Service & Maintenance Manual Models 3394RT 4394RT S/N 0200191606 to Present including S/N’s: 0200186972, 0200187002, 0200187013 3121249 May 16, 2014
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - October 6, 2008 Revised - November 3, 2008 Revised - November 30, 2010 Revised - July 19, 2012 Revised - May 16, 2013 Revised - May 16, 2014 b – JLG Lift – 3121249
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A A A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Hydraulic Component Start-Up Procedures & Recommendations . . . . . . . . . . . . . . . . . . . . . . . .4-9 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 2-1. 2-2. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41. 3-42. 3-43. 3121249 TITLE PAGE NO. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 3-44. 3-45. 3-46. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 4-32. 4-33. 4-34. iv Engine Tray Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 4-35. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. 6-18. 6-19. 6-20. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. 6-30. 6-31. 6-32. 6-33. 6-34. 3121249 Oscillating Axle Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 5-1 5-2 5-3 5-4 5-5 vi TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS 1.2 CAPACITIES Table 1-1.
SECTION 1 - SPECIFICATIONS 1.4 Table 1-5. Deutz F3M2011 Specifications Fuel Oil Capacity Low RPM High RPM Alternator Battery Fuel Consumption: Low RPM High RPM Horsepower DIesel 8.5 Quarts (8 L) w/Filter 900 2800 95 Amp, Belt Drive 112 Amphour, 950 Cold Cranking Amps, 12 VDC 1.3 GPH (4.9 lph) 1.6 GPH (6.0 lph) 48 @ 2800 RPM, full load Table 1-6. GM 3.0L Specifications (Tier 2 and 3 Engine) Fuel Gasoline or Gasoline/LP Gas No.
SECTION 1 - SPECIFICATIONS 1.7 SERIAL NUMBER LOCATIONS 1.8 For machine identification, a serial number plate is affixed to the machine. The plate is located at the rear of the machine on the center of the axle. In addition, should the serial number plate be damaged or missing, the machine serial number is stamped onto the lip of the rear axle.
SECTION 1 - SPECIFICATIONS 1.9 CYLINDER SPECIFICATIONS 1.11 CRITICAL STABILITY WEIGHTS Table 1-11. Cylinder Specifications Description Bore Stroke Rod Dia Lift Cylinder 4.5 in (114 mm) 83 in (2.1 mm) 3.5 in (89 mm) Leveling Jack Cylinder 2.5 in (63.5 mm) 27 in (686 mm) 2 in (51 mm) Lockout Cylinder (Oscillating Axle) 2.5 in (6.4 cm) 4.13 in (10.5 cm) 1.75 in (4.4 cm) Power Deck Cylinders 15 in (38.1 mm) 48 in (1219.2 mm) 1 in (25.4 mm) Steer Cylinder 2.5 in (63.5 mm) 9.2 in (233.
SECTION 1 - SPECIFICATIONS 1.12 LUBRICATION SPECIFICATIONS Table 1-16. Mobil 424 Specs Table 1-14. Hydraulic Oil Hydraulic System Operating Temperature Range Sae Viscosity Grade 0°F to +23°F (-18°C to -5°C) 10W 0°F to +210°F (-18°C to +100°C) 10W-20,10W-30 +50°F to +210°F (+10°C to +100°C) Type Synthetic Biodegradable SAE Grade 10W-30 Gravity, API 29.0 Density 7.35 lb/gal ( Pour Point, Max -46°F (-43°C) Flash Point, Min.
SECTION 1 - SPECIFICATIONS 1.13 OPERATOR MAINTENANCE 1. Fuel Tank 2. Drive Hubs 3. Hydraulic Oil Tank 4. Sliding Wear Pads 5. Oil Change w/Filter - Deutz 6. Oil Change w/Filter - GM 7. Fuel Filter - Deutz 8. Fuel Filter (Gasoline) - GM 9. Air Filter 10. Electronic Pressure Regulator (LP Only) 11. Fuel Filter (Propane) - GM NOTE: Item #5 through #11 are on the opposite side of the machine and not shown. See following pages. Figure 1-2.
SECTION 1 - SPECIFICATIONS Drive Hub Engine Oil Change w/Filter - Deutz • Lube Points - Fill Plugs (4) • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7016331) • Lube - EPGL - Mobilube HD 80W-90 or equivalent • Capacity - 6.3 qt. (5.9 L) engine only • Interval - Every 2 years or 1200 hours • Lube - EO • Total Capacity - 23.75 oz. each hub • Interval - Every Year or 600 hours of operation • Comments - Check level daily/Change in accordance with engine manual.
SECTION 1 - SPECIFICATIONS Oil Change w/Filter - GM Engine Fuel Filter - Deutz D 2.9 L4 - T4F • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) • Capacity - 4.5 qt. (4.
SECTION 1 - SPECIFICATIONS Fuel Filter (Propane) - GM • Interval - 3 Months or 150 hours of operation • Comments - Replace filter. Refer to Propane Fuel Filter Replacement 4. Push in the Emergency Switch once the engine stops. 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR.
SECTION 1 - SPECIFICATIONS 7. Once all of the oil has been drained, reinstall the LPG fuel temperature sensor and reconnect the electrical connector. 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. Propane Fuel Filter Replacement INSTALLATION: BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL. 1.
SECTION 1 - SPECIFICATIONS 1.14 TORQUE CHARTS Figure 1-4.
SECTION 1 - SPECIFICATIONS Figure 1-5.
SECTION 1 - SPECIFICATIONS Figure 1-6.
SECTION 1 - SPECIFICATIONS Figure 1-7.
SECTION 1 - SPECIFICATIONS Figure 1-8.
SECTION 1 - SPECIFICATIONS NOTES: 1-16 – JLG Lift – 3121249
SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL 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 2.3 LUBRICATION AND INFORMATION 3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20°F (-29°C). However, use of this oil will give poor performance at temperatures above 120°F (49°C). Systems using DTE 13 oil should not be operated at temperatures above 200°F (94°C) under any condition. Hydraulic System 1. The primary enemy of a hydraulic system is contamination.
SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Maximum acceptable cylinder drift is to be measured using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, upper boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 in (5 cm) in 10 minutes.
SECTION 2 - GENERAL 2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed.
SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 300 Hours (6 months) 600 Hours (1 year) 1200 Hours (2 years) PLATFORM 1. Controller 1,11 2. Switches 1,11 3. Placards and Decals 1,2 4. Control Tags 1,2 5. Hoses and Cables 4,8 6. Wear Pads 8 7. Handrails and Chains 1,4 CHASSIS 1. Engine Oil 3 5 2. Battery 3 5 3. Air Cleaner 1 14 4. Exhaust System 1 1,5 5. Engine Mounts 1 6. Hydraulic Pump 1 5 7. Valves 1 5 8.
SECTION 2 - GENERAL Figure 2-1.
SECTION 2 - GENERAL Figure 2-2.
SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121249
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS 3.1 OPERATING CHARACTERISTICS Generator Leveling Jacks The machine may be equipped with auto leveling jacks. These leveling jacks are operated through one switch unlike the traditional four switch system. The leveling jacks are operated by a bang bang valve. NOTE: The engine speed will drop when the leveling jacks are in contact with the ground. 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS • any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to ensure the damage has not propagated beyond the allowable criteria. 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, PLATFORM & SCISSOR ARMS Drive Assembly 1. Tire & Rim 4 2. Lugnuts 5 3. Drive Motor/Hub Assembly (Bosch Rexroth) 4. Bolt, 5/8"-11NC x 1 1/2" 1 5. Hardened Washer NOTE: Rear Axle Shown 3 2 Figure 3-1. Drive Assembly (Bosch Rexroth ) REMOVAL: INSTALLATION: 1. Follow "Removal" procedures in reverse order. SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO PREVENT MACHINE FROM MOVING DURING REPAIRS. 2. Refer to Table 3-1, Wheel Torque Chart when torqueing Lugnuts (2). 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1. Tire & Rim 8 7 2. Lugnuts 3. Drive Hub (Fairfield) 4. Bolt, 5/8"-11NC x 1 3/4" 5. Hardened Washer, 5/8" 6 1 6. Drive Motor (Sauer) 7. Nut, 1/2"-13NC 8. Hardened Washer, 1/2" 3 NOTE: Rear Axle Shown 5 4 2 Figure 3-2. Drive Assembly - (Fairfield/Sauer) REMOVAL: INSTALLATION: 1. Follow "Removal" procedures in reverse order. SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO PREVENT MACHINE FROM MOVING DURING REPAIRS. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.3 INTEGRATED TORQUE/DRIVE HUB (BOSCH REXROTH) . The Integrated Torque/Drive Hub is an axial piston-hydraulic motor with integrated, hydraulic released multi plate parking brake and a 2-stage planetary gearbox and a disconnect mechanism. To ensure an optimum balancing of loads, each planetary stage is comprised of planet gears in sets. The externally toothed wheels are case-hardened.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 36 34 37 32 26 35 1 10 13 15 2 24 9 12 5 33 30 28 31 29 25 27 14 8 18 19 17 11 20 16 6 4 21 22 3 7 23 1. Planet Gear 11. Tapered Roller Bearing 21. Thrust Washer 31. O-Ring 2. Planet Gear 12. Retaining Ring 22. Gear, Ring Options 32. Spring 3. Sun Gear 13. Retaining Ring 23. O-Ring 33. Shift Rod 4. Shaft Nut 14. Retaining Ring 24. Retaining Ring 34. Brake Housing 5. Planet Pin 15. Support Disk 25. Sun Gear Shaft 35.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-3. Gearbox Maintenance Schedule After 150 motor operating hours - First oil change Weekly: - Inspect visually - Check for unusual noise - Check oil level THE MAXIMUM GEAR DRIVE TOWING SPEED OF 72 RPM MUST NOT BE EXCEEDED. ENGAGE GEAR DRIVE OR SECURE MACHINE WHEN MACHINE IS SEPARATED FROM THE TOWING VEHICLE.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Gearbox Disassembly 4. Remove Sun Gear Shaft (25). For numbers in parenthesis, refer to Figure 3-4., Drive Motor/Hub Assembly. 