Service Manual Owner's manual

ManualsBrandsJLG ManualsSpecial machinery450A_AJ Series II

Service and Maintenance Manual

Model

450A Series II

450AJ Series II

S/N 0300160835

to Present

P/N - 3121290

October 4, 2013

Summary of content (396 pages)

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Service and Maintenance Manual Model 450A Series II 450AJ Series II S/N 0300160835 to Present P/N - 3121290 October 4, 2013
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NOTE: This manual also applies to machines with the following Serial Numbers: 0300159794, 0300159795, 0300160088, and 0300160456.
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revision 1 A-2 January 10, 2013 October 4, 2013 – JLG Lift – 3121290
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TABLE OF CONTENTS SECTION NO. SECTION A B C SECTION 1.1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 SECTION 2.1 2.2 2.3 2.4 2.5 2.6 3121290 TITLE PAGE NO. A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. SECTION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 ii TITLE PAGE NO. 3 - CHASSIS & TURNTABLE Tires And Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Damage . . . . .
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TABLE OF CONTENTS SECTION NO. 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3121290 TITLE PAGE NO. Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 500 hours . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.17 3.18 SECTION 4.1 4.2 iv TITLE PAGE NO. DGC Diagnostic Support And Trouble Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Fault Code Broadcast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 4.3 SECTION 5.1 5.2 5.3 5.4 5.5 5.6 5.7 3121290 TITLE PAGE NO. Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install New Link . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. SECTION 6.1 6.8 SECTION 7.1 7.2 7.3 7.4 7.5 vi TITLE PAGE NO. 6 - JLG CONTROL SYSTEM introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Using Analyzer . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41. 3-42. 3-43. 3-44. 3-45. 3-46. 3-47. 3121290 TITLE PAGE NO. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 3-68. 3-69. 3-70. 3-71. 3-72. 3-73. 3-74. 3-75. 3-76. 3-77. 3-78. 3-79. 3-80. 4-1. 4-2. 4-2. 4-3. 4-4. 4-5. 4-6. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. viii TITLE PAGE NO. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 5-43. 5-44. 5-45. 5-46. 5-47. 5-48. 5-49. 5-50. 5-51. 5-52. 5-53. 5-54. 5-55. 5-56. 5-57. 5-58. 5-59. 5-60. 5-61. 5-62. 5-63. 5-64. 5-65. 5-66. 5-67. 5-68. 5-69. 5-70. 5-71. 5-72. 5-73. 5-74. 3121290 TITLE PAGE NO. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-75. 5-76. 5-77. 5-78. 5-79. 5-80. 5-81. 5-82. 5-83. 5-84. 5-85. 5-86. 5-87. 5-88. 5-89. 5-90. 5-91. 5-92. 5-93. 5-94. 5-95. 5-96. 5-97. 5-98. 5-99. 5-100. 5-101. 5-102. 5-103. 5-104. 5-105. 5-106. 5-107. 5-108. 5-109. 5-110. 5-111. 5-112. 5-113. 5-114. 5-115. 5-116. 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. 7-1. 7-2. x TITLE PAGE NO. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7-33. 7-34. 7-35. 7-36. 7-37. 7-38. 7-39. 3121290 TITLE PAGE NO. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 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 3-11 3-12 3-13 3-14 3-15 3-16 3-17 5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 xii TITLE PAGE NO. Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Reach Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS AND PERFORMANCE DATA 1.2 DIMENSIONAL DATA Table 1-3. Dimensional Data Table 1-1. Operating Specifications Unrestricted Rated Capacity ANSI CE & Australia Overall Width 500 lb. (227 kg) 500 lb. (230 kg) Maximum Travel Grade (Gradeability) with Boom retracted and approximately horizontal. Tower Boom fully lowered (if equipped). 2WD 4WD 0 Stowed Height 4° 7 ft. 8 in. (2.34 m) 1.3 CHASSIS Table 1-4.
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SECTION 1 - SPECIFICATIONS Table 1-9. GM 3.0L 1.5 TIRES Fuel Table 1-6. Tires Size Type Gasoline or Gasoline/LP Gas No. of Cylinders Pressure Weight 12x16.5 Pneumatic 90 psi (6 Bar) 128 lb (58 kg) 12x16.5 Foam-Filled N/A 328 lb (149 kg) 33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lb (61 kg) 33/1550x16.5 Foam-Filled N/A 395 lb (179 kg) 14x17.5 Pneumatic 90psi (6 Bar) 170 lb (77.2 kg) 14x17.
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SECTION 1 - SPECIFICATIONS 1.8 HYDRAULIC OIL Table 1-13. Mobil DTE 13M Specs Table 1-11. Hydraulic Oil ISO Viscosity Grade #32 Specific Gravity 0.877 Hydraulic System Operating Temperature Range S.A.E. Viscosity Grade Pour Point, Max -40°F (-40°C) +0° to + 180° F (-18° to +83° C) 10W Flash Point, Min.
