Service Manual Models 266, 307 & 266 LoPro 3126024 Revised February 04, 2008 An Oshkosh Truck Corporation Company
EFFECTIVITY PAGE June 10, 2005 - A - Original Issue Of Manual September 23, 2005 - B - Revision of Manual November 4, 2005 - C - Revised Manual to add 266 LoPro February 3, 2006 - D - Revised Manual September 29, 2006 - E - Revised Axle Mounting Torque, ”Accident Prevention Tags”, “Tire Removal/Installation” and Tire specifications. Added Controller procedure in Section 9. February 4, 2008 - F - Revised pages 6.5 & 8.4. Added Non-Return Fuel Valve information to pages 7.6, 7.8 & 7.10.
EFFECTIVITY PAGE -b 266, 307, 266 LoPro
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator & Safety Manual . . . . . . . . .
Section Subject Page Section 6 Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.2 6.3 6.4 6.5 6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.6 1.7 266, 307, 266 LoPro TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability. Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.
Safety Practices 1.5 SAFETY INFORMATION To avoid possible death or injury, carefully read, understand and comply with all safety messages. In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety. 1.
Safety Practices 1.6.3 General Hazards SOLVENTS: Only use approved solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.). FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 266, 307, 266 LoPro TITLE PAGE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2.2.2 ASTM Fastener Torque Chart (Metric) . . . . .
General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate is located as indicated in the figure. MAH0310 IMPORTANT: The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the machine, and will void the warranty.
266, 307, 266 LoPro 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 40 48 32 40 32 36 24 32 20 28 1.5000 1.3750 1.2500 1.1250 1.0000 0.8750 0.7500 0.6250 0.5625 0.5000 0.4375 0.3750 0.3125 0.2500 0.1900 0.1640 0.1380 0.1120 IN BOLT DIA. 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 0.00604 0.00661 0.00909 0.01015 0.01400 0.
2.4 TENSILE STRESS AREA SQ. IN. SQ. IN. BOLT DIA. IN IN LB. LB. CLAMP LOAD N, m DRY OR LOCTITE 263 N, m N, m N, m LUB N, m N, m LOCTITE 262 TORQUE Note: These torque values do not apply to cadmium plated fasteners. SIZE THDS. PER INCH N, m LOCTITE 242 OR 271 N, m LB. LB.
General Information and Specifications 2.2.3 Metric Fastener Torque Chart VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY CLASS 8.8 METRIC BOLTS & CLASS 8 METRIC NUTS SIZE PITCH CLASS 10.9 METRIC BOLTS & CLASS 10 METRIC NUTS TORQUE TENSILE STRESS AREA CLAMP LOAD sq. mm TORQUE DRY OR LOCTITE 263 LUB LOCTITE 262 LOCTITE 242 OR 271 KN N, m N, m N, m N, m CLAMP LOAD DRY OR LOCTITE 263 LUB LOCTITE 262 LOCTITE 242 OR 271 KN N, m N, m N, m N, m 3 .5 5.03 2.19 1.3 1.0 1.
General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speeds 266 & 266 LoPro 307 First Gear 10 kmph (6 mph) 7 kmph (4 mph) Second Gear 34 kmph (21 mph) 33 kmph (20 mph) 2.3.2 Hydraulic Cylinder Performance Specifications Note: Machine with no load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating temperature. Function Approximate Times (sec.) 266 & 266 LoPro 307 Boom Extend 5.66 7.09 Boom Retract 4.51 5.59 Boom Lift 5.87 8.
General Information and Specifications 2.3.4 Engine Performance Specifications Description 266, 307 & 266 Lopro Engine Make/Model Deutz BF 4M 2012 Low Idle 925 ±50 rpm High Idle 2370 ±50 rpm Horsepower 100.4 BHP/ 74.9 kW @ 2200 rpm Fuel Delivery Fuel Injection Air Cleaner 2.3.5 Dry Type, Replaceable Primary and Safety Elements Tires Description Tire Air Pressure (Minimum) 405/70-20 3,5 bar (51 psi) 405/70-24 (266 & 307 only) 4 bar (58 psi) 17-5-24 (307 only) 2,2 bar (32 psi) 12.