1. Remove Screw Plugs (18, 19) and drain oil into appropriate container. 5. Remove complete 1st planet stage. 2. Remove Snap Ring (24). 6. Remove ring gear fastening Bolts (20), Ring Gear (22), and O-ring (16).. 3. Remove the assembled Cover (8) with Shift Rod (33) and O-ring (23).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7. Remove Snap Rings (13). 10. Drilling Hole Sketch 8. Pull out Plane Gears (1). 11. Split the Shaft Nut (4) in the area of the two drill holes by means of a chisel, and remove from Spindle (34). 9. Drill 2 holes into Shaft Nut (4) at 180° spacing according to Drilling Hole Sketch (step 10). DO NOT DAMAGE THE BEARING CAGE OF THE BEARING (11). DO NOT TURN THE SHAFT NUT; POSSIBILITY OF SPINDLE THREAD DAMAGE.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Remove the Support Ring (6) from the Spindle (34). Components stay in Supporting Ring (6). 15. Repair deformed threads on the Spindle (34) in the area of the ball detend with a thread file of 1.5mm pitch. 13. Remove Radial Shaft Seal Ring (17). Gearbox Assembly NOTE: Clean all parts before assembling the gearbox. 1. Make sure during assembly of the preassembled planet gears that the larger radius on the bearing bore is oriented towards the planet carrier.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS c. Secure the gears with new Snap Rings (12). 5. Insert the bottom part of the double Tapered Roller Bearing (11). NOTE: Heat Supporting Ring (6) to approximately 189.5° F (70° C) in a heating furnace. 3. Insert outer rings into heated Supporting Ring (6). (check for proper axial seat) 6. Insert radial Shaft Seal Ring (17) into Supporting Ring (6) and fill mounting space between sealing lips with roller bearing grease.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS b. The Loctite® setting time equals 24 hours at ambient temperature of 68° F (20° C). 8. Heat upper ring with roller cage of double Tapered Roller Bearing (11) to approximately 189.5° F (70° C) and mount onto Spindle (34). Allow cooling time of approximately 15 minutes before continuing assembly. 9. De-grease threads of Spindle (34) and Shaft Nut (4). Then evenly apply coat of Loctite® 270 to Shaft Nut (4) threads. 11.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 13. Assembly of planet gear (Main Stage): a. Mount the planet gears with Bearing Assembly (1, 10), heated to approximately 189.5° F (70° C), onto the planet bolts of the Spindle (34) and secure the gears with new Snap Rings (13). 16. Install completely pre-assembled 1st planet stage into the gear drive. 17. Install Sun Gear Shaft (25). 14. Install the Ring Gear (22). 18. Check axial clearance: a.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 20. Insert Shift Rod (33) into preassembled Cover (8). 23. Install Plugs (18) with new Seal Rings (19) into Cover (8). 21. Install preassembled Cover (8) into Ring Gear (22). 22. Install Snap Ring (24). NOTE: Prior to operating, fill the drive with new oil.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-5.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Motor Disassembly 3. Disassemble guide ring: a. Seal Ring (1) 1. Mark port plate to the supporting axle. b. Pressure Springs (2) (quantity = 26) c. Guide Ring (3) 2 1 3 2. Remove port plate. 4. Disassemble retaining ring.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 5. Disassemble bearing with synchronizing plate. 8. Disassemble lamination kit. 6. Remove pressure ring with extractor. 9. Disassemble Seeger snap ring. 7. Remove pressure ring. 3121249 10. Disassemble cradle stop with 2 screws, M4 x 75mm.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 11. Disassemble rotary group completely with cradle. 12. Disassemble control piston with spring. 13. Pull out swivel balls. 3-18 14. Disassemble shaft seal ring. 15. Insert disc. Pull off bearing ring with device. Remove disc. 16. Disassemble bearing ring from port plate.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 17. Remove bearing ring (1). Disassemble spool (2). 1 19. Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (Otherwise: Pistons must be replaced in sets). 2 20. Check cylinder bores, splines. 18. Disassemble shuttle valve (1). Disassemble throttle screw with throttle pin (2). 2 3121249 1 21.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Check splines (1) for damage or fretting; running surfaces (2);groove cut by shaft seal (3). 1 25. Make sure the sealing surfaces are damage free. 3 2 23. Check that sliding surface is free of grooves (1); cups are free of grooves and there are no pittings (2). 1 2 24. Make sure the seat of the shaft seal in the case has no damage. 3-20 26. Press bearing ring in port plate (with tool). 27. Press bearing ring in supporting axle (with tool).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 28. Press bearing on drive shaft. 30. Attach a measuring device. Ascertain tolerance. Grip shaft with Seeger ring pincers and move up and down. [Simulation ring 1mm + tolerance + (bearing pretension 0.05 - 0.08) is resulting in thickness of the synchronizing disc]. Grind synchronizing disc to dimension. 29. Install shaft in supporting axle (1). Place in simulation ring (2).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Motor Assembly 2. Install rotary group with cradle. Observe installation position of swivel balls. 1. Press in swivel balls (with tool) (1). Insert shaft seal ring (with tool) (2). Insert control piston with spring (3). NOTE: Slightly grease swivel balls. 3. Mount sleeve and pressure ring in cradle stop. Insert cradle stop. NOTE: Stick with grease.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Mount Seeger snap ring. Opening of snap ring must be on the opposite side of the control piston. 6. Assemble piston with retaining plate. Oil piston and slipper pad. 7. Assembly aid: Hold the pistons by using an o-ring. 5. Fit pressure pins using an assembly aid. Pre-tension the spring using a suitable device.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Install laminations in correct order. 10. Grease seal rings, install in supporting axle. 9. Mount support ring (1) and quad ring (2) in pressure ring. Be careful not to excessively extend the rings. 1 2 21 3-24 11. Mount retaining ring.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Mount seal rings (1). Insert and line-up guide ring. 14. Mount synchronizing disc (1) and bearing (2). 2 1 1 15. Mount bearing ring with device. Mount spool. Mount fixation pin. 13. Align the two holes for fixation cylinder pin - port plate (item 2).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 16. Fix control plate with grease at port plate. 18. Mount and screw port plate on supporting axle. 17. Fill case with oil.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.4 DRIVE HUB (FAIRFIELD) The following steps describe the proper procedure for tightening and torquing bolts or socket head cap screws in a bolt circle. Roll and Leak Testing 1. Tighten (but do not torque) bolt ”A” until snug. Always roll and leak test Drive-Hubs after assembly to make sure that the unit’s gears and sealants are working properly. The following information briefly outlines what to look for when performing these tests. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7B 7D 7C 7D 16 29 28 7 30 6F 6E 6D 6C 6I 7A 10 39 2 6H 6G 6G 40 41 6 6B 1I 37 1H 11 20 11 22 1F 6A 21 1E 1 24 5A 21 1G 4 24 5 3G 1J 15 19 3E 1D 34 33 1C 3 3A 3B 14 3C 8 3D 3C 13 27 1B 1 36 35 1A 38 25 3F 9 3B 26 12 23 32 31 23 17 18 Figure 3-6.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-4. Drive Hub Part Description NOTE: Refer to Figure 3-6., Drive Hub. Item # Table 3-4.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1. Hub-Spindle Sub-Assembly 2. Internal Gear 6 A. Cover 7 C. Spring 1 A. Spindle 3. Carier Sub-Assembly 6 B. Cover Cap 7 D. Spacer 1 B. Seal 3 A. Carrier Housing 6 C. Bolt 8. Input Gear 1 C. Bearing Cup 3 B. Thrust Washer 6 D. Disconnect Cap 9. Thrust Spacer 1 D. Bearing Cone 3 C. Needle Roller 6 E. Disconnect Rod 11. Thrust Spacer 1 E. Bearing Cup 3 D. Spacer 6 F. O Ring 12. Bolt 1 F. Bearing Cone 3 E. Planet Shaft 6 G.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Disassembly for Drive Hub BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU REMOVE THE O-RING. NOTE: Refer to Figure 3-7. for part location and listing. 1. Turn hub (1G) over onto its side. Remove coupling (14) from the wide end of spindle (1A). 2. Mark location of shoulder bolt holes on outside of ring gear and hub for easy re-alignment when rebuilding. Remove the four shoulder bolts (13) and twelve bolts (12) from cover (6). 3.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Turn hub (1G) over onto its small end. Remove two pipe plugs (1J) from the two pipe plug holes in the side of hub. 5. Remove one spacer (3D) from inside cluster gear (3F). 6. Remove the remaining 16 needle rollers (3C) from the other side of cluster gear (3F). Discard the needle rollers. NOTE: If the unit does not have studs, skip this step: 9. Press the nine studs (1N) out of the stud holes in hub (1G). 7.