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SECTION 1 - SPECIFICATIONS Table 1-16. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Table 1-17. Quintolubric 888-46 Viscosity NOTE: Density 0.91 @ 15°C (59°F) Pour Point <-20°C (<-4°F) Flash Point 275°C (527°F) at 40° C 25.8 cSt Fire Point 325°C (617°F) at 100° C 9.3 cSt Autoignition Temperature 450°C (842°F) Viscosity Index 376 Viscosity Mobil/Exxon recommends checking oil viscosity annually.
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SECTION 1 - SPECIFICATIONS Figure 1-2.
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SECTION 1 - SPECIFICATIONS 2. Swing Bearing/Worm Gear Teeth 1.10 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Diagram. Table 1-18. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
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SECTION 1 - SPECIFICATIONS 3. Wheel Bearings (2WD Only) 6. Hydraulic Charge Filter Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter, or as shown by Condition Indicator. 7. Hydraulic Tank 4. Wheel Drive Hub Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.
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SECTION 1 - SPECIFICATIONS 8. Oil Change w/Filter - Deutz D2011 L03 9. Oil Change w/Filter - Deutz 2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10 Qt (9.4 L) Lube - EO Interval - Every Year or 600 hours of operation Comments - Check level daily/Change in accordance with engine manual. 10. Oil Change w/Filter - GM Fill Cap/Spin-on Element (JLG P/N7016641) Capacity - 11 Qt (10.5 L) Crankcase; 5 Qt (4.
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SECTION 1 - SPECIFICATIONS 12. Fuel Filter - GM 14. 2-Stage Vaporizer (LP only) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 13. Air Filter Interval - 3 Months or 150 hours of operation Comments - Drain oil build up. Refer to Propane Fuel Filter Replacement in Section 3. 15. Fuel Filter (Propane) - GM Engine DEUTZ, GM Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Filter Replacement in Section 3.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Size TPI Bolt Dia Torque (Dry) Tensile Clamp Load Stress Area Torque Lubricated TM Loctite® 242 Vibra-TITE 4 6 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 NOTES: TM or 271 TM 111 or 140 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
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SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
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SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 Reference JLG Pre-Delivery and Frequent Inspection Form and Inspection and Preventative Maintenance Schedule for items requiring inspection during these inspections. Reference appropriate areas of this manual for service and maintenance procedures. MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides information needed by personnel responsible to place machine in operation readiness and maintain its safe operating condition.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operation and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to ensure nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
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SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION 2. Always keep hydraulic oil clean. If oil must be poured from original container into another, clean all possible contaminants from the service container. Always clean the filter mesh element and replace cartridge any time system oil is changed. 3. While unit is shut down, make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing machine back in service.
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SECTION 2 - GENERAL 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES 2.6 NOTE: This instruction applies to repairs or modifications to machine and to welding performed from machine on an external structure or component, Filament wound bearings. 1. Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment a. Excessive sloppiness in joints. • Disconnect the battery. b. Noise originating from joint during operation. 2.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Tire Replacement Tire Inflation Pneumatic tire air pressure must be equal to air pressure stenciled on side of JLG product or rim decal for safe and proper machine operation. Tire Damage JLG recommends replacement tire be the same size, ply, and brand as originally installed on machine. Refer to the JLG Parts Manual for part number of approved tires for a particular machine model.
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SECTION 3 - CHASSIS & TURNTABLE 2. Wheel Installation Tighten nuts in the following sequence: WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND DANGEROUS SEPARATION OF WHEEL FROM AXLE. USE ONLY NUTS MATCHED TO CONE ANGLE OF WHEEL. Tighten lug nuts to proper torque to prevent wheels from coming loose. Use a torque wrench to tighten fasteners.
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SECTION 3 - CHASSIS & TURNTABLE 3.2 TORQUE HUB Tightening and Torquing Bolts Oil Information 1. 1. TYPE – EP90 Use EP90 for normal applications. For applications where lubricant must meet special requirements, the O.E.M can recommend a suitable substitute. 2. OIL TEMPERATURE Continuous – 160° F (70° C) Intermittent – 200° F (95° C). 3. OIL CHANGE Initial – After 50 hours or 50,000 revolutions of operation. Subsequent – After 1000 hours or (1) year, whichever comes first.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-3.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-2.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-4.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-3.
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SECTION 3 - CHASSIS & TURNTABLE MAIN DISASSEMBLY for “B” Drives Hub-Spindle Disassembly 1. Turn hub (1G) on side, Remove coupling (14) from wide end of spindle (1A). 2. Mark location of shoulder bolt holes on outside of ring gear and hub for easy realignment when rebuilding. Remove four shoulder bolts (13) and 12 bolts (12) from cover (6). 3. Remove 16 flat washers (16) from cover (6). 4. Lift cover sub-assembly (6) off ring gear (4). Set cover on table with interior side facing up.
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SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Assemble Carrier 1. Remove two bolts (6C) holding disconnect cap (6D) to cover (6A). 2. Remove disconnect cap (6D) from on top of cover cap (6B) and cover (6A). 3. Remove two bolts (6C) holding cover cap (6B) to cover (6A). 4. Remove cover cap (6B) from cover (6A). 5. Remove disconnect rod (6K) from cover cap (6B). 6. Pry O-ring (6F) out of groove inside cover cap (6B). Discard O-ring. 7. Remove O-ring (6G) from flange of cover cap (6B).
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SECTION 3 - CHASSIS & TURNTABLE 4. Set carrier housing (3A) on table, sideways. Insert a planet shaft (3E), roll pin hole last, into one of the planet shaft holes from roll-pin-holed side of carrier housing (3A). 5. Place thrust washer (3B) on end of planet shaft (3E) inside carrier. Fit tang of thrust washer into slot on inside edge of planet shaft hole. 6. 3-10 7.
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SECTION 3 - CHASSIS & TURNTABLE Cover Sub-Assembly 1. Using disconnect rod, push O-ring (6F) into groove inside cover cap (6B). 2. Place O-ring (6G) onto cover cap (6B) so it rests against flange of cover cap. 3. Insert disconnect rod (6E) into cover cap (6B). 3121290 – JLG Lift – 4. Set cover (6A) on table, exterior side up. Place cover cap (6B) on cover (6A). Align pipe plug hole in cover cap over pipe plug hole in cover. 5.
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SECTION 3 - CHASSIS & TURNTABLE 7. With large end down, place disconnect cap (6D) on cover cap (6B), aligning pipe plug hole in disconnect cap over pipe plug hole in cover cap. 8. Place two remaining bolts (6C) in bolt holes in disconnect cap (6D) and tighten bolts. 9. 3-12 10. Apply a light coat of “Never-Seize” to pipe plug (6H) and tighten it in pipe plug hole in cover (6A). Hub-Spindle Sub-Assembly NOTE: Make sure cup sits square with counterbore before pressing. 1. Set hub (1G) on large end.
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SECTION 3 - CHASSIS & TURNTABLE 3. Apply a light coat of “Never-Seize” to two pipe plugs (1J) and tighten them in two pipe plug holes in side of hub (1G). 6. Press seal (1B) in small end of hub (1G). 7. Oil spindle, then lower hub (1G) small end down, onto spindle (1A). 8. Press bearing cone (1F) on spindle (1A) in hub (1G). NOTE: Make sure cup sits square with counterbore before pressing. 4. 5. Turn hub (1G) over to small end. Press bearing cup (1E) into counterbore in deep end of hub (1G).
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SECTION 3 - CHASSIS & TURNTABLE 9. Place spacer (1H) on spindle (1A) in hub (1G). Main Assembly SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING. 1. Grease O-ring (5) and place it into counterbore in hub (1G). NOTE: O-ring may be stretched or pinched together to make it fit into counterbore. NOTE: 10. Make sure retaining ring is securely seated in groove. Place retaining ring (1I) over spacer onto spindle (1A) in hub (1G). 2. 11.
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SECTION 3 - CHASSIS & TURNTABLE 3. Place thrust washer (11) around spindle (1A) so it rests on bottom of internal gear (2). 4. Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A). 6. Place other spacer (7D) on smooth end of input shaft (7A). UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. 5. 7.
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SECTION 3 - CHASSIS & TURNTABLE 9. Place thrust spacer (9) onto input shaft (7). 12. Place carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning “X” marked shoulder bolt hole in ring gear (4) over one of the shoulder bolt holes in hub. Mark location of shoulder bolt holes on outside of ring gear and hub. NOTE: You may lift ring gear off hub to align shoulder bolt holes. Ring gear and carrier are installed together only to keep punch marks on carrier in place.
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SECTION 3 - CHASSIS & TURNTABLE 18. Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten. 19. Place remaining 12 flat washers (16) on remaining bolt holes in cover (6). 20. Place 12 bolts in remaining bolt holes in cover (6) and tighten. SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALLING O-RING. 15. Set cover (6A) on table, interior side up. Grease O-ring (5) and place in counterbore around edge of cover (6A).
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SECTION 3 - CHASSIS & TURNTABLE 21. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm). Torque bolts (12) 18 to 25 ft-lb (25 to 34 Nm). 22. Turn hub (1G) on its side. Insert coupling (14) into end of spindle (1A). 3-18 23. Roll test unit in clockwise and counterclockwise directions. Perform same number of turns in each direction as the ratio of the unit. The ratio is the last two digits of the model number on the unit’s ID tag. 24. Leak test unit at a pressure of 5 psi (34.
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SECTION 3 - CHASSIS & TURNTABLE Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E). 4. T-109691 ASSEMBLY PRESSING TOOL FOR CONE (1F). The following specialized tools are used to assemble this unit. Tool diagrams in this manual are intended for the customer who may wish to have a tool made. All tools are one piece and must be made from mild steel. All dimensions are in inches. NOTE: Tools may be carburized and hardened to improve tool life.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 RE-ALIGN TORQUE HUB INPUT COUPLING 3.4 DRIVE MOTOR NOTE: This procedure covers: This procedure applies to torque hubs with integral brakes: Equipment Required 2WD motors used on GM powered machines. 1. Hydraulic power supply (hand pump) capable of producing 200 psi (13.8 bar). 2WD motors used on Caterpillar and Deutz powered machines. 2. Hydraulic fittings to adapt hydraulic supply to brake release port on hub. All 4WD motors. Description Procedure 1.