General Information and Specifications 2.4 FLUIDS, LUBRICANTS AND CAPACITIES Engine Crankcase Oil Capacity w/Filter Change 9,0 liters (9.6 quarts) Filter Capacity 1,0 liter (1.05 quarts) Oil Type 15W-40 CE Fuel Filters Primary Fuel Filter Capacity Fuel Filter Capacity Approx. 1,0 liter (1.05 quarts) 0,6 liters (0.16 quarts) Fuel Tank Capacity Type of Fuel 266 & 266 LoPro- 95 liters (25 gallons) 307 - 102 liters (27 gallons) U.S.A.
General Information and Specifications 2.5 MAINTENANCE SCHEDULES 2.5.1 2.5.
General Information and Specifications 2.6 LUBRICATION SCHEDULES 2.6.1 8 Hour Lubrication Schedule EVERY 8 MYSTIK TETRIMOLY (NLGI 2 GC-LB) MAH0820 2.
General Information and Specifications 2.6.2 50 Hour Lubrication Schedule EVERY 50 MYSTIK TETRIMOLY (NLGI 2 GC-LB) MAH0830 266, 307, 266 LoPro 2.
General Information and Specifications This Page Intentionally Left Blank 2.
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 266, 307, 266 LoPro TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.
Boom 3.2 3.2.1 BOOM SYSTEM - TWO SECTION BOOM Boom System Description The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick, tilt cylinder, extend/retract cylinder, lift/lower cylinder, compensating cylinder, electronic sensors, various pivots, supporting hardware and other components. 3.3 BOOM ASSEMBLY MAINTENANCE The boom assembly consists of the first and second section booms and supporting hardware.
Boom 3.3.1 Boom Removal 1. Remove any attachment from the quick switch assembly. 2. Be sure there is enough room in front of the machine to allow the boom sections to be removed. Park the machine on a hard, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4.
Boom 6. Pull the second boom section out 15 cm to 20 cm (6 in to 8 in) to be able to loosen and remove all the bolts and remove all the wear pads, backing plates and shims from the front inside of the first section boom. Tag each pad, backing plate, shim and bolts from each location. WARNING: NEVER weld or drill the boom. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply can result in death or severe personal injury. 7.
Boom 6. With the sling still in place, install the compensating cylinder, pin (2) and lock bolt. Apply Loctite® #242 and torque to 90 Nm (66 lb-ft). 3.4 BOOM WEAR PADS The wear pads on this machine are flat rectangular wear pads with metal inserts. On the 266 and 307 a total of 16 wear pads are installed on the outer boom. 3.4.1 2 1 Wear Pad Inspection Inspect all wear pads (3) for wear. If the angle indicators (4) on the ends of the wear pads are visible, the wear pads can be reused.
Boom 3.5 QUICK SWITCH ASSEMBLY This machine is equipped with a quick switch system for easy attachment changes. 3.5.1 6 Connecting with a Mechanical Quick Switch Device 1. Retract quick switch device to provide clearance. Check to be sure lock pin (8) and retainer pin (9) is out. 2. Align attachment pin (11) with recess in attachment (10). Raise boom slightly to engage attachment pin in recess. 3. Engage quick switch device.
Boom 3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment 1. Lower attachment to ground. Set parking brake, shut off engine and turn key back to the “ON” position. 2. Relieve pressure in the hydraulic system by actuating the joystick. 3. Connect the quick-disconnect fittings. 4. Start the engine. 3.5.4 Quick Switch Removal 1. Remove the lock bolt (12) holding the tilt cylinder rod end pin to the quick switch assembly. Remove the tilt cylinder pin. 2.
Boom 3.6 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting Problem 1. Boom will not extend or retract. Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/Retract hydraulic system not operating properly. 2. Refer to Section 8, “Hydraulic System.” 3. Faulty extend/retract cylinder. 3.
Boom Boom Troubleshooting (Continued) Problem 6. Rapid boom pad wear. 7. Auxiliary hydraulics will not operate. 3.10 Cause Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 266, 307, 266 LoPro TITLE Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
Cab and Covers WARNING: DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 4.2 4.2.1 OPERATOR’S CAB Operator’s Cab Description The welded metal cab features a modular design, allowing for a relatively quick, simple exchange of the entire cab and/or component parts. The cab is bolted directly to the frame.
Cab and Covers 4.3.2 Steering Column/Valve Replacement a. Steering Column and Valve Removal 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4.
Cab and Covers 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Disconnect the battery negative (-) cable at the battery negative (-) terminal. 4.3.4 Inching Valve a. Inching Valve Removal 1.
Cab and Covers Note: The dimensional values given for inching valve adjustment are to be used as a starting point. More thorough adjusting may be required. 6. Install and secure the lower dash panel. 7. Connect the battery negative (-) cable to the battery negative (-) terminal. Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Close and secure the engine cover. 4.3.5 b. Throttle Pedal Installation 1.
Cab and Covers 4.3.6 Joystick Assembly Replacement a. Joystick Assembly Removal 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Disconnect the battery negative (-) cable at the battery negative (-) terminal. 4. Remove the two capscrews.
Cab and Covers WARNING: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. 5. Place a suitable container beneath the radiator drain plug or petcock. Slowly turn the cap on the coolant overflow bottle to allow any pressure to escape.
Cab and Covers parts to the replacement cab after the replacement cab is securely mounted on the machine. 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Block the wheels to ensure that the machine does not move. 3. Open the engine cover. Allow the system fluids to cool. 4. Disconnect the battery negative (-) cable at the battery negative (-) terminal. 5.
Cab and Covers 4.5 CAB INSTALLATION 12. Connect the battery negative (-) cable to the battery negative (-) terminal. 1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation. 13. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions. 2. Attach a sling with suitable lifting capacity through the previously installed eye bolts. 14.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 266, 307, 266 LoPro TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts.
Axles, Drive Shafts, Wheels and Tires wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary.
Axles, Drive Shafts, Wheels and Tires removing it from beneath the machine. Place the axle on a suitable support or holding stand. 5.3.6 Axle Installation 1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine. 2. If applicable, raise the machine using a suitable jack or hoist.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 1. Excessive axle noise while driving. Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2. Drain axle and/or wheel end housings and fill to correct level with Mobilube HDLS 80W-90 Fluid. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 3.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. 266, 307, 266 LoPro Cause Remedy 1. Drain plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs 80 Nm (59 lb-ft). 2. Hose fittings loose. 2. Tighten fittings. 3.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 5.8 Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with Mobilube HDLS 80W-90 fluid. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 2.
Axles, Drive Shafts, Wheels and Tires 5.4 5.4.1 DRIVE SHAFTS To Front Axle 1 Drive Shaft Inspection Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later. Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft. Attempt to turn drive shaft in both directions.
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 4 WARNING: Risk of death or serious personal injury. Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information.
Axles, Drive Shafts, Wheels and Tires 5.5.2 Installing Wheel and Tire Assembly onto Machine IMPORTANT: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. 5.6 5.6.1 Steering Angle Adjustment Steering angle adjustment instructions can be found in the appropriate Carraro Repair Manual. 5.7 Tread “arrows” must point forward STEERING ADJUSTMENT 5.7.1 BRAKES Brake Disk Inspection.
Axles, Drive Shafts, Wheels and Tires This Page Intentionally Left Blank 5.
Section 6 Transmission: Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 266, 307, 266 LoPro TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission: 6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section. Hydrostatic Transmission Directional Valve MAH0250 6.
Transmission: WARNING: DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury. 6.4 TRANSMISSION REPLACEMENT Note: Contact your local JLG distributor if internal transmission repair is required during the warranty period. TRANSMISSION DESCRIPTION IMPORTANT: To help ensure safety and optimum performance, replace the transmission if it is damaged.
Transmission: chain, but DO NOT raise the transmission at this time. 13. Remove the two Allen head bolts that attach the transmission to the engine. WARNING: Risk of personal injury. The transmission may move while hoisting it out of the chassis. Carefully move the transmission and adjust the sling as needed. Keep fingers, hands, legs and other body parts clear of the transmission. 14. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts. 15.
Transmission: 6.5 TOWING A DISABLED MACHINE 1 Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power. Towing is only possible by using the "towing" feature built into the hydrostatic pump and disengaging the park brake on the front axle. 1. Securely block all four wheels. 1 1 WARNING: BLOCK ALL FOUR WHEELS.
Transmission: This Page Intentionally Left Blank 6.
Section 7 Engine: Deutz BF 4M 2012 Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 266, 307, 266 LoPro TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . .
Engine: Deutz BF 4M 2012 7.1 7.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine: Deutz BF 4M 2012 Air Cleaner Assembly Coolant Overflow Tank Primary Fuel Filter Fan Shroud Engine Mount Fan Radiator/Oil Cooler Implement Pump Oil Filter Fuel Filter Alternator Thermostat Starter Hydrostatic Transmission MAH0230 266, 307, 266 LoPro 7.