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Set carrier housing (3A) sideways on a table. Insert a planet shaft (3E), roll pin hole last, into one of the planet shaft holes from roll-pin-holed side of carrier housing. 7. Following the cluster gear, place one more thrust washer (3B) onto planet shaft (3E) through the opposite planet shaft hole in carrier housing (3A). 8. Use an alignment punch or similar tool to align the roll pin holes in carrier housing (3A) and planet shaft (3E). 5.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Cover Sub-Assembly 1. Using the disconnect rod, push o-ring (6F) into the groove inside the cover cap (6B). 2. Place the o-ring (6G) onto the cover cap (6B) so that it rests against the flange of the cover cap. 5. Place two of the cover cap bolts (6C) into any two bolt holes that are 180° apart on the cover cap (6B) and tighten bolts. 6. Using a torque wrench, apply 2.95 to 3.69 ft. lbs. (4 to 5 Nm) of torque to both bolts (6C). 3.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7. With the large end down, place the disconnect cap (6D) onto the cover cap (6B), aligning the pipe plug hole in the disconnect cap over the pipe plug hole in the cover cap. 8. Place the two remaining bolts (6C) into the bolt holes in the disconnect cap (6D), and tighten the bolts. 10. Apply a light coat of "Never-Seize" to pipe plug (6H) and tighten it into the pipe plug hole in the cover (6A).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Apply a light coat of "Never-Seize" to two pipe plugs (1J) and tighten them into the two pipe plug holes in the side of the hub (1G). 6. Press seal (1B) into the small end of hub (1G). 7. Oil spindle, then lower hub (1G), small end down, onto spindle (1A). NOTE: Make sure the cup sits square with the counterbore before pressing. 4. Turn hub (1G) over onto its small end. Press bearing cup (1E) down into the counterbore in the deep end of the hub (1G). 8.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Assembly 9. Place spacer (1H) onto spindle (1A) in hub (1G). BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING 1. Grease o-ring (5) and place it into the counterbore in hub (1G). NOTE: O-ring may be stretched or pinched together to make it fit the counterbore exactly. NOTE: Make sure the retaining ring is securely seated in the groove. 10. Place retaining ring (1I) over the spacer onto spindle (1A) in hub (1G). 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Place thrust washer (11) around spindle (1A) so it rests on the bottom of the internal gear (2). 7. Place other spacer (7D) onto the smooth end of input shaft (7A). 5. Stand input shaft (7A) on its splined end. Place one spacer (7D) onto the smooth end of input shaft (7A).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 10. Place thrust spacer (9) onto input shaft (7). the location of shoulder bolt holes on the outside of ring gear and hub. NOTE: You may lift the ring gear off the hub to align the shoulder bolt holes. The ring gear and carrier are installed together only to keep the punch marks on the carrier in place. 11. Set carrier sub-assembly (3) on a flat work surface so the large ends of cluster gears (3F) face up.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 16. Set the cover (6A) on table, interior side up. Grease o-ring (5) and place it into the counterbore around the edge of cover (6A). 19. Place shoulder bolts (13) into the four shoulder bolt holes in cover (6) and tighten by hand. NOTE: The o-ring may be stretched or pinched together to make it fit the counterbore exactly. 20. Place the remaining 12 flatwashers (16) onto the remaining bolt holes in cover (6). 17.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Torque the shoulder bolts (13) 18 to 25 ft. lbs. (25 to 34 Nm). Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 Nm). 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for 2 to 3 minutes. 26. At this point the main assembly is complete. 23. Turn hub (1G) over onto its side. Insert coupling (14) into the end of the spindle (1A). 24. Roll test the unit in both clockwise and counterclockwise directions.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E) The following specialized tools are used to assemble this unit. The tool diagrams included in this manual are intended for the customer who may wish to have a tool made. All tools exist as one piece and must be made from mild steel All dimensions are given in inches. NOTE: In order to improve tool life, tools may be carburized and hardened.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 5. Install the drive motor on the hub, then release the hydraulic pressure at the brake release port. The coupling will remain in position. Shaft Seal Replacement Disconnect the hydraulic power supply and reconnect the line going into the brake release port. 3.5 DRIVE MOTOR (SAUER) 1. Remove the snap ring (1) retaining the shaft seal and support washer.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS INSPECT THE COMPONENTS 2. Using a 1/4 in hex wrench, remove plug (3). 3. Remove O-rings (4, 5, and 6). Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear, and contamination. Polish the shaft and clean the housing if necessary. 4. Using pliers, remove centering springs (7, 8, and 9). 5. Remove spring retaining washers (10 and 11). 6. Remove shift spool (12). INSTALLATION 7. Remove orifice poppet (13). 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Troubleshooting Table 3-5. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil supply to the motor. Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply cause system noise. to the motor is adequate and the lines are unobstructed. Check for air in the system.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Disassembly 17 NOTE: Removal of the endcap voids warranty. 19 During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. 15 Replace all O-Rings and gaskets. 14 It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. 21 6 9 11 5 7 2 18 13 3 10 8 4 12 16 16 1 20 14. 15. 16. 17. 1. 2. 3. 4.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Using a 9/16 in internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 25 22 27 30 29 26 28 27 23 24 25. 26. 27. 28. 29. 30. 22. Screw 23. End Cap 24. O-ring Figure 3-14. End Cap Valve Plate End Cap O-ring Rear Shaft Bearing Minimum Angle Stop Servo Spring Figure 3-15. Valve Plate & Rear Shaft Bearing 13. Using an 8 mm internal hex wrench, remove the endcap screws (22). 14. Remove the endcap (23).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 18. Remove minimum angle stop (29) and servo spring (30) from the housing. shaft seal (34). Discard the seal. To avoid damaging the shaft during seal removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal. 31 36 35 37 38 31. Cylinder Kit Assembly Figure 3-16. Cylinder Kit 19. Turn the housing on its side and remove the cylinder kit assembly (31).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Lift here 44 39 45 47 40 48 43 42 49 41 46 53 52 39. 40. 41. 42. 43. 50 Swashplate Servo Piston Piston Seal O-ring Journal Bearings 51 44. 45. 46. 47. 48. Figure 3-19. Swash Plate & Servo Piston 23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever. 24. Remove the servo piston (40). Remove the piston seal (41) and O-ring (42) from the servo piston. Discard the seal and O-ring. 25.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining ring (51). Carefully release the pressure and remove the outer block spring washer (50), block spring (52), and inner block spring washer (53) from the cylinder block.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS BALL GUIDE AND SLIPPER RETAINER Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat. Do not reuse. Replace swashplate if the difference in thickness from one side to the other exceeds specification. 0.0025 mm [0.0001 in] Slipper retainer 25.8 mm LV [1.015 in] mm KV 24.6 [0.969 in] Ball guide Thickness equality side to side: 0.05 mm [0.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SERVO PISTON AND MINIMUM ANGLE STOP Assembly Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace if necessary. 1. Install new O-ring (1) and piston seal (2) to the servo piston (3). Install the piston seal over the O-ring. Installing the piston seal stretches it, making it difficult to install the servo piston in its bore. Allow 30 minutes for the seal to relax after installation.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (7) into the groove in the cylinder block. 6. Install the journal bearings (13) into the housing seats. Use assembly grease to keep the bearings seated during assembly. Ensure the locating nubs drop into the cavities in the seats.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) onto shaft. 10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the slippers facing the swashplate. Rock the shaft to align the block splines and slide the cylinder kit into place.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Press the rear shaft bearing (22) into the endcap. Install the bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface. 22 2 mm [0.08 in] 23 3 mm [0.12 in] 15. Install the endcap (25) onto the housing with the endcap screws (26). Check to ensure the endcap will properly seat onto the housing without interference.