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SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement Loop Flushing Valve REMOVAL 1. REMOVAL Remove snap ring (1) and support washer (2). 1. Remove plug (1) and (2) with 11/16" internal hex wrench. 1 2 3 1. 2. 3. Snap Ring Support Washer Shaft Seal Figure 3-7. Removing Shaft Seal NOTE: To avoid damaging shaft during removal, install a large sheet metal screw into chuck of a slide hammer. Drive screw into seal surface and use slide hammer to pull seal. 2. 1. 2. 3. 4. Plug Plug Plug O-ring 5.
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SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-4. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil supply to motor. Insufficient hydraulic fluid could lead to cavitation that would cause system noise. Fill reservoir to proper level and ensure oil supply to motor is adequate and lines are unobstructed. Check for air in system. Air trapped in system lines or motor could result in cavitation that would cause system noise.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly 17 NOTE: Removal of endcap voids warranty. 19 During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts are lubricated during start-up. 15 Replace all O-Rings and gaskets. Lightly lubricate O-rings with clean petroleum jelly prior to assembly. 14 6 9 11 5 7 2 21 13 3 18 12 10 8 4 16 1 16 20 1. 2. 3. 4. Plug Plug Plug O-ring 5. 6. 7. 8. O-ring O-ring Spring Spring 9. Spring 10. Washer 11. Washer 14. 15.
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SECTION 3 - CHASSIS & TURNTABLE 25 22 27 30 29 23 29 26 24 28 22. Screw 23. End Cap 24. O-ring 25. Valve Plate 26. End Cap Figure 3-11. End Cap 27. O-ring 28. O-ring 29. Angle Stop Servo Spring Figure 3-12. Valve Plate & Rear Shaft Bearing 13. Using an 8 mm internal hex wrench, remove endcap screws (22). 14. Remove endcap (23). Remove O-ring (24) from housing or endcap. NOTE: When endcap screws are removed, pressure from servo spring will cause endcap to bind on shaft.
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SECTION 3 - CHASSIS & TURNTABLE . 32 33 31 34 30. Cylinder Kit Assembly Figure 3-13. Cylinder Kit 19. Turn housing on its side and remove cylinder kit assembly (31). Set assembly aside. Do not to scratch running surface. 31. Snap Ring 32. Support Washer 33. Shaft Seal NOTE: Grooves on surface of cylinder kit identify its displacement: Figure 3-14. Shaft Seal Table 3-7. Displacement Identifiers # of Grooves Frame L Frame K 1 25 38 2 30 45 3 35 -- 20.
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SECTION 3 - CHASSIS & TURNTABLE Lift here 44 39 45 47 40 48 43 42 49 41 46 53 52 38. 39. 40. 41. 42. Swashplate Servo Piston Piston Seal O-ring Journal Bearings 50 51 Figure 3-16. Swash Plate & Servo Piston 23. Turn housing over and remove swashplate (39) by lifting on end opposite servo lever. 24. Remove servo piston (40). Remove piston seal (41) and O-ring (42) from servo piston. Discard seal and O-ring. 25. Remove journal bearings (43) from housing.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Slipper Foot Thickness & End Play Inspection Wash all parts after disassembly (including end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow out oil passages in housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any rework or resurfacing. Measurement Slipper Foot Thickness mm (in.) L Frame K Frame 2.71 (0.11) 4.07 (0.
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SECTION 3 - CHASSIS & TURNTABLE VALVE PLATE Valve plate condition is critical to motor efficiency. Inspect valve plate surfaces for excessive wear, grooves, or scratches. Replace or resurface grooved or scratched valve plates. Measure valve plate thickness and replace if worn beyond minimum specification. Valve plate can be resurfaced if finished thickness is not below minimum specification shown in drawing. Inspect journal bearings for damage or excessive wear.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 1. Install new O-ring (1) and piston seal (2) to servo piston (3). Install piston seal over O-ring. NOTE: Installing piston seal stretches it, making it difficult to install servo piston in its bore. Allow 30 minutes for seal to relax after installation. To speed up seal relaxation, compress seal by installing piston head in servo cavity in endcap and let it stand for at least five minutes. COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY.
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SECTION 3 - CHASSIS & TURNTABLE 8. IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. 5. Install pistons (11) to slipper retainer (12). Install piston/ retainer assembly in cylinder block. Ensure concave surface of retainer seats on the ball guide. Lubricate pistons, slippers, retainer, and ball guide before assembly. Set cylinder kit aside on a clean surface until needed. 6. Install journal bearings (13) into housing seats. Use assembly grease to keep bearings seated during assembly.
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SECTION 3 - CHASSIS & TURNTABLE 10. Verify swashplate and bearings are properly seated. Install cylinder kit (19) onto shaft. Install with slippers facing swashplate. Rock shaft to align block splines and slide cylinder kit into place. Orient motor with shaft pointing downward and verify cylinder kit, swashplate, journal bearings, and servo piston are all secure and properly installed. 12. Press rear shaft bearing (22) into endcap. Install bearing with letters facing out.