Engine: Deutz BF 4M 2012 7.2 ENGINE SERIAL NUMBER The Deutz BF 4M 2012 serial number is located on a tag on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer. Supply the engine serial number and/or data tag information when communicating about an engine or engine components. 7.
Engine: Deutz BF 4M 2012 container. Dispose of properly if coolant needs to be replaced. Close the radiator petcock. 10. Label, disconnect and cap all coolant hoses attached to the radiator. Cap all fittings and openings to keep dirt & debris from entering the cooling system. 11. Label, disconnect and cap all hydraulic hoses attached to the radiator. Cap all fittings and openings to keep dirt & debris from entering the hydraulic system. 12. Detach the fan safety shroud. 1 8.
Engine: Deutz BF 4M 2012 Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10° below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication. Note: When using diesel fuel with a sulfur content below 1.3 percent, the filter change interval must be reduced by 75 hours. The use of fuel with a sulfur content above 1.3 percent is not recommended. 7.6.
Engine: Deutz BF 4M 2012 d. Disassembly and Assembly The fuel/hydraulic oil reservoir is a one piece-unit integral to the chassis frame and cannot be disassembled. 7.6.4 After Fuel System Service 1. Drain and flush the fuel tank if it was contaminated. 2. Fill the fuel tank with fresh, clean diesel fuel as required. Note: If bleeding of the fuel system is required, contact your local Deutz AG Service Partner. 7.
Engine: Deutz BF 4M 2012 22. Detach exhaust and air cleaner hoses from the engine. Cover air inlets to protect from dirt & debris. 23. Remove air cleaner assembly from engine compartment. 24. Completely disconnect exhaust pipe. 25. Remove the hydraulic reservoir fill tube. 26. Secure the engine with a lifting strap or chain from the appropriate lifting points (3). Use a suitable hoist or overhead crane. 27. Remove the 4 motor mount bolts that attach the engine to the frame. 28.
Engine: Deutz BF 4M 2012 16. Check that all hydraulic, electrical, cooling, fuel and exhaust system connections are correct and connected tightly. 17. Run engine to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks. 18. Allow the engine to cool. Check the radiator coolant level, and top off with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. 4 6 5 3 19.
Engine: Deutz BF 4M 2012 7.
Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 266, 307, 266 LoPro TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoses, Tube Lines, Fittings, Etc. . . . . .
Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8.2 SAFETY INFORMATION WARNING: DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury. Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions.
Hydraulic System ALWAYS replace a used o-ring with a new part. 8.5.1 Check all routing of hoses, wiring and tubing for sharp bends or interference with any rotating members. Install appropriate protective devices such as tie wraps and conduit to help shield hoses from damage. All tube and hose clamps must be tight. In general, follow the steps below whenever conducting pressure checks and performing adjustments: 8.
Hydraulic System 8.5.2 Main Control Valve Pressure Checking Attach 345 bar (5000 psi) gauge to the test port (1) on the main control valve port to check the system pressure. The main control valve pressure should be 250 ± 5 bar (3600 psi) at full throttle. 8.5.5 Steering Pressure Checking Attach a pressure gauge to the test fitting (4) on the appropriate hose of the implement pump. The pressure reading should be 180 bar (2610 psi) with the steering wheel fully turned to one direction.
Hydraulic System 8.6 HYDRAULIC SCHEMATIC RIGHT REAR STEERING CYLINDER LEFT E A B T FRONT STEERING CYLINDER LEFT B T R L L P H RIGHT P SEE SHEET 2 FOR TRAILER BRAKE OPTION LS T P C K P T LS P EF PRIORITY FLOW VALVE C INLET M O ITEM A B1 B2 B3 C D E F G H J K L M N O P Q R 8.
Hydraulic System COMPENSATION LEVAGE LIFT SEE SHEET 2 FOR AUXILIARY OPTIONS TELESCOPAGE CROWD INCLINGISON TILT OUTILLAGE AUX F A B B A 280 280 B 280 B A 280 A PS P2B T4 250 T1 P1 UL T3B T2B TP G 2 R 3 1 X3 D X1 X2 G Ps T2 T1 R Fa Fa1 Fe B B B Mb A U T1 Vg min. Ma X1 X2 G Mh S A T2 A Vg max. M MAH1020 266, 307, 266 LoPro 8.