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with the cup side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. Install seal support washer (28) and snap ring (29). 19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation torques. 5/16 in 63 ft.lbs. (85 Nm) 1/4 in 33 ft.lbs.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Initial Start-up Procedures 20. Install orifice poppet (30). Follow this procedure when starting-up a new motor or when installing a motor that has been removed. 37 36 33 39 34 41 11/16 in 30 27 ft.lbs. (37 Nm) 40 5/8 in 20 ft.lbs. (27 Nm) 32 35 38 Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.6 FRONT AXLE Steering Assembly 16 14 17 1 15 12 13 10 2 5 6 20 19 8 9 4 18 7 15 11 3 3 14 1. Steer Cylinder 6. Bearing 11. Washer 16. Thrust Washer 2. Screw, 3/4"D x 1 3/4" 7. Tie Rod 12. Cylinder Block 17. Bearing 3. Nut 8. End Bearing Rod 13. Spindle 18. Thrust Washer 4. Thrust Washer 9. Nut 14. Bolt, 3/8"-16 x 3/4" 19. O-ring 15. Kingpin 20. Bearing 5. Thrust Washer 10. Bolt, 1/2"-13 x 3 1/2" Figure 3-32.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Axle Assembly 1 7 5 5 4 7 6 1. Front Axle 4. Axle Pivot Pin 2. Bolt, 5/8"-11NC x 1 1/2" 5. Thrust Washer 3. Pin Keeper 6. Thrust-Axle Washer 3 2 7. Bearing Figure 3-33. Axle Assembly REMOVAL: ASSEMBLY: 1. When installing the axle assembly, follow Removal Steps in reverse. SUPPORT THE FRAME AND AXLE BEFORE ATTEMPTING ANY REMOVAL AND/OR ASSEMBLY PROCEDURES. NOTE: Apply Loctite® #271 to bolt (2). 1. Disable machine operation.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Front Axle - Tow Bar Installation (If Equipped) 2 5 6 2 1 3 4 6 1. Tow Bar Axle Mount 2. Tow Bar Steering Stops 3. Tow Bar 4. Steering Link 5. Pivot Pin 6. Tie Rod/Tow Bar Shoulder Screws Figure 3-34. Tow Bar Installation (If Equipped) INSTALLATION: 4. Install the steering link (4) to the tow bar (3) with the shoulder screw (6), placing a thrust washer between the steering link and the tow bar as shown above.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Axle Lockout Cylinder 1 3 2 1. Axle Lockout Cylinder 2. Bolt, 1/2"-11NC x 2 3/4" 3. Washer Figure 3-35. Axle Lockout Cylinder REMOVAL: INSTALLATION: 1. Disable machine operation. 2. Disconnect, cap and label hydraulic lines on the axle lockout cylinder (1). 3. Remove the four bolts (2) and washers (3) connecting the cylinder to the frame. 4. Carefully remove cylinder from the frame. 1. Attach cylinder to frame using four bolts (2) and washers (3).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.7 LEVELING JACKS (IF EQUIPPED) Cylinder Removal 1 1. Cover 2. Bolt, 1/4"-20NC x 7/8" 3. Flatwasher 2 3 4. Tinnerman Nut 3 2 4 4 5. Jack Cover Bracket 6. Bolt, 1/2"-13NC x 3" 8 7. Nut 7 8. Leveling Jack Cylinder 5 6 Figure 3-35. Leveling Jack Cylinder Removal REMOVAL: INSTALLATION: 1. Disable machine operation. 1. Follow Removal Steps in reverse. 2. Remove the four bolts (2), flatwashers (3) and tinnerman nuts (4) from cover (1).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Assembly Removal NOTE: Applies to both front and rear of machine. 2 7 5 7 4 6 9 8 4 3 1 1. Leveling Jacks Assembly 4. Washer 7. Washer 2. Bolt, 1/2"-13NC x 1 3/8" 5. Bolt, 3/4" - 10NC x 3 1/4" 8. Plate 3. Nut 6. Nut 9. Support Figure 3-36. Leveling Jacks Assembly REMOVAL: 5. Carefully lower assembly from the supports (9). 6. Supports can be removed from chassis by removing the four bolts (5), nuts (6) and washers (7).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.8 PLATFORM 1. Platform 2. Scissor Arms 3. Slide Block 4. Bolt, (metric) 10 x 200 5. Locknut, (metric) M10 x 1.5 1 6. Pin 7. Spacer Tube 3 8. Bolt, 3/8"-16NC x 1 3/8" 4 3 9. Locknut 7 8 10. Pin Keeper 9 10 11 6 5 11. Pin 3 2 Figure 3-37. Platform Removal 4. Detach the center attach link from the platform by removing the bolt (8), locknut (9) pin keeper (10) and pin (11).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Deck Extension Cylinders (if equipped) 1. Platfrom & Deck Extension 2. Deck Extension Cylinders 3. Shoulder Screw 4. Flatwasher 5. Locknut, 5/8"-11NC 6. Hanger Bracket 7. Clamp 1 8. Bolt, 3/8"-16NC x 4 1/2" 9. Locknut, 3/8"-16NC 8, 9, 10 6 8, 9, 10 11 3, 12, 13 10. Flatwasher 11. Cylinder Attach Bracket 12. Shoulder Screw 13. Flatwasher 3, 4, 5 2 7 2 Figure 3-38. Deck Extension Cylinders Removal REMOVAL: INSTALLATION: 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Control Station 5 1. Mounting Bracket 14 2. Bolt, 1/4"-20NC x 1/2" 1 3. Starwasher ! 7, 9 2 3 8 6 7 4. Console Box 5. Console Lid 6. Self Tapping Screw, #8-18 x 3/4" 7. Washer 8. Insulation Tape 9. Plastite Screw, #10-32NC x 1/2" 10. Self Tapping Screw, #8-18 x 3/4" 11. Terminal Nut 12. D-Ring Bracket 13. Harness 4 14. Joystick Controller 13 10 12 11 Figure 3-39. Platform Control Station DISASSEMBLY: ASSEMBLY 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Joystick Controller Figure 3-40. Joystick Controller Table 3-11. Joystick Specifications Input Voltage Table 3-12. Joystick Plug Loading Chart 5V Terminal Color Function Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right Reverse Voltage 4.60V to 4.80V 2 Green Steer Left Forward Voltage 0.40V to 0.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.9 SCISSOR ARMS Lift Cylinder Removal 1 2 5 4 3 Bottom Connection Point Top Connection Point 1 7 8 6 1. Lift Cylinder 4. Nut 7. Bolt, 1/2"-13NC x 1 5/8" 2. Pin 5. Collar 8. Nut 3. Bolt, 3/8"-16NC x 3" 6. Pin Figure 3-41. Lift Cylinder Removal REMOVAL: 4. Attach lifting straps to overhead crane and lift cylinder and support cylinder before attempting to remove from arm assembly.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Scissor Arms Removal Scissor Arm Assembly Removal 3 1 6 1 3 2 2 5 5 4 1. Scissor Arm 4. Nut 2. Pin 5. Collar 3. Bolt, 3/8"-16NC x 3" 6. Bearing 3 4 1. Scissor Arm 4. Bolt, 3/8"-16NC x 1 1/4" 2. Slider 5. Nut 3. Pin Figure 3-43. Scissor Assembly Removal - Chassis Connection Figure 3-42. Scissor Arms Removal NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.10 SIDE COMPARTMENT COVERS Inside: REMOVAL: Front: 1 2, 3, 4 9 5, 6, 7 9 2, 3, 4 6. Open the hood (8). 7. Remove the two bolts (2), washers, (3) and nuts (4) attaching the cover to the bracket (9). 8 2, 3, 4 1. Compartment Cover 6. Washer 2. Bolt, 3/8"-16NC x 1 1/8" 7. Nut 3. Washer 8. Hood 4. Nut 9. Bracket Rear: 5. Screw, 3/8" x 1" NOTE: Procedures apply to both left and right side compartment hoods. 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.11 GROUND CONTROL STATION Ground Control Station Control Station Removal 1 2 2 1 1. Ground Control Box 4 2. Lid Figure 3-45. Ground Control Station 3 DISASSEMBLY: 1. Disconnect the harnesses from the ground control box (1). 2. Open the lid (2) to gain access to components inside the ground control box. 1. Ground Control Box 3. Bolt, 1/4"-20NC x 3/4" 2. Control Box Mount 4. Lockwasher 3.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.12 FUEL TANK 1. Fuel Tank 2. Fuel Lines 3. Bolt, 3/8"-16NC x 1 1/8" 3, 4, 5 4. Washer 5. Nut 6. Bolt, 3/8"-16NC x 1" 7. Washer 8. Nut 1 2 6, 7, 8 Figure 3-46. Fuel Tank Removal REMOVAL: INSTALLATION: 1. Disable machine operation. 1. Follow Removal Steps in reverse. 2. Drain fuel from the fuel tank (1). Store fuel in appropriate receptacle. 3. Disconnect and cap the two fuel lines (2) attached to the fuel tank.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.13 HYDRAULIC TANK 1. Hydraulic Tank 2. Drain Plug 3. Ground Control Box Mount 4. Bolt, 3/8"-16NC x 1" 5. Washer 6. Nut 7. Bolt, 3/8"-16NC x 1 1/8" 8. Washer 9. Nut 2 7, 8, 9 3 1 4, 5, 6 Figure 3-47. Hydraulic Tank Removal REMOVAL: NOTE: It is recommended to remove the side compartment cover before attempting to remove the hydraulic tank (refer to Section 3.10, Side Compartment Covers).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.14 BATTERY 1. Battery 2. Battery Terminal (+) 3. Battery Terminal (-) 4. Bracket, Bolt, Nut & Washers 5. Fuse Mounting Block Figure 3-48. Battery Removal REMOVAL: INSTALLATION: 1. Disconnect the red battery cable from the positive battery terminal (2). 1. Place battery in the seat. Positive battery terminal (2) should be closest to outside of machine. 2. Disconnect the black battery cable from the negative battery terminal. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.15 DUAL FUEL/LPG SYSTEM Using Liquid Petroleum (LP) Gas IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN MOMENTARILY. WHEN REFUELING LPG POWERED SIZZOR LIFTS, ALWAYS FOLLOW MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE REGULATIONS.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.16 DEUTZ ENGINE Deutz EMR 2 The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are connected by means of separate cable harnesses to the EMR control unit.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS CONTROL ROD POSITION SENSOR/ACTUATOR POWER SUPPLY COOLANT TEMPERATURE SENSOR CAMSHAFT SPEED SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE & FAULT REPORTING. OIL PRESSURE SENSOR Figure 3-50.
Figure 3-51.
Figure 3-52.
Figure 3-53.
Figure 3-54.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-55.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-56.
Figure 3-57.
Figure 3-58.
Figure 3-59.
Figure 3-60.