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SECTION 3 - CHASSIS & TURNTABLE 15. Install endcap (25) on housing with endcap screws (26). Check endcap properly seats on housing without interference. 18. IMPROPER ASSEMBLY OF INTERNAL COMPONENTS MAY PREVENT ENDCAP FROM SEATING PROPERLY. ENSURE O-RINGS SEAT PROPERLY WHEN INSTALLING ENDCAP. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with cup side facing motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging seal.
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SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). 21. Install shift spool (31). 22. Install spring retaining washers on springs (32 and 33). 23. Carefully install centering springs (34, 35, and 36). 24. Install new O-rings (37, 38, and 39). Initial Start-Up Procedures Follow this procedure when starting up a new motor or after reinstalling a motor. Prior to installing motor, inspect for damage incurred during shipping or storage.
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SECTION 3 - CHASSIS & TURNTABLE D E A B C Table 3-10. Chassis Torque Values Ft-Lb Nm A 120 163 B 240 325 C 170 230 D 85 115 E 165 224 Figure 3-29.
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SECTION 3 - CHASSIS & TURNTABLE 3.5 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE 1. With turntable centered, adjust bracket with washers to push plunger in 5/16" ± 1/16" (7.9 ± 1.6 mm). 3.6 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST FULLY LOWER PLATFORM AND CENTER BOOM OVER REAR AXLE BEFORE STARTING BLEEDING PROCEDURE. ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, AND BRAKE WIRE IS DISCONNECTED. Lockout Cylinder Bleeding (Ram Cylinders) 1. 2. 3. 1.
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SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 3.7 SWING BEARING Description LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels before starting lockout cylinder test. 1. Place a 6" (15 cm) high block with ascension ramp in front of left front wheel. 2. From platform control station, activate machine hydraulic system. 3.
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SECTION 3 - CHASSIS & TURNTABLE 5 6 3 Inner Race 1 4 Outer Race 8 7 2 Figure 3-31.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly 5. Lift directly up and remove pinion and gear assembly (10, 16 - 22) from housing (4). 6. Disassemble pinion and gear assembly using a press. Support worm gear (20) on press wIth pinion (10) facing down. Allow room for pinion to be pressed out of gear. Press pinon out of bearing (22), spacer (21), and worm gear (20). 7. Remove face seal (18) and O-ring (19) from face of worm gear (20). Note how seal is assembled. 8.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-32.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 16. Place gear cap assembly over pinion assembly and install shims set aside in Step 6. 17. Install eight 12 point screws (11). Torque to 60 ft-lb (81 Nm). 18. Install two small screws (8). 19. Install seal (28) in worm cap (26). 20. Install motor (1) to adapter (23) with two bolts (2), washers (3), and sealant. Torque to 80 ft-lb (108 Nm). 21. Install turntable bearing (7) to housing (4) with two bolts (5) and washers (6). 22.
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SECTION 3 - CHASSIS & TURNTABLE 5. Use suitable lift equipment and install bearing/rotation box assembly to frame with soft spot (red) 90 degree relative to load axis. If reusing old bearing, align scribed line of outer bearing race with scribed mark on frame. 2 6 15 10 10 14 6 2 19 15 11 14 SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN FRAME AND TURNTABLE. JLG INDUSTRIES RECOMMENDS ALL REMOVED GRADE 8 BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS.
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SECTION 3 - CHASSIS & TURNTABLE Turntable Bearing Mounting Bolt Checks Wear Tolerance NOTE: Check must be performed after first 50 hours of machine operation and every 600 hours of machine operation thereafter. Replace missing or loose bolts with new bolts and torque as specified after lubricating bolt threads with JLG Thread Locking Compound PN 0100019. Recheck all bolts for looseness after replacing and torquing individual bolts. Check Frame To Bearing Bolts 1.
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SECTION 3 - CHASSIS & TURNTABLE • Before you disassemble motor or any of its components read this entire section. It provides important information on parts and procedures to service motor. 3.8 SWING MOTOR IF HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS CAN SHRINK, HARDEN, OR CRACK AND LOSE THEIR SEALING ABILITY. • Before disconnecting and removing motor, thoroughly clean off all outside dirt, especially from around fittings and hose connections.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Swing Motor Troubleshooting Trouble Oil Leakage Cause Remedy 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or “O” Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit. 3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion. 4. Internal shaft seal (16) worn or damaged. 5.
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SECTION 3 - CHASSIS & TURNTABLE PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPONENTS. DO NOT FORCE OR ABUSE CLOSELY FITTED PARTS. • Keep parts separate to avoid nicks and burrs. WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. • Discard seals and seal rings as they are removed from motor.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly and Inspection Refer to Figure 3-41., Swing Motor - Exploded View. 1. Place motor in a soft jawed vice, with coupling shaft (12) pointed down and vise jaws clamping firmly on sides of housing (18) mounting flange, or port bosses. Remove manifold port O-rings if applicable. 3. Remove special ring head bolts (1) with 1/2" or 9/16" socket. Inspect bolts for damaged threads or sealing rings. Replace damaged bolts. 4.
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SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure end cover valve apertures are free of contamination. Inspect end cover for cracks and bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. . NOTE: A polished pattern (not scratches) on the cover from rotation of commutator (5) is normal.