Hydraulic System 8.6 Hydraulic Schematic (Continued) Q X L TRAILER BRAKE VALVE R B K LS N P EF P PRIORITY FLOW VALVE TRAILER BRAKES C INLET F B A B 280 A 280 B 280 A 280 B A PS P2B T4 250 T1 P1 UL T2B T3B TP MAH1030 8.
Hydraulic System AUXILIARY OPTIONS REAR AUX FRONT AUX FRONT AUX 1ST FRONT AUX REAR AUX 2ND 1ST FRONT AUX J REAR AUX P 2ND FRONT AUX 2ND 1ST 2ND 1ST P J J B 280 A 280 OPTIONAL REAR AUXILIARY J J B 280 A 280 OPTIONAL REAR AUX WITH MANUAL SECOND FRONT AUX B 280 A 280 OPTIONAL REAR AUX WITH ELECTRIC SECOND FRONT AUX B 280 A 280 OPTIONAL SECOND FRONT AUXILIARY -MANUAL- B 280 A 280 OPTIONAL SECOND FRONT AUXILIARY -ELECTRIC- MAH1040 266, 307, 266 LoPro 8.
Hydraulic System 8.6 Hydraulic Schematic (Continued) S B A B 280 A 280 B A B A 280 280 B A PS T P2B T4B 250 T1B P1 UL Ø0.6 ID ORIFICE T2B T3 TP PTO OPTION REAR AUX 2 REAR AUX 1 FRONT AUX J J B 280 A 280 OPTIONAL DUAL REAR AUX 8.
Hydraulic System 8.7 HYDRAULIC RESERVOIR The hydraulic reservoir and fuel tank are part of the frame. For this reason, neither tank can be removed. For cleaning instructions, see Section 7.6.3, “Fuel/Hydraulic Oil Tank.” Occasionally, fluid may seep, leak or be more forcefully expelled from the filter head when system pressure exceeds the rating of the filter head or breather.
Hydraulic System d. Pump Inspection Inspect internal pump components for wear, damage, etc. If inner surfaces of the pump DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal pump seals and damage to the polished surfaces within the pump and other hydraulic system components. Inspect the o-ring groove and shaft seal recess in the mounting flange. Be sure they are undamaged and free from burrs.
Hydraulic System 6. Carefully fit the mounting plate in its original position. The drain hole in the rear face must be to the low pressure side, DO NOT DAMAGE THE SEAL ON THE SHAFT. 7. Fit washers and nuts to studs and torque to 88-95 Nm (65-70 lb-ft). 8.9 FRONT DRIVE PUMP For internal service instructions and detailed specifications, contact your local JLG distributor for a copy of the Rexroth Repair Manual (P/N 31200123). 1 8.
Hydraulic System 8.10 8.10.1 VALVES AND MANIFOLDS Main Control Valve The main control valve is mounted on the rear of the machine behind the rear access panel. The main control valve assembly consists of various working sections with their own valve assemblies, each providing a specific hydraulic function. The section assemblies are the outlet, extend/retract (1), auxiliary (2), tilt (3), lift/lower (4) and load sense outlet sections. b. Main Control Valve Disassembly 1.
Hydraulic System d. Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts. e. Main Control Valve Assembly Note: ALWAYS replace seals, o-rings, gaskets, etc.
Hydraulic System 8.10.3 Parking Brake The park brake is secured with two capscrews (1) and lockwashers (2) at the left side of the seat base. 1 2 MAH0030 6. Remove the bolts that mount the service brake valve to the steering column support Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective. b. Service Brake Valve Installation 1.
Hydraulic System 3. Check the routing of all hoses for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. 4. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions. 5. Inspect the park brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 6. Replace the brake valve cover. 7.
Hydraulic System 6. Remove the steer select manifold with attached steer select valve from the machine. Wipe up any hydraulic fluid spillage in, on, near and around the machine. b. Steer Select Valve and Manifold Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2. Separate the steer select valve from the manifold by removing the capscrews. Discard the old o-rings. 3. Remove the solenoid valves and cartridges from the steer select housing. 4.
Hydraulic System 8.11 HYDRAULIC CYLINDERS 1 8.11.1 2 General Cylinder Removal Instructions 3 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 4 2. Chock the wheels. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the engine cover. Allow the system fluids to cool. 1 5.