Figure 3-61.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Generator (if equipped) 3, 4 1 5, 6 2 -OR7 1. Generator (120V or 220V) 2. Deutz Engine 3. Bolt, 5/16"-18NC x 1" 4. Washer 5. Bolt, 7/16"-14NC x 2 1/4" 6. Washer 7. Voltage Regulator Figure 3-62. Generator (Deutz Engine) INSTALLATION: 1. Follow Removal Steps in reverse. Ensure belt is tight before securing generator with the bolts. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. NOTE: Apply Loctite® #242 to the bolts (3, 5). REMOVAL: 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust System 8, 9 7 6 3, 4, 5 2 1 10, 11 1. 2. 3. 4. Muffler Exhaust Tail Pipe Bolt, 3/8"NC-16 x 1" Washer 5. 6. 7. 8. Nut Clamp Exhaust Pipe Nut 9. Washer 10. Bolt, 3/8"NC-16 x 1" 11. Washer Figure 3-63. Exhaust System (Deutz Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse. NOTE: Apply Loctite® #242 to bolt (10). REMOVAL: 1. Disable machine operation. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Cleaner System 5 3 2 1 1. Air Cleaner 2. Air Intake Hose 3. Clamp 4. Mounting Bracket 5. Engine 4 3 Figure 3-64. Air Cleaner System (Deutz Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse. REMOVAL: 1. Disable machine operation. 2. Loosen the two clamps (3) attaching the air intake hose (2) to the engine (5) and air cleaner (1). 3.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Relays 1 3, 4, 5 6 1. Weather Proof Relay 2. Solenoid Relay 2 3. Bolt, NO10-24 x 0.75" 4. Locknut 7, 8, 9 5. Washer 6. Relay Mounting Bracket 10 7. Glow Plug Harness 8. Bolt, NO8-32 x 0.625" 9. Locknut 10. Muffler Mounting Bracket Figure 3-65. Relays (Deutz Engine) REMOVAL: INSTALLATION: 1. Disable machine operation. 1. Follow Removal Steps in reverse. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pumps 8 5 6 7 4 1 2 3 1. Gear Pump 4. O-ring 7. Washer, 2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Pump Coupling 3. Washer 6. Bolt, 1/2"-13NC x 1 1/2" Figure 3-66. Pump Assemblies (Deutz Engine) ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 4. Remove the two bolts (6) and washers (7) attaching the axial pump to the flange of the motor. Carefully remove the axial pump. INSTALLATION: REMOVAL: 1. Follow Removal Steps in reverse.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pump Coupling 4 1 1. Muffler Mounting Bracket 2. Bolt, M10 x 85mm 3. Washer 4. Pump Coupling 5. Bolt, Coupling 3 5 2 Figure 3-67. Pump Coupling (Deutz Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. REMOVAL: 1. Follow Removal Steps in reverse. NOTE: Apply Loctite® #242 to bolts (2). Torque coupling bolts to 50 lb-ft (68 Nm). 1. Disable machine operation. 2. Remove exhaust system and pumps (refer to Figure 3-63.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1. Deutz Engine 2. Rear Engine Mount 3. Bolt, M14 x 30mm 4. Front Engine Mount 5. Bolt, M14 x 55mm 6. Spacer Tube 3 2 1 5, 6 4 Figure 3-68. Engine Removal (Deutz Engine) 6. Remove the bolts (5) and spacer tubes (6) securing the engine to the front engine mount (4). ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 7. Slowly lift the engine up and out of the engine compartment. REMOVAL: 1. Disable machine operation. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Radiator 3, 4, 5 1. Radiator 2. Radiator Hose 2 3. Bolt, 3/8"-16NC x 1" 4. Washer 5. Nut 2 6. Bolt, 5/16"-18NC x 7/8" 7. Washer 1 6, 7 Figure 3-69. Radiator (Deutz Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW RADIATOR TO COOL DOWN BEFORE SERVICING. REMOVAL: 1. Disable machine operation. 2. Disconnect, cap and label the radiator hoses (2) on the radiator (1). 3. Remove the engine (refer to Figure 3-68.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.17 GM ENGINE • Check the Positive and Negative battery cables for any corrosion build up, rubbing or chafing, Check connection on the chassis to ensure they are tight. Maintenance of the Drive Belt The serpentine drive belt utilizes a spring loaded tensioner which keeps the belt properly adjusted. The drive belt is an integral part of the cooling and charging systems and should be inspected frequently.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 5. Oil level must be between the "FULL" and "ADD" marks. Engine Tray Figure 3-43. Engine Oil Dip Stick 6. If the oil level is below the "ADD" mark, proceed to Step 7 and 8 and reinstall the dipstick into the dipstick tube. 7. Remove the oil filter cap from the valve rocker arm cover. 8. Add the required amount of oil to bring the level up to but not over "FULL" mark on the dipstick. 9.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Generator 3, 4 1 5, 6 2 7 1. Generator 4. Washer 7. Voltage Regulator 2. GM Engine 5. Bolt,7/16"-14NC x 1 1/4" 3. Bolt, 5/16"-18NC x 1 1/4" 6. Washer Figure 3-71. Generator (GM Engine) INSTALLATION: 1. Follow Removal Steps in reverse. Ensure belt is tight before securing generator with the bolts. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. NOTE: Apply Loctite® #242 to the bolts (3, 5). REMOVAL: 1. Disable machine operation.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust System 7 6 8 2, 3, 4 5 1 1. Tail Pipe 4. Nut 7. Exhaust Pipe 2. Bolt, 3/8"-16NC x 1" 5. Exhaust Pipe 8. Mounting Bracket 3. Washer 6. Muffler Figure 3-72. GM Exhaust System (GM Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse. REMOVAL: 1. Disable machine operation. 2. Remove the exhaust pipe (5) from the muffler (6) and tail pipe (1) by removing the bolts. 3.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Cleaner System 6 5 4 1. Air Cleaner 2. Mounting Bracket 3. Rubber Elbow 4. Air Intake Tube 5. Sleeve 1 6. Air Intake Tube 2 3 Figure 3-73. Air Cleaner System (GM Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse. REMOVAL: 1. Disable machine operation. 2. Pull the rubber elbow (3) off of the air cleaner (1) and air intake tube (4). 3. Pull the air intake tube out of the sleeve (5).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Radiator 1 4 2 5, 6, 7 3 1. Radiator 2. Radiator Hose 3. Radiator Hose 4. Coolant Overflow Container 5. Bolt, 1/4"-20NC x 7/8" 6. Washer 7. Nut 9, 10, 11 8. Radiator Hose 9. Bolt, 3/8"-16NC x 1" 10. Washer 11. Nut 8 Figure 3-74. Radiator (GM Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW RADIATOR TO COOL DOWN BEFORE SERVICING. 2. Ensure drain valve on radiator (1) is closed. Refill radiator with 2.63 gal (10 ltr) of anti-freeze fluid.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Fuel Components 9 10 8 5 6 1. Fuel Pump 2. Fuel Tank 3. Fuel Line - Supply from Tank 4. Fuel Line - to Fuel Filter 5. Fuel Filter 6. Fuel Line - to Fuel Pump 7. Fuel Line 8. Fuel Regulator 9. Fuel Line - Return to Tank 10. Fuel Line - to Engine 2 3 1 4 Figure 3-75. Fuel Components (GM Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. REMOVAL: 1. Follow Removal Steps in reverse. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pumps 7 6 2 3 5 4 8 1 1. Gear Pump 4. O-ring 7. Washer 2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Coupling Flange 3. Washer 6. Bolt, 1/2"-13NC x 1 1/2" Figure 3-76. Pump Assemblies (GM Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. REMOVAL: 1. Disable machine operation. Disconnect, cap and label all hydraulic hoses connected to pumps (1, 4). Disconnect and label all wiring connected to pumps. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pump Coupling 4 1 3 2 1. Muffler Mounting Bracket 2. Coupling Cover 3. Coupling 4. Engine Figure 3-77. Pump Coupling (GM Engine) INSTALLATION: ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse. REMOVAL: 1. Disable machine operation. 2. Remove exhaust system and pumps (refer to Figure 3-72. and Figure 3-76.). 3. Remove the bolts and washers to remove the muffler mounting bracket (1) from the coupling cover (2).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1. Bolt, 1/2"-13NC x 1 1/2" 2. Washer 3. Nut 4. Engine 5. Engine Tray 1, 2, 3 4 5 1, 2, 3 Figure 3-78. Engine Removal (GM Engine) 6. Slowly lift the engine up and out of the engine compartment. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING. BE CAREFUL NOT TO DAMAGE THE RADIATOR FAN ON THE RADIATOR HOUSING WHEN LIFTING THE ENGINE. REMOVAL: 1. Disable machine operation. 2.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.18 GM ENGINE DUAL FUEL SYSTEM lock off supply voltage is controlled by the engine control module (ECM). The Dual Fuel system allows the operator to operate the vehicle on either gasoline or LPG by positioning a selector switch on the platform control station. When the operator places the selector switch in the gasoline mode, the gasoline fuel pump is energized. While in the gasoline mode, the LPG fuel lock-off is isolated and will not energize.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Low Pressure Regulator (LPR) Air Fuel Mixer The LPR is a combination vaporizer, pressure regulating device. The LPR is a negative pressure, two stage regulator that is normally closed when the engine is not running. When the engine is cranking or running, a partial vacuum is created in the fuel line which connects the regulator to the mixer. This partial vacuum opens the regulator permitting fuel to flow to the mixer.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Electronic Throttle Control (ETC) Engine Control Module (ECM) Engine speed and load control is maintained by an ETC device. Speed and load control are determined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine. The Electronic Throttle Control device, or "throttle body assembly", is connected to the intake manifold of the engine.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Heated Exhaust Gas Oxygen Sensor (HEGO) There are two Heated Exhaust Gas Oxygen Sensors (HEGO). The first HEGO is mounted in the exhaust system downstream of the engine. It is used to measure the amount of oxygen present in the exhaust stream and communicate that to the ECM via an electrical signal. The amount of oxygen present in the exhaust stream indicates whether the fuel/air ratio is too rich or too lean.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Fuel Filter 3.19 GM ENGINE FUEL SYSTEM REPAIR After the fuel is drawn into the fuel pump, the fuel flows through the gasoline fuel filter. The fuel filter will trap small particles as the fuel passes through the filter to remove debris and prevents the fuel pressure and temperature manifold and fuel injectors from becoming damaged. Maintenance of the fuel filter is required as indicated in Section 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Propane Fuel Filter Replacement 3. Install the housing seal. 4. Drop the magnet into the bottom of the filter housing. 1 5. Install the filter into the housing. 7 6. Install the retaining bolt into the filter housing. 8 2 7. Install the filter up to the bottom of the electric lock off. 9 3 10 8. Tighten the filter retaining bolt to 106 in.lbs. (12 Nm). 4 9. Open manual shut-off valve.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Disconnect the electrical connector from the Electric Lock off. 7. Connect the fuel supply line and tighten until fully seated. 5. Remove the Electric Lock Off from the regulator. 8. Connect the EPR electrical connector. 6. Remove the lock pin from the vapor fitting on the regulator housing. Remove the fitting and hose and retain the pin. 9. Open the manual valve. 7. Remove the lock pin from the pressure sensor on the regulator housing.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Temperature Manifold Absolute Pressure (TMAP) Sensor Electronic Throttle Control Replacement See Figure 3-91. REMOVAL: 1. Disconnect the negative battery cable. 2. Remove the air intake duct. 3. Release the hose clamp on the vapor fuel line and remove the vapor hose. 4. Disconnect the TMAP electrical connector. 5. Disconnect the electronic throttle control connector. 6.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 2. Install the two quad seals. Install one seal at a time to ensure the seal does not roll. The seal must sit flat on the throttle body. 4. Place gasket on intake manifold and attach mixer/ throttle assembly to manifold. Figure 3-92. Mixer Assembly Mixer Replacement 3. Attach mixer and throttle body together. The two parts do not bolt together; they will be secured when you mount it on the intake.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Coolant Hose Replacement INSTALLATION: REMOVAL: 1. Drain the coolant into an appropriate container. 2. Using hose clamp pliers, disconnect both hose clamps on each hose. THE CONTROLLER IS CALIBRATED FOR EACH ENGINE. VERIFY YOU HAVE THE CORRECT CONTROLLER 1. Plug connector into controller. 3. Remove the hose from each of the fittings. 2. Push lock into place. INSTALLATION: 3. Mount controller into mounting bracket.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.20 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel and that liquid fuel is being delivered to the LPR.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2 2 Perform the On Board Diagnostic (OBD) System Check. Are any DTCs present in the ECM? -- Go to the applicable DTC Table Go to Step 3 3 Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual valve is open and the tank quick connect is fully engaged.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO -- Go to Step 14 Go to Step 16 12W - 16W Go to Step 15 Go to Step 23 13 1. Turn OFF the ignition. 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. 4. Crank the engine. The test light should illuminate. Does the test light illuminate? 14 Using a DVOM, check the resistance of the low pressure lock-off (LPL).