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SECTION 3 - CHASSIS & TURNTABLE 2. Remove rotor set (8) and wearplate (9), together to hold rotor set in its assembled form, keeping same rotor vane to stator contact surfaces. Drive link (10) may come away from coupling shaft (12) with rotor set and wearplate. Shift rotor set on wearplate and remove drive link if needed. Inspect assembled rotor set for nicks, scoring, or spalling on any surface, and for broken or worn splines.
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SECTION 3 - CHASSIS & TURNTABLE 5. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion, and missing rollers. 6. Check exposed portion of coupling shaft (12) for signs of rust and corrosion which might prevent its withdrawal through seal and bearing. Use crocus cloth or fine emery paper as needed. NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 0.020" (0.51 mm) diametrically, replace coupling shaft.
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SECTION 3 - CHASSIS & TURNTABLE 9. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 10. Remove seal (16) and back up ring (17) from housing (18) and backup washer (25). Discard both. 12. Inspect housing (18) assembly for cracks, machined surfaces for nicks, burrs, brinelling, or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage.
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SECTION 3 - CHASSIS & TURNTABLE 14. Measure and note depth or location of bearing/bushing (13) in relation to housing wear plate surface, and depth or location of bearing/bushing (19) in relation to beginning of bearing/bushing counter bore before removing bearings/bushings. This ensures correct reassembly of new bearings/bushings. 3121290 – JLG Lift – 15.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. Bolt End Cover Seal Ring O-Ring 5. 6. 7. 8. Commutator Commutator Ring Manifold Rotor Set 8A. Rotor 8B. Stator Half 8C. Stator Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 11. Coupling Shaft 12A. Key 12. 13. 14. 15. Inner Bushing Thrust Washer Thrust Bearing Inner Shaft Seal 16. 17. 18. 19. Backup Ring Housing Bearing Outer Shaft Seal Figure 3-41.
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SECTION 3 - CHASSIS & TURNTABLE Assembly Refer to Figure 3-41., Swing Motor - Exploded View. Replace seals and seal rings with new ones each time motor unit is reassembled. Lubricate seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: If A bearing mandrel is not available and alternate methods are used to press in bearing/bushing (13) and (19).
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SECTION 3 - CHASSIS & TURNTABLE 3. 4. 5. 3-54 Press new dirt and water seal (20) into housing (18) outer bearing counterbore. Press in dirt and water seal (20) until flange is flush against housing. Place housing (18) assembly into a soft jawed vise with coupling shaft bore down, clamping against mounting flange. 6. Install thrust washer (14) and thrust bearing (15). NOTE: Motor requires one thrust washer (14) with thrust bearing (15). Coupling shaft seats directly against thrust bearing. 7.
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SECTION 3 - CHASSIS & TURNTABLE 8. Apply a generous amount of clean, corrosion resistant grease to lower (outer) housing bearing/bushing (19). Install coupling shaft (12) into housing (18), seating it against thrust bearing (15). OUTER BEARING (19) IS NOT LUBRICATED BY SYSTEM HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH RECOMMENDED GREASE. 9. Apply a small amount of clean grease to a new seal ring (4) and insert it in housing (18) seal ring groove.
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SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over drive link (10) and alignment studs onto housing (18). 12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into seal ring groove on wear plate side of rotor set stator. 13. Place assembled rotor set (8) on wear plate (9) with rotor counterbore and seal ring side down and splines into mesh with drive link splines.
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SECTION 3 - CHASSIS & TURNTABLE 15. Place manifold (7) over alignment studs and drive link (10) and onto rotor set. Be sure correct manifold surface is against rotor set. 16. Apply grease to new seal ring (4) and insert it in manifold seal ring groove. 17. Install commutator ring (6) over alignment studs on manifold. 3121290 – JLG Lift – 18. Install new seal ring (3) flat side up, into commutator (5). Assemble commutator over end of drive link (10) on manifold (7) with seal ring side up. 19.
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SECTION 3 - CHASSIS & TURNTABLE 20. Assemble bolts (1) and screw in finger tight. Remove and replace two alignment studs with bolts after other bolts are in place. Alternately and progressively tighten bolts to pull end cover and other components into place with a final torque of 25-30 ft-lb (34-41 Nm). NOTE: If end cover has a valve (24) or five bolt holes, use line scribed on cover to radially align end cover to its original position.
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SECTION 3 - CHASSIS & TURNTABLE 4. One Piece Stator Assembly A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled using the following procedures: 1. Assemble six vanes, or as many vanes that readily assemble in stator vane pockets. Place stator on wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure seal ring is in place.
PAGE 100
SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Assembly A disassembled rotor set (8) that cannot be easily by hand and has a two piece stator, can be assembled using the following procedures: 1. Place stator half on wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure seal ring is in place. 2. Align stator bolt holes with wear plate and housing bolts.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-42.
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SECTION 3 - CHASSIS & TURNTABLE 3.9 GENERATOR Overload Protection Every 250 hours Check drive belt tension every 250 hours of operation. STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER. The circuit breaker protects generator windings from overload. If circuit breaker opens, generator output stops. If circuit breaker continues to open, check for faulty equipment connected to platform receptacles. 1/2 in.