Hydraulic System Note: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed. Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 149-204° C (300-400° F) will destroy the bond.
Hydraulic System 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 1 2 9. Close and secure the engine cover. 3 8.11.7 Steering Cylinders The steering cylinders are attached to each axle center housing. The steer cylinders are covered in the appropriate Carraro axle literature. 4 1 5 2 6 MAH0160 8.11.6 General Cylinder Installation 1. Grease the bushings at the ends of the hydraulic cylinder.
Hydraulic System 8.11.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 266, 307, 266 LoPro TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.
Electrical System 9.12 9.13 9.2 9.11.7 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.8 Main Control Valve Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Load Moment Indicator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.
Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
Electrical System 9.2 SPECIFICATIONS Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 9.3.1 FUSES AND RELAYS Engine Compartment Relays and Fuses There are two relays and one buss bar located inside the engine compartment, mounted on a bracket behind the engine. The relays control the starter (1) and engine preheat (2). 1 2 MAH0480 9.
Electrical System 9.3.2 Power Distribution Module F1 F8 F22 F2 F9 F23 F3 F10 F24 F4 F11 F25 F5 F12 F26 F6 F13 F27 F7 F14 F28 F15 F29 F16 F30 F17 F31 F18 F32 F19 F33 F20 F34 K1 K5 K9 K2 K6 K10 K3 K7 K11 K4 K8 K12 F21 MAH0490 Fuse/Relay Function Amp Rating F1 Right Headlight High 7.5 F2 Right Headlight Low 7.5 F3 Left Headlight High 7.5 F4 Left Headlight Low 7.
Electrical System 9.6 F13 Right Park/Side Lights 7.5 F14 Front Worklights 15 F15 Rear Worklights 15 F16 Boom Lights 15 F17 Beacon/Aux 15 F18 Reserved Switch 15 F19 Reserved Bat 15 F20 Reserved Ignition 10 F21 PCB Bat 10 F22 Ignition 2 15 F23 LMI/Joystick 10 F24 PCB Ignition 15 F25 Rear Wiper 20 F26 Flasher Pwr 15 F27 Key Bat 15 F28 Brake Lights 15 F29 A/C Compressor 7.
Electrical System 9.4 ELECTRICAL SYSTEM SCHEMATICS 9.4.1 Cab Roof Schematic Note: For more detailed schematics, contact your local JLG distributor.
B A + ALL DIODES 1N5404 3A. 400V.
START INTLK RELAY FRONT WIPER RELAY FLASHER K3 K4 K5 WORK LIGHTS RELAY BOOM LIGHTS RELAY REAR WIPER RELAY HEATER FAN RELAY K10 K11 K12 IGN PWR 3 RELAY IGN PWR 2 RELAY K9 K8 K7 IGN PWR 1 RELAY REVERSE TRAVEL RELAY K2 K6 IGN PWR 4 RELAY K1 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 C2 31 49a 49 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 87a 30 87 86 85 4m
+ 1 2 - 50mm BLK CHASSIS GROUND BATTERY DISCONNECT SWITCH (OPT) 50mm RED 1 2 3 (GRN) EMPTY 50mm BLK 135 GND 135 GND LMI CELL1 LMI CELL2 GND18 LT PARK LT REV OUT LT TURN BRK LTS EMPTY EMPTY 12 VDC BATTERY BOOM LIGHTS (OPT) 2ND AUX HYD CONN SEL VLV ON BOOM (OPT) REAR AXLE LOAD CELL 1 2 3 4 5 6 7 GND17 RT PARK LT REV OUT RT TURN BRK LTS EMPTY EMPTY 1 2 3 4 5 6 7 1 2 3 4 5 LICENSE LIGHT GND16 NEGATIVE CABLE TO STARTER (BODY) POSITIVE CABLE TO STARTER SOLENOID EMPTY EMPTY 218 300 GND EM
1 2 REV OUT GND15 1 2 FWD GND15 REV AC PRESSURE SWITCH (OPT) AC PSI SW AC COMP M AC COMPRESSOR CLUTCH (OPT) AC COMP FWD A B C D E F G H TO CAB HARNESS X44 DEUTSCH HD36-18-8SE POWER/GND HARNESS ALL 4.0 MM WIRES IN THIS CONNECTOR A B C D E F G H J K L M N O P Q R S T U V W X TO CAB HARNESS X07 DEUTSCH HD36-24-23SE ENGINE HARNESS ALL 1.