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO -- System OK -- -- System OK -- The fuel supply system is operating normally, if a failure of the control solenoids is suspected. Refer to Fuel Control System Diagnosis. 25 26 3-120 1. Install the test plug in the LPR secondary chamber. 2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic procedure. Is the action complete? 1.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s): Lamp (MIL) • A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating. • The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Exhaust System Checks Action • Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure • Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis. Hard Start DEFINITION: The engine cranks OK, but does not start for a long time.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Exhaust System Checks Action • Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure • Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service Manual.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Hesitation, Sag, Stumble DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's severe enough. Preliminary Checks Refer to Important Preliminary Checks. Fuel System Checks • Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Lack of Power, Sluggishness, or Sponginess DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks • Refer to Important Preliminary Checks. • Refer to the LPG Fuel system OBD System Check. • Compare the customer's vehicle with a similar unit. Make sure the customer has an actual problem.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Ignition System Checks Action • Verify that the spark plugs are correct for use with LPG (R42LTS). • Check the spark plugs.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Engine Mechanical Check Action • Check the engine for the following: - Broken motor mounts - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes Surges/Chuggles DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-17.
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-17.
SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 CYLINDERS - THEORY OF OPERATION Cylinders are of the double acting type. The steer system incorporates a double acting cylinder. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod).
SECTION 4 - HYDRAULICS Cylinders With Single Counterbalance Valve Oscillating Axle Cylinder Test (Lockout) OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 1. Using all applicable safety precautions, activate hydraulic system. 2. Shut down hydraulic system and allow machine to sit for 10-15 minutes.
SECTION 4 - HYDRAULICS 4.4 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fixture. NOTE: The following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
SECTION 4 - HYDRAULICS tighten the cap screw(s) until the bushing is loose on the piston. 13. Remove the bushing from the piston. 7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8.
SECTION 4 - HYDRAULICS 8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary. 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. 10. Inspect threaded portion of head for damage. Dress threads as necessary. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual.
SECTION 4 - HYDRAULICS Figure 4-9. Wiper Seal Installation 3. Place a new “o”ring and back-up seal in the applicable outside diameter groove of the cylinder head. Figure 4-11. Piston Seal Kit Installation 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible. Figure 4-10. Installation of Head Seal Kit 4. Install washer ring onto rod.
SECTION 4 - HYDRAULICS 17. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged. 19.
SECTION 4 - HYDRAULICS Table 4-1. Cylinder Piston Nut Torque Specifications Description Nut Torque Value Setscrew torque Value Lift Cylinder 400 lb-ft (542 Nm) 100 in.lbs. (12 Nm) Lockout Cylinder N/A N/A Steer Cylinder N/A N/A Torque Value Sun - 7/8 hex M20 x 1.
SECTION 4 - HYDRAULICS “Jog” or slowly rotate prime mover until charge pressure starts to rise. Start prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from high pressure lines through high pressure gauge ports. DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START-UP.
SECTION 4 - HYDRAULICS inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher than it is capable of. Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port.
SECTION 4 - HYDRAULICS 3. Using light clamping pressure on the ears of the front cover, secure unit in vise with shaft side down. Remove the cap screws (14) and washers (9). 4. Separate rear cover (6) from the body (13). The static seal (8) may remain either with the body or the cover. In either case, remove the static seal and discard. NOTE: A somewhat heavier wear pattern is normal on the low pressure (inlet) side of the bearing blocks (2). However, there should be no heavy scoring in this area. 5.
SECTION 4 - HYDRAULICS . 2. Clamp front cover into vise so that the ring groove is up. Apply a small amount of grease to the seal groove and install a new seal ring (8) into the groove. 8. Place a small amount of grease in the seal groove on the rear bearing block (2). Install a new load seal and anti extrusion seal in the groove. Insert the bearing block into the body, making sure that the load seal and anti extrusion seal are positioned properly.
SECTION 4 - HYDRAULICS 4.8 VALVES 1 1. Main Valve 3 2 2. Flow Divider Valve 3. Outrigger Directional Valve Figure 4-15. Hydraulic Compartment REMOVAL: INSTALLATION: 1. Disconnect, cap and lable all hydraulic hoses and any electrical harness connected to valves. 1. Re-attach valve blocks to tray with bolts. 2. Re-connect all hydraulic lines and electrical harness. 2. Remove the valve blocks from the hydraulic tray by removing the attaching bolts.
SECTION 4 - HYDRAULICS Main Valve SV5, CL1 OSC AXLE 1 SV7, CL2 DUMP VALVE SV6, CL2 OSC AXLE 2 CV1 PLG6 SV1, CL2 LIFT UP SV2, CL1, CL1 STEER SV4, CL1 BRAKES LS1 SV3, CL1 2-SPD T1 P3 PLG6 PLG4 T3 L2 CV3 T4 LO F PLG6 P2 R RV2 P1 L1 MP1 RV1 S1 S2 B2 ORF1 MP2 T2 G RV3 B1 2S2 PLG6 ORF2 2S1 Figure 4-16.
SECTION 4 - HYDRAULICS Table 4-3. Main Valve Torque Specs Component Table 4-4. Porting Specs Port Torque Size L2, P1 & T1 SAE 10 L1 SAE 08 SV1 (Lift Up) 25 lb-ft (34.2 Nm) SV2 (Steer) 20 lb-ft (27.3 Nm) G, P2, P3, T4 & T2 SAE 06 SV3 (2-Spd) 20 lb-ft (27.3 Nm) All Others SAE 04 SV4 (Brakes) 20 lb-ft (27.3 Nm) SV5 (Osc Axle 1) 20 lb-ft (27.3 Nm) SV6 (Osc Axle 2) 25 lb-ft (34.2 Nm) SV7 (Dump Valve) 25 lb-ft (34.2 Nm) CL1 & CL2 (Coil) 5 lb-ft (6.8 Nm) RV1, RV2 & CV3 25 lb-ft (34.
SECTION 4 - HYDRAULICS Flow Divider Valve 9 13 9 7 CV4 3 CV3 CV5 CV6 6 CV2 OR2 11 10 8 5, OR1 FD2 FD1 2 12 1 OR3 CV7 4 CV8 FD3 Figure 4-18.
SECTION 4 - HYDRAULICS PB1 PB2 PB3 PB4 PA1 PA2 PA3 PA4 Leveling Jacks Directional Valve LP PA2 PB1 PA1 PB3 T PA3 PB2 LP PB4 PA4 T Figure 4-19. Leveling Jacks Directional Valve Table 4-5.
SECTION 4 - HYDRAULICS Powerdeck Valves SV1, CL1, CL1 P 1 T 2 RV1 Figure 4-20. Powerdeck Valve (Single) SV1, CL1, CL1 SV2, CL1, CL1 P T RV1 3 1 4 2 RV2 Figure 4-21. Powerdeck Valve (Double) Table 4-6. Powerdeck Valve Torque Specs 4-18 Item Torque SV1, SV2 25 lb-ft (34.2 Nm) CL1 5 lb-ft (6.8 Nm) RV1, RV2 20 lb-ft (27.3 Nm) NOTE: All ports are SAE 04.
SECTION 4 - HYDRAULICS Leveling Jack Valves 3 4 1 2 B A NOTE: Applies to all four Leveling Jacks. Figure 4-22. Leveling Jack Valves Table 4-7. Leveling Jack Valves Torque Specs 3121249 Item Torque 1 3 to 4.5 lb-ft (4.1 to 6.1 Nm) 2 18.5 to 22 lb-ft (25.1 to 29.8 Nm) 3 40 lb-ft (54.2 Nm) 4 32 lb-ft (43.
SECTION 4 - HYDRAULICS Pressure Setting Procedures decrease. (The relief valve is on the same face as the solenoid valves). Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures. 1. 5.
SECTION 4 - HYDRAULICS 4.9 GEAR PUMP Table 4-8. Gear Pump Specs Rotation (Viewing Drive End) Displacement Clockwise 0.878 in/rev (14.4 cc/rev) Max Rated Speed 3500 rpm Rated Pressure 3625 psi (250 bar) Minimum Speed at Rated Pressure 1000 rev/min Gear Pump Priming 1 The gear pump is mounted with the suction hose up. Air trapped in this area can cause an air lock on start up.
SECTION 4 - HYDRAULICS 4.10 AXIAL HI 45 PUMP 8 7 6 2 4 5 3 11 12 1 10 9 1. Case Drain Port L2 (SAE#12) 5. Charge Pressure Filtration Port (to inlet on filter) 2. Deutsch DT04-2P Connector 3. M5 Servo Gage Port (SAE#4) 4. Charge Pressure Filtration Port (from outlet on filter) 9. Port A (SAE#16) 6. MB Gage Port (SAE#6) 10. Charge Pump Suction Port (SAE#16) 7. M3 Charge Gage Port (SAE#6) 11. Port B (SAE#16) 8. M14 Gage Port (SAE#4) 12. Case Drain Port L1 (SAE#12) Figure 4-24.