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SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings 2 3 Acceptable Unacceptable Brushes must ride completely on slip rings 1 1/4 in (6 mm) Or Less - Replace 2 7/16 in - 1/2 in (11 - 12 mm) New 3 1. 2. 3. Brush Holder Assembly Brushes Slip Rings Figure 3-43.
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SECTION 3 - CHASSIS & TURNTABLE 3.10 DEUTZ ENGINE 4. Open oil drain valve and drain oil. NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions. 5. Close oil drain valve. 6. Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-45., Engine Oil Viscosity. Check Oil Level 1. Make sure machine and engine are level and switch engine OFF before checking oil level. 2. Remove oil dipstick and wipe with clean cloth. 3.
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SECTION 3 - CHASSIS & TURNTABLE 5. Lightly coat new oil filter rubber gasket with clean oil. Clean Fuel Strainer (D2011 L03 Only) FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM. 6. 1. Unscrew hexagonal nut (1). 2. Remove fuel strainer cover (2). 3. Clean fuel strainer with diesel fuel and replace as needed. 4. Place seal (3) in position. 5.
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SECTION 3 - CHASSIS & TURNTABLE 3.11 DEUTZ EMR 2 The EMR2 system consists of sensors, control unit, and an actuator. Engine-side controls and the JLG Control System are connected by separate cable harnesses to the EMR control unit. The EMR2 is equipped with safety devices and measures in the hardware and software for emergency running (Limp home) functions. Engine sensors provide control unit electronics with information of the current condition of engine and preconditions (throttle position etc.).
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Figure 3-47.
PAGE 108
Figure 3-48.
PAGE 109
Figure 3-49.
PAGE 110
Figure 3-50.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-51.
PAGE 112
SECTION 3 - CHASSIS & TURNTABLE Figure 3-52.
PAGE 113
Figure 3-53.
PAGE 114
Figure 3-54.
PAGE 115
Figure 3-55.
PAGE 116
Figure 3-56.
PAGE 117
Figure 3-57.
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SECTION 3 - CHASSIS & TURNTABLE 3.12 BIO FUEL IN DEUTZ ENGINES APPROVED ENGINES General 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513 series are approved for bio-diesel from year of manufacture 1993 under compliance with basic conditions specified below. Use of bio fuels is permitted for the compact engines made by DEUTZ. BASIC CONDITIONS TO BE OBSERVED • A power loss of 5-9% in relation to diesel fuel in accordance with EN 590 is possible due to the lower heating value.
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SECTION 3 - CHASSIS & TURNTABLE Biological Contamination In Fuels SYMPTOMS The following symptoms may indicate a fuel tank is contaminated by micro-organisms: • Internal tank corrosion, • Filter blockage and associated loss of power due to gel-like deposits on the fuel filter (especially after long standstills) CAUSE Micro-organisms (bacteria, yeasts, funguses) can form biosludge under unfavorable conditions - particularly heat and water.
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SECTION 3 - CHASSIS & TURNTABLE 3.13 GM ENGINE GENERAL MAINTENANCE Checking/Filling Engine Oil Level Drive Belt Maintenance 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. AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED FULL MARK) CAN CAUSE AN OIL LEAK, A FLUCTUATION OR DROP IN THE OIL PRESSURE, AND ROCKER ARM “CLATTER” IN THE ENGINE.
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SECTION 3 - CHASSIS & TURNTABLE Change Engine Oil 1. Loosen worm gear clamp on coolant line to EPR as shown below and remove hose from EPR. Place a rag under hose to prevent coolant from running onto engine/machine. 2. Remove radiator cap. Fill radiator with coolant until coolant starts to appear from previously removed hose at EPR. Reinstall hose to EPR and continue to fill radiator with coolant. 3. With radiator cap still removed, start engine and run until thermostat opens.
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SECTION 3 - CHASSIS & TURNTABLE 3.14 GM ENGINE DUAL FUEL SYSTEM HEATED COOLANT MAY SPILL OUT DUE TO AIR “BURPING” OUT OF SYSTEM WITH RADIATOR CAP OFF WITH ENGINE RUNNING OR WHEN SHUTTING OFF ENGINE. 5. Verify two coolant hoses on the EPR are warm. If they are not warm repeat step 3 and 4, otherwise continue to step 6. A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIATOR HOSE AND A WARM EPR HOSE.
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SECTION 3 - CHASSIS & TURNTABLE 1. 1 inch Split Loom 2. 90° Fitting 3. 90° Fitting 4. 90° Fitting 5. Clamp 6. Adapter Fitting 7. Hose 8. Hose 10. Clamp 11. Nipple 12. Lock-Off Valve 15. Clamp 16. Regulator 17. 45° Fitting 18. Bolt 19. Bolt 20. Nut 101. Plug 102. Electronic Pressure Regulator 103. Adapter 104. Mixer 105. Bolt 106. Stud 107. Nut 108. Spacer (600A Only) 201. Throttle Body 202. Gasket 203. O-Ring 204. Adapter 205. Spacer 206. Bolt 207. Washer 208. Bolt 402. T-MAP Sensor 403. Bolt 404.