Electrical System 9.5 CIRCUIT BREAKDOWNS 9.5.1 Charge Circuit Breakdown ENGINE HARNESS POSITIVE CABLE TO BATTERY + NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY 50mm (BLK) STARTER M 50mm (RED) 16mm (RED) ALT BAT 16mm (RED) ALT BAT ALT W ALTERNATOR ALT D+ TO CAB HARNESS X07 A B C D E F G H J K L M N O P Q R S T U V W X ALT D+ ALT W CAB HARNESS X07 DEUTSCH HD36-24-23SE ENGINE HARNESS ALL 1.
Electrical System 9.5.2 Start Circuit Breakdown CAB HARNESS ALL 1.0 MM WIRES IN THIS CONNECTOR FNR/GEAR SHIFTER S19 KEY SWITCH S15 KEY IGN 1 KEY IGN 1 KEY STRT 1 2 3 4 5 6 7 8 9 10 30 30 17 17 SWITCH S18 N BAT BAT HEAT HEAT R 0 1 2 3 15 IGN 15 IGN 50A STRT 19 HEAT 19 HEAT EMPTY F 4 3 5 6 2 1 1 2 0 1 2 3 GND 3 2 ON OFF 1 STRT INTLK NEUT KEY BAT 1 KEY BAT 1 PARK BRAKE NEUT STRT INTLK KEY STRT KEY IGN 1 CAB HARNESS X00 TO POWER DIST.
Electrical System 9.5.
Electrical System 9.5.4 Constant Power Circuit Breakdown ENGINE HARNESS POSITIVE CABLE TO BATTERY + STARTER M CAB PWR 4 CAB PWR 3 CAB PWR 2 CAB PWR 1 PREHEAT PWR ALT BAT ALTERNATOR 30 STRT PWR B+ STARTER RELAY 87 86 W D+ 1 2 3 4 5 G 85 ALT BAT 50 ENGINE GLOWPLUGS CONTROL ENGINE HEATER FUSE 50A SLO BLO 30 8 9 87 STRT PWR PREHEAT PWR PREHEAT RELAY TO CAB HARNESS X44 DEUTSCH HD36-18-8SE POWER/GND HARNESS ALL 4.
Electrical System 9.6 ENGINE START CIRCUIT 9.6.1 Starter The starter (1) is located on the left side of the engine (the left side of the machine) underneath a heat shield attached to the flywheel. 3. If the starter only “clicks” it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. 4.
Electrical System f. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with fasteners. Torque fasteners to 43 Nm (32 lb-ft). 2. Connect the positive (+) battery cable to the upper solenoid stud. Install the wires to the upper solenoid stud, and secure with lockwasher and nut. 3. Connect the wire to the solenoid mounting stud. 4. Reattach the starter heat shield. 5.
Electrical System 2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting capscrew. Be sure to leave enough room to attach the drive belt. 9.8.2 Load Moment Sensor Detailed instructions for the load moment sensor can be found in the appropriate Carraro Axle Repair Manual. Refer to Section 5.3.3, “Axle Internal Service.” 3. Attach the fan drive belt to the alternator. 4.
Electrical System 9.8.4 9.9 Instrument Cluster 9.9.1 15 10 20 WINDOW WIPER/WASHER Windshield Wiper Motor a. Removal 25 5 0 RPM X 100 Note: It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing. 30 000000 h 1. Open the engine cover. MAH0170 a. Removal CAUTION: Static electricity can cause damage to the operator’s instrument cluster. Avoid any manner of touching (hands, tools, etc.
Electrical System d. Installation and Testing 1. Install all required hardware to the motor assembly. 2. Align motor with the mounting holes and bolt the motor to the mounting bracket. 2. With the help of an assistant, insert the wiper motor through the roof hole and have the assistant thread the hex nuts onto the wiper motor shaft and the wiper motor. Insure that the motor housing is facing the front of the cab. 3. Connect the wiper linkage to the wiper motor shaft.
Electrical System b. Disassembly DO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective. c. Installation and Testing 6. Pull the control panel out from the dash panel, and if removing variable speed fan control, remove the cab harness connector. 7. If removing the temperature control knob, disconnect the cable connector and remove control knob. 1. Connect the windshield washer hoses to the reservoir. 8. Remove the hex locknut from the suspect control shaft. 2.
Electrical System 9.11 9.11.1 SWITCHES, SOLENOIDS AND SENDERS 4. Install the lower dash panel. 5. Connect the battery negative (-) cable to the battery negative (-) terminal. 6. Close and secure the engine cover. Ignition Key Switch 9.11.2 a. Ignition Switch Removal 1. Open the engine cover. Allow the engine to cool. Dash Switches a. Switch Removal 2. Disconnect the battery negative (-) cable from the battery negative (-) terminal. 1. Open the engine cover. Allow the engine to cool. 3.
Electrical System 3. Turn the ignition key switch to the OFF position. The fuel level indicator needle should return to the EMPTY position. b. Fuel Level Circuit Tests 9.11.5 Coolant Temperature Sender The coolant temperature sender (1) is located on the back of the engine towards the rear of the machine. 1 2 If the fuel level indicator is suspected of giving a false reading, perform the following checks: 1. If the fuel level indicator needle does not move, check the fuel tank for fuel. 2.
Electrical System pump, loose fan belt, defective instrument display, etc. 5. Close and secure the engine cover. 9.11.6 Fuel Shut-off Solenoid The fuel shut-off solenoid (2) is located on the top of the engine near the fuel filter. a. Fuel Shut-off Solenoid Removal 9.11.7 Oil Pressure Sender The oil pressure sender (3) is located on the engine near the oil filter. a. Oil Pressure Sender Removal 1. Open the engine cover. Allow the engine to cool. 2.
Electrical System 9.11.8 Main Control Valve Solenoids 4 9.12 If the controller has been replaced, the default settings for the Load Moment Indicator and the Joystick functions must be properly configured. 9.12.1 The Load Moment Indicator (LMI) must be set to remain active with the machine. Without a functioning LMI, a potentionally dangerous situation may occur resulting in serious injury or death. a. Main Control Valve Solenoid Removal 1. Open the engine cover. Allow the engine to cool. 3.
Electrical System 9.13 9.13.1 TROUBLESHOOTING Analyzer Usage Help messages can be viewed using the JLG Analyzer (P/N 2901443). The Help messages can be accessed by pressing the ENTER key while viewing the current Help message. The Help message shall be EVERYTHING OK when no fault is present. The Analyzer cable plugs into the X26 connector of the PCB board located behind the operator’s seat. When the analyzer is first connected, it defaults to access level 2. Settings may only be viewed in level 2.
Electrical System 9.13.2 Fault Codes The following Fault codes can be viewed with either the JLG Analyzer or by translating the flash codes on the PCB board. The LED on the PCB flashes out all fault codes from highest to lowest priority. Help Message Flash Code Fault Condition Action SYSTEM VOLTS LOW 2-1 System voltage at pin J1-38<10 volts If occurrence lasts for more than 3.2 seconds then disable all outputs.
Electrical System AUX HYD 1 OPEN FAULT 4-8 Open on pin J1-8 None. Fault shall be latched and only reset upon power down of the controller. AUX HYD 2 OPEN FAULT 4-7 Open on pin J1-28 None. Fault shall be latched and only reset upon power down of the controller. TELE OUT SHORT FAULT 5-1 Short to plus on pin J1-21 Disable Telescope Out output. Fault shall be latched and only reset upon power down of the controller.
Electrical System 9.13.3 Analyzer Diagnostic Help Messages The table below lists Diagnostic Help Messages that the Control System communicates to the Analyzer.
Electrical System JOYSTICK: X POSITION ±XXX% Displays position in percentage for this axis IN NEUTRAL, NOT NEUTRAL, ERROR Indicates whether joystick is in neutral position for this axis ±XXX% Displays position in percentage for this axis IN NEUTRAL, NOT NEUTRAL, ERROR Indicates whether joystick is in neutral position for this axis ±XXX% Displays position in percentage for the analog rocker IN NEUTRAL, NOT NEUTRAL, ERROR Indicates whether analog rocker is in neutral position S1 ON/OFF Displa
Electrical System VERSION: GM SW PX.X Displays ground module software version GM HW REV XXXX Displays ground module hardware version XXXXXX Displays ground module serial number JYSTK SW XX.X Displays joystick software version ANALYZER VX.XXXX Displays Analyzer software version GM SN 266, 307, 266 LoPro 9.
Electrical System 9.
An Oshkosh Truck Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng.