SECTION 4 - HYDRAULICS 14 1 2 13 12 3 11 4 5 6 7 8 9 10 1. Electric Displacement Control 6. Shaft 11. Charge Pump 2. Swashplate Feedback Pin 7. Front Bearing 12. Rear Bearing 3. Piston 8. Swashplate Bearing 13. Valve Plate 4. Slipper 9. Swashplate 14. Servo Piston 5. Shaft Seal 10. Cylinder Block Figure 4-25.
SECTION 4 - HYDRAULICS General Repair Instructions Start-Up Procedure REMOVAL: PRIOR TO PERFORMING REPAIRS, REMOVE THE UNIT FROM THE MACHINE. CHOCK WHEELS ON THE MACHINE TO INHIBIT MOVEMENT. BE AWARE THAT HYDRAULIC FLUID MAY BE UNDER HIGH PRESSURE AND/OR HOT. INSPECT THE OUTSIDE OF THE PUMP AND FITTINGS FOR DAMAGE. CAP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION. KEEP IT CLEAN Clean the outside of the pump thoroughly before disassembly. Take care not to contaminate system ports.
SECTION 4 - HYDRAULICS AGE HYDRAULIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS. DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND FLUID HAS BEEN THOROUGHLY FILTERED. 8. Disable the engine to prevent it from starting. Crank the starter for several seconds. Do not exceed the engine manufacturer’s recommendation. Wait 30 seconds and then crank the engine a second time as stated above. This operation helps remove air from the system lines. Refill the reservoir to recommended full oil level.
SECTION 4 - HYDRAULICS Electric Control Module D050 (3X) 4 mm D1 4 ft.lbs. (5 Nm) D250 5 mm 10 ft.lbs. D025A D025A Torque sequence D084 4 ft.lbs. (5 Nm) 1 2 D150 6 5 4 3 F100 (2X) 3 mm 1.8 ft.lbs. (2.5 Nm) D300 (2X) REMOVAL: 8. Install the control module and six cap screws (D250). 1. Using a 5 mm internal hex wrench, remove the six cap screws (D250). 2. Remove the control module and gasket (D150). Discard the gasket. 3.
SECTION 4 - HYDRAULICS ing ring diameter is less than 1.53 in (38.84 mm) when installed on the shaft. 6. Install solenoid with three cap screws (D050) using a 4 mm internal hex wrench. Torque screws to 5 Nm (4 lb-ft). 7. Install the shaft/bearing assembly into the pump. 7. Install coil using a 12 point 26 mm socket. Torque coil nut to 3.7 lb-ft (5 Nm). 8. Lubricate and install a new O-ring (J260) onto seal carrier (J275). Press a new seal (J250) into the seal carrier.
SECTION 4 - HYDRAULICS 8. Remove the charge pump outer ring (S150), and gearset (S100). Charge pump removal/installation 9. Remove valve plate (S250) with seal (S300). Discard seal K400 8 mm INSPECTION: 10. Inspect the components for wear, scratches or pitting. Carefully inspect the valve and pressure-balance plates. Scratches on these components will cause a loss of charge pressure. If any component shows signs of wear, scratching or pitting, replace it. K100 G450 G450 K150 REASSEMBY: K500 11.
SECTION 4 - HYDRAULICS Charge Check/HPRV Charge Pressure Relief Valve REMOVAL: 1. Using a 22 mm hex wrench, remove the HPRVs (L100/L200). Remove and discard the O-rings (L060) and backup rings (L068). Replace the charge pressure relief valve (V10) as a complete unit. Do not attempt to repair the internal components of the valve. Torque to 38 lb-ft (52 Nm). REMOVAL: 1. Using a 22 mm wrench, remove the charge pressure relief valve (V10). Discard seal (V024). INSPECTION: 2.
SECTION 4 - HYDRAULICS Pressure Limiter Valve Replacement 4.11 CHARGE PUMP FILTER NOTE: Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual components. 2 1 REMOVAL: 1. Using a 14 mm wrench, remove the pressure limiter valves (L300/L400). Discard O-rings. INSPECTION: 2. Inspect the sealing surfaces of the pump for nicks or scratches. REASSEMBY: 3. Install new O-ring. Lubricate 0-ring with petroleum jelly. 4. Replace pressure limiter valves.
SECTION 4 - HYDRAULICS 4.12 AUXILIARY PUMP MOTOR 1 4 5 2 3 Hydraulic Schematic Item # Torque 1. UNF-2A Terminal 2. 2x 96 - 120 in-lbs (11 - 14 Nm) 84 in-lbs (9.5 Nm) 3. Check Valve Cap 144 - 180 in-lbs (16 - 20 Nm) 4. 4x 180 - 216 in-lbs (20 - 24 Nm) 5. 8x 114 - 150 in-lbs (13 - 17 Nm) Figure 4-27. Auxiliary Pump Motor • Displacement: 0.097 CU. IN/REV (1.59 CC/REV) 3121249 • Delivers 1.2 min. GPM (4.5 min Liters/Min) at 1500 psi (103.
SECTION 4 - HYDRAULICS 4.13 CYLINDER ASSEMBLIES 8 9 3 7 6 5 4 1. Barrel Weldment 2. Rod Weldment 3. Cylinder Head 1 4. Wear Ring 5. O-ring 6. Back-up Ring 7. O-ring 4 8. Wiper 5 9. Seal 6 7 10. Wear Ring 3 11. T-Seal 9 8 2 10 11 Figure 4-28. Steer Cylinder NOTE: Apply ant-seize lube to threads of Cylinder Head (3) and torque to 200 lb-ft (271.2 Nm).
SECTION 4 - HYDRAULICS 10 9 6 11 6 10 4 26 25 OR 7 OR 5 1 3 OR 26 2 5 10 5 5 OR 8 27 23 22 23 21 30 19 14 20 17 24 12 15 18 16 28 13 29 26 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cable Adapter Bolt Bracket Manual Descent Cable Plug, O-Ring Jam Nut Cotter Pin Cartridge, Lift Holding Solenoid Cartridge, Lift Holding Solenoid Cartridge, Check 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Flat Washer Wiper Seal Ring, Wear Seal Ring, Back-Up Setscrew Head Seal Ring, Wear 21. 22. 23. 24. 25.
SECTION 4 - HYDRAULICS Hydraulic Schematic 3 8 Lift Cylinder Port Block 10 9 12 1 11 2 Hydraulic Schematic 4 Hydraulic Schematic 6 5 7 Item Torque 1 100 lb-ft (135.6 Nm) 2 100lb-ft (135.6 Nm) 3 25 lb-ft (33.9 Nm) 4 10 - 12 lb-ft (13.6 - 16.3 Nm) 5 35 lb-ft (47.5 Nm) 6 5 lb-ft (6.8 Nm) 7 30 lb-ft (40.7 Nm) 8 25 lb-ft (33.9 Nm) 9 40 lb-ft (54.2 Nm) 10 40 lb-ft (54.2 Nm) 11 40 lb-ft (54.2 Nm) 12 60 lb-ft (81.3 Nm) Figure 4-30.
SECTION 4 - HYDRAULICS 6 7 8 9 1 1. Barrel 2. Rod 3. Wiper 4. Wear Ring 4 5. Rod Seal 6. Plug 5 7. Piston Pilot 8. Check Valve 9. Bleeder Valve 4 NOTE: Torque item #8 to 25-27 lb-ft (34-37 Nm) 3 2 THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF THE BLEEDER VALVE IS LOOSENED. Figure 4-31.
SECTION 4 - HYDRAULICS 5 15 5 1. Head 2. Barrel 2 3. Rod 4. Jack Plate 5. Ring, Lock 6. Ring, Wear 7. Ring, Washer 3 8. Ring, Retaining 9. O-Ring 10. Screw 11. Capscrew 12. Seal 9 13. WIper 6 14. Ring, Back-Up 8 15. T-Seal 1 4 14 12 13 10 16. Jack Pad 8 10 7 11 10 16 Figure 4-32. Leveling Jack Cylinder NOTE: Apply a light coat of grease to the Cylinder Rod (3) before installing the Jack Pad (16). Apply Loctite® #242 to Capscrews (11) and torque to 30 lb-ft ( 40.7 Nm).
SECTION 4 - HYDRAULICS Hydraulic Schematic 1 2 3 Item Description Torque 1 Solenoid Directional Valve 40 lb-ft (54.2 Nm) 2 Straight Fitting 32 lb-ft (43.4 Nm) 3 Straight Fitting 40 lb-ft (54.2 Nm) Figure 4-33.
SECTION 4 - HYDRAULICS 5 3 2 4 6 1 9 10 8 11 12 7 13 1. Locknut 6. Spacer Tube 11. Seal 2. Piston 7. Head 12. Wiper Ring 3. Seal 8. Rod 13. Retaining Ring 4. O-Ring 9. O-Ring 5. Barrel 10. Back-up Ring Figure 4-34.
SECTION 4 - HYDRAULICS Oscillating Axle Cylinder Bleeding Procedure 2 1 1. Oscillating Axle Cylinder 2. Bleeder Valve Figure 4-35. Oscillating Axle Cylinder Bleeding 1. Start the engine. 2. Raise the arms high enough so that the left axle cylinder bleeder valve can be accessed. NOTE: A fast stream of oil will exhaust the air out of the hoses and cylinder better than a slow stream of oil. 8. Every 3-4 seconds, close the bleeder valve so that a slower stream of oil is being purged.
SECTION 4 - HYDRAULICS NOTES: 4-40 – JLG Lift – 3121249
SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER men u: HELP:PRESS ENTER Analyzer Display Escape Key Enter Key To return home or access previous menu Stores and selects Top Level, Sub Level, and item menus Left & Right Arrow Keys Up & Down Arrow Keys Used to move between Top Level, Sub Level, and item menus Value Selector Figure 5-1. Hand Held Analyzer To Connect the Hand Held Analyzer: 1.
SECTION 5 - JLG CONTROL SYSTEM NOTE: The cable has a four pin connector at each end; the cable cannot be connected backwards. 2. Power up the Control System by turning the lower key to the platform position and pulling out both emergency stop buttons. Using the Analyzer: play will scroll the fault across the screen.
SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer: Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly: When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered.
SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION. PERSONALITIES: DRIVE ACCEL 3.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to Table 5-3, Machine Configuration Programming Information and Table 5-5, Machine Model Adjustment for default settings. Password 33271 will give you access to level 1, which will permit you to change all machine personalities and/or machine setup settings. CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE. IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
SECTION 5 - JLG CONTROL SYSTEM 5.2 CALIBRATIONS 3 1 2 1. Scissor Arm Assembly 3. Rotary Angle Sensor 2. Proximity Sensor (on frame inboard slide channel) Figure 5-3. Limit Switch Location Elevation Sensor Calibration 3. SET 30FT ELEV (3394RT) or SET 36FT ELEV (4394RT); Using the Analyzer, in Access Level 1, go to MENU: CALIBRATION: a. Raise platform to a height of 30 feet on the 3394RT or 36 feet for the 4394RT (measured deck to ground). 1. SET STOW ELEV; a.
SECTION 5 - JLG CONTROL SYSTEM Joystick Calibration b. Tilt sensor mounting on machine or wedged crooked in control box: If the machine mounting/grade appears acceptable, open the Ground Control box carefully. Observe whether the tilt sensor is properly seated. Using the Analyzer, in Access Level 1, go to MENU: CALIBRATION: JOYSTICK and press ENTER. 1. Following the analyzer screen prompts: a. Move the Joystick FORWARD and press ENTER. 2 b. Allow Joystick to be in CENTER position and press ENTER.
SECTION 5 - JLG CONTROL SYSTEM an electrical/electronic failure (tilt sensor, control board, electrical connections). a. Open the Ground Control Box. b. Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connections. 4. The Tilt Sensor (1) can be removed from the Sensor Mount (2) by removing the three Screws (7). NOTE: Follow the above procedures in reverse order when installing the tilt sensor assembly.
SECTION 5 - JLG CONTROL SYSTEM 5.3 FLASH CODES AND DESCRIPTIONS Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected. None FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Reported when the trigger is not closed with function selected and joystick out of center.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority Flash code 2/2 indicates difficultly with the platform controls. TRIGGER SWITCH WIRING SHORTED HIGH IN PLATFORM CABLE Reports when the CAN message coming from the platform board and the DI on ground board conflict.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority Flash code 2/3 indicates difficultly with ground controls. FUNCTION LOCKED OUT – GROUND LIFT UP PERMANENTLY CLOSED Reported when the ground lift up switch is closed during power up. FUNCTION LOCKED OUT – GROUND LIFT DOWN PERMANENTLY CLOSED Reported when the ground lift down switch is closed during power up.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority Flash code 2/5 indicates issues that may cutout functions. 2/5 ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLTAGE OUT OF RANGE Reported when the elevation rotary sensor voltage is outside the range of acceptable values. ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when the rotary calibration value does not exist.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority Flash code 2/6 indicates leveling jack or power deck issues. 2/6 3121249 FRONT LEFT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the front left leveling jack is open circuit.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description FRONT DECK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the front deck retract valve is short to ground. FRONT DECK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the front deck retract valve is short to battery.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority Flash code 5/5 indicates a speed sensor issue. 5/5 SPEED SENSOR READING INVALID SPEED Reported when the speed sensor is reading a value over 4000 RPM. SPEED INPUT LOST Reported when the speed sensor is reading zero RPM and the oil pressure is over eight PSI. CAN BUS FAILURE Reported when there is a problem with the CANbus.
5-16 – JLG Lift– LIFT: DECEL X.X S LIFT: MIN UP X% LIFT: MAX UP X% LIFT: MIN DOWN X% LIFT: MAX DOWN X% DRIVE: ACCEL X.X S DRIVE: DECEL X.X S DRIVE: MIN FORWARD X% DRIVE: MAX FORWARD X% DRIVE: MIN REVERSE X% DRIVE: MAX REVERSE X% DRIVE: MID ENG XXXXRPM DRIVE: ENGINE XXXXRPM STEER: ENGINE XXXX RPM PERSONALITIES: STEER DECK RETRACT: ENGINE XXXX RPM DECK EXTEND: ENGINE XXXX RPM PERSONALITIES: POWER DECK GROUND MODE: LIFT DN X% GROUND MODE: LIFT UP X% PERSONALITIES: GROUND MODE Figure 5-6.
3121249 – JLG Lift – TO SHEET 3 MENU: CALIBRATIONS MENU: MACHINE SETUP FROM SHEET 1 ENGINE: 4=DEUTZ ECM LEVEL VEHICLE: YES: ENTER NO: ESC CALIBRATIONS: TILT SENSOR MARKET: 4=AUSTRALIA ENGINE: 3=DEUTZ F3(T2) MODEL NUMBER: 3=43RT 4WD SET XXFT ELEV: YES: ENTER NO: ESC SET XXFT ELEV: YES: ENTER NO: ESC CALIBRATIONS: SET XXFT ELEV LOAD: YES: ENTER NO:ESC CALIBRATIONS: LOAD LOAD: 2=CUTOUT ALL GROUND ALARM: 2=MOTION CALIBRATIONS: SET XXFT ELEV LOAD: 1=CUTOUT PLT GROUND ALARM: 1=DESCENT ENGINE
5-18 MENU: DIAGNOSTICS MENU: SYSTEM TEST FROM SHEET 2 – JLG Lift– VALVES: OPTION VLVE XXX VALVES: STEER RIGHT XXX VALVES: 2 SPD XXX VALVES: LIFT UP XXX VALVES: LIFT DN XXX VALVES: PROP LIFT X% VALVES: LOSC AXLE XXX VALVES: ROSC AXLE XXX VALVES: FL L/J VLVE XXX VALVES: FR L/J VLVE XXX VALVES: RL L/J VLVE XXX VALVES: RR L/J VLVE XXX SYSTEM: HORN XXXX SYSTEM: TILT XX.X XX.
SECTION 5 - JLG CONTROL SYSTEM NOTE: When configuring an RT, the Machine Configuration must be completed before any Personality settings can be changed. Changing the Personality settings first and then changing the Model of the Machine Configuration will cause the Personality settings to return to default values. Table 5-3.
SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Configuration Programming Information Configuration Digit Setting Description 0 NOT INSTALLED — Load Sensing System (LSS) is not fitted to the vehicle. 1 CUTOUT PLT — Load Sensing System (LSS) is fitted, and Platform Controls are prevented in the event of an Overload. Ground Controls remain functional. This is the default setting for CE machines. 10 (LOAD) 2 Default Number 0 CUTOUT ALL — Load Sensing System (LSS) is fitted.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM Table 5-5. Machine Model Adjustment Adjustment Adjustment Range Model Default Values 3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD DRIVE Accel 0.1 - 5.0 (sec) 3 3 3 3 Decel 0.1 - 3.0 (sec) 1.2 1.2 1.2 1.
SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-26 – JLG Lift– 3121249
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector Assembly (2 of 4)). 2. Pull back on the contact wire with a force of 1 or 2 lbs.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Figure 6-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 6-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 6-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal 11.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.5 SWITCHES Basic check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3. Access the terminals to the switch. 4.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. 1. Connect instrumentation to monitor and/or control the parameter the switch is measuring. 2. Observe switch state in control system with the Analyzer.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.6 SCHEMATICS Figure 6-18.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-18.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103487 B Figure 6-19.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-17
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-21
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488 B Figure 6-22.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-23.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001106835_D Figure 6-24.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001106834_F Figure 6-25.
1001103708_B SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-26.
1001103709_C SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-27.
3121249 – JLG Lift – 1001103711 A Powerdeck Selection Valve Front Powerdeck Valve Dual Front Extension Cylinders Aux Pump In Out Left Right Main Valve Rear Extension Cylinders Aux Pump Suction Hydraulic Tank Rear SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-28.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103552_B Figure 6-29.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-31
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS STARTER THROTTLE ACTUATOR BATTERY FUSE BLOCK + ENGINE CONTROL (DEUTZ) OIL PRESSURE SWITCH OIL TEMP GLOW SWITCH PLUG IGNITION RELAY HEADLIGHTS ALTERNATOR (DIESEL MACHINES) LIGHTS RELAY CIRCUIT BREAKER PLATFORM WORKLIGHTS ENGINE HARNESS (DEUTZ) TAILLIGHTS POWER DECK VALVES AC POWER AT PLATFORM GENERATOR GENERATOR VOLTAGE REGULATOR AUXILIARY PUMP AUX POWER RELAY GENERATOR CONTROL BOX GENERATOR RELAY LEVELING JACK PORT BLOCKS (W/ POWER DEC
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ENGINE SPEED SENSOR GLOW PLUG RELAY START RELAY PLATFORM CONTROL BOX LP LOCK & ASSIST (GAS MACHINES) OR GLOW PLUGS IGNITION RELAY ALTERNATOR (GAS MACHINES) LIFT CYLINDER PORT BLOCK J2 HYDRAULIC PUMPS IGNITION POWER RELAY (GM MACHINES) J1 ENGINE CONTROL (GM) LIFT DOWN VALVE FUEL LEVEL SENSOR ELEVATION SWITCH J5 J4 PROP VALVE J3 PLATFORM MODULE BEACON LIGHT ROTARY SENSOR FUEL REGULATOR (GM HARNESS) PORT BLOCKS (OSCILLATING AXLE CYLIND
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 6-34 – JLG Lift – 3121249
3121249 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 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.