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SECTION 3 - CHASSIS & TURNTABLE Direct Electronic Pressure Regulator (DEPR) Air Fuel Mixer THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOULD ONLY BE SERVICED BY QUALIFIED TECHNICIANS. THE AIR/FUEL MIXER IS AN EMISSION CONTROL DEVICE. COMPONENTS INSIDE THE MIXER ARE SPECIFICALLY CALIBRATED TO MEET THE ENGINE’S EMISSIONS REQUIREMENTS AND SHOULD NEVER BE DISASSEMBLED OR REBUILT. IF THE MIXER FAILS TO FUNCTION CORRECTLY, REPLACE WITH AN OEM REPLACEMENT PART.
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SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control (ETC) Engine Control Module (ECM) The Electronic Throttle Control device or "Throttle Body Assembly" is connected to the intake manifold of the engine. The electronic throttle control device utilizes an electric motor connected to the throttle shaft. When the engine is running, electrical signals are sent from equipment controls to the engine ECM.
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SECTION 3 - CHASSIS & TURNTABLE Heated Exhaust Gas Oxygen Sensor Gasoline Fuel Pump 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.
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SECTION 3 - CHASSIS & TURNTABLE Fuel Filter 3.15 GM ENGINE FUEL SYSTEM REPAIR After fuel is drawn into the fuel pump, the fuel flows through the gasoline fuel filter. The fuel filter traps small particles as fuel passes through the filter to remove debris and prevents fuel pressure and temperature manifold and fuel injectors from becoming damaged. Fuel filter maintenance is required as shown in Section 1.
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SECTION 3 - CHASSIS & TURNTABLE INSTALLATION Propane Fuel Filter Replacement REINSTALL FILTER MAGNET IN HOUSING BEFORE INSTALLING NEW SEAL. 1. 2. 3. 4. 5. 6. Electric Lock Off Solenoid Mounting Plate Housing Seal Filter Magnet Filter Housing Seal 7. 8. 9. 10. 11. 12. Electrical Connector Fuel Outlet O-ring Filter Fuel Inlet Retaining Bolt 1. Install mounting plate to lock off O-ring seal. 2. Install retaining bolt seal. 3. Install housing seal. 4. Drop magnet in bottom of filter housing. 5.
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SECTION 3 - CHASSIS & TURNTABLE 13. Check/Drain Oil Build-Up In 2-Stage Vaporizer Slowly open manual service valve. NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components. During normal operation for LPG engines oil or “heavy ends” may build inside the Vaporizer secondary chamber. These oil and heavy ends may be a result of poor fuel quality, fuel contamination, or regional variation of the fuel make up. A significant build up of oil can affect performance of the secondary diaphragm response.
PAGE 130
SECTION 3 - CHASSIS & TURNTABLE Exhaust System And Catalytic Converter Inspection And Maintenance Throttle Body (ETC) Replacement NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components. REMOVAL EXHAUST SYSTEM ON THIS EMISSION CERTIFIED ENGINE CONTAINS A HEATED EXHAUST GAS OXYGEN SENSOR (HEGO) WHICH PROVIDES FEEDBACK TO THE ECM ON AMOUNT OF OXYGEN PRESENT IN THE EXHAUST STREAM AFTER COMBUSTION. OXYGEN IN THE EXHAUST STREAM IS MEASURED IN VOLTAGE AND SENT TO THE ECM.
PAGE 131
SECTION 3 - CHASSIS & TURNTABLE Electronic Pressure Regulator (EPR) Replacement REMOVAL Coolant Hose Replacement REMOVAL NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components. 1. Unplug EPR (102) electrical connector. 2. Remove hoses from EPR. 3. Remove four flange nuts (107) and EPR from Mixer (104). 4. If new EPR is being installed, remove and retain hose adapter (103) and four bolts (105). Install EPR (102) on Mixer (104). Secure with four flange nuts (107). 3. Reattach all hoses.
PAGE 132
SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL REMOVAL 1. Disconnect Negative battery cable. 2. Remove controller from mounting bracket. 3. Push connector lock back to unlock connector. 4. Unplug and remove controller. 1. Disconnect negative (-) battery cable. 2. Disconnect O2 sensor electrical connector. 3. Using an O2 Sensor socket, remove and discard Sensor.
PAGE 133
SECTION 3 - CHASSIS & TURNTABLE 3.16 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on LPG. If vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Fuel System Description NOTE: Before proceeding with this procedure, verify vehicle has sufficient quantity of fuel and liquid fuel is being delivered to the LPR.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12. 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 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 LPG fuel tank has a minimum of 1/4 tank of fuel, manual valve is open and tank quick connect is fully engaged Does vehicle have fuel? -- Go to Step 4 -- 4 1.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION 14 Using a DVOM, check resistance of Low Pressure Lock-off (LPL). Is resistance within specified range? 15 1. Turn ignition OFF. 2. Close LPG tank manual shut-off valve. VALUE(S) YES NO 12W - 16W Go to Step 15 Go to Step 23 -- Go to Step 23 Go to Step 17 LIQUID LPG MAY BE PