 2 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only. 1 NO: ClearSky (telematics) options is disabled. 2 YES: ClearSky (telematics) option is enabled. 1 NO: Cribbing Option is disabled.
SECTION 6 - JLG CONTROL SYSTEM 3 Ground Alarm Japan 3 CSA 3 24RS ANSI Export Japan 3 Table 6-3. Machine Configuration Programming Settings ANSI USA CSA Model Number ANSI Export 24RS ANSI USA Table 6-3.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC EVERYTHING OK or GROUND MODE OK 0011 The platform station (EVERYTHING OK) or ground station (GROUND MODE OK) is selected and the system detects no problems exist. No response required.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC Control System Response or Machine Condition L/S JOY. CENTER TAP BAD 2220 The Platform Module detects that the Lift/Swing center tap voltage is out of range Disable Lift and Swing in Platform Mode.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC Control System Response or Machine Condition FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED 2251 The machine is in Platform mode and the telescope switch is sending a continual telescope in signal. Machine enters Creep Mode and Tele In and Out prohibited.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message DTC FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH 236 Condition Producing DTC The Ground Module detects one of the following conditions: Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Engine start is disabled Release all function switches.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC FUNCTION PROBLEM - LIFT UP PERMANENTLY SELECTED 23107 The machine is in Ground mode and the Lift switch is selected and trying to activate the Lift Up function at startup. Lift Up and Down prohibited. With the machine controls not enabled, return the Lift switch to neutral.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMANENTLY SELECTED 23113 The machine is in Ground mode and the Platform Rotate switch is selected and trying to activate the Platform Rotate Left function at startup. Platform Rotate Right and Left prohibited.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC FUNCTIONS LOCKED OUT – CONSTANT DATA VERSION IMPROPER 2520 The Ground Module detects a mismatch between programmed sections of the processor memory. Disable all machine and engine functions (i.e., command engine shutdown and do not permit start).
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC MAIN DUMP VALVE – OPEN CIRCUIT 3359 The Ground Module detects an open circuit at the Main Dump Valve output. No response required. Check for a good connection at the solenoid and for continuity through this circuit.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC STEER DUMP VALVE – SHORT TO BATTERY 3367 The Ground Module detects a short to battery at the Steer Dump Valve output. Ground Module Steer Dump, Steer, and Flow Control outputs are disabled; Steer, Tele In/Out, Level Up/Down, and Rotate Left/Right functions are disallowed.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC Control System Response or Machine Condition PLATFORM LEVEL UP VALVE – OPEN CIRCUIT 3383 The Ground Module detects an open circuit at the Platform Level Up Valve output. Platform Level speed is limited to Creep.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC Control System Response or Machine Condition SWING LEFT VALVE – SHORT TO GROUND 33122 The Ground Module detects a short to ground at the Swing Left Valve output. Ground Module Swing Left and Right outputs are disabled. Inspect wiring for physical damage and check for wire continuity.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC Control System Response or Machine Condition GLOWPLUG – SHORT TO BATTERY 33280 The Ground Module detects a short to battery at the Glow Plug output. (Kubota) Ground Module Glow Plug relay output is disabled. Inspect wiring for physical damage and check for wire continuity.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message DTC Condition Producing DTC Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DRIVE FORWARD VALVE – OPEN CIRCUIT 33317 The Ground Module detects an open circuit at the Drive Forward Valve output.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC LIFT UP VALVE – SHORT TO GROUND 33406 The Ground Module detects a short to ground at the Lift Up Valve output. Lift Up is disabled; Lift Down speed is limited to Creep Inspect wiring for physical damage and check for wire continuity.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC SWING – CURRENT FEEDBACK READING LOST 33418 Measured feedback current is less than 225mA while Ground Module output is greater than 40% (Displayed on Analyzer DIAGNOSTICS menu).
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message DTC Condition Producing DTC Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault PLATFORM ROTATE LEFT VALVE – SHORT TO GROUND 3411 The Platform Module detects a short to ground at the Platform Rotate Left Valve output and reports it to the Ground Module. Platform Rotate Right and Left outputs are disabled.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC JIB LIFT DOWN VALVE – SHORT TO BATTERY 3419 The Platform Module detects a short to battery at the Jib Lift Down Valve output and reports it to the Ground Module. Jib Lift Up and Down outputs are disabled. Check for a good connection at the solenoid and for continuity through this circuit.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Condition Producing DTC Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC ENGINE TROUBLE CODE 437 The engine controller reports a J1939 fault Engine will operate at 1800RPM until power cycle. Cycle power to clear the fault.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC FUEL ACTUATOR – OPEN CIRCUIT 4327 The Ground Module detects an open circuit at the fuel actuator output. (Kubota) The Ground Module controls revert to Open Loop and restrict machine speeds to Creep.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Help Message Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault DTC Condition Producing DTC LSS BATTERY VOLTAGE TOO LOW 444 The machine is configured with and Load Sensing System and the Ground Module detects that the LSS reports supply voltage less than 9.0 volts.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC CANBUS FAILURE – EXCESSIVE CANBUS ERRORS 6613 More than 22 error frames per second for 4 seconds or more than 500 Buss Off conditions since last power cycle. No functions are inhibited. Cycle power to clear the fault.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC DRIVE & BOOM PREVENTED – PLATFORM OVERLOADED 827 The Platform is Overloaded and Machine Setup LOAD SYSTEM = CUTOUT PLATFORM, Platform Mode is active, and conditions of Table 6-6, Overload Variations apply.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Troubleshooting Information Control System Response or Machine Condition Corrective Action/ Operational Requirement for Function Movement and/or to Clear Fault Help Message DTC Condition Producing DTC LSS INTERNAL ERROR – DRDY MISSING FROM A/D 994 The Ground Module detects an LSS report of an anomaly that exists in the LSS A/D converter operations. The Ground Module sets the Platform Load State to Overloaded Cycle power to clear the fault.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-58 – JLG Lift – 3121287
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL Polarity This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
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.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connections: • Main Boom Rotary sensor connections (on Celesco Sensor), • LSS Modules connections, • Deutz EMR 2 ECM connection.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only. NOTE: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal more difficult. Deutsch HD, DT, DTM, DRC Series The Deutsch connector system is commonly used for harsh environment interconnect. Follow the installation instructions.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Exclusions A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application. Dielectric grease may not be required in properly sealed enclosures. BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact material to resist corrosion and an o-ring seal for moisture integrity.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AMP JUNIOR TIMER MIL-C-5015 SPEC CONNECTORS This type of connector uses back-seals for moisture integrity. However, the low-force contacts cannot displace dielectric grease and create electrical contact. It is possible to use solvents (i.e. contact cleaner or mineral spirits) for the removal of improperly applied dielectric grease. The EMR2 engine control module from Deutz employs this connector system (for example).
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO28-J8 CO28-J7 CO28-J12 CO28-J1 CO28-J4 CO28-J2 CO28-J3 MS72 MS54 RL50 MS52 MS51 Figure 7-7.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV40 HV41 HV37 HV35 HV34 HV43 HV42 HV39 HV38 HV36 HV30 HV53 HV33 HV32 HV53 X124B X29A X124A Figure 7-8.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X103A X103B HV106 HV105 Figure 7-9.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW126-1A SW126-1B LB64 LB65 LB66 SW126-2B SW126-2A LB62 EMERGENCY STOP SW56 LB61 SW57 SW55 SW58 SW60 SW59 GD67 SW69-B1 SW69-B SEE DETAIL I SW69-1 SW69-3 SW69-2 DETAIL I Figure 7-10.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CONNECT TO LIFT DN AS SHOWN X125A X124B X124A X29A X128A CONNECT TO BEACON HARNESS AS SHOWN CONNECT TO BOOM CABLE AS SHOWN Figure 7-11.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS RL80-86 RL80-85 RL79-87 RL79-86 RL79-85 RL116-85 RL116-86 X87 X88 BT81+ X100A X101A X84 X83 DETAIL H SEE DETAIL H Figure 7-13.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-14.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-15.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001129238-B Figure 7-16.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-17.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001129238-B Figure 7-18.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001129238-B Figure 7-20.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001129238-B Figure 7-22.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-23.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001129238-B Figure 7-24.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-25.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001131498-A Figure 7-26.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-28 – JLG Lift – 3121287
3121287 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65813058 JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG Latino Americana Ltda. Rua Eng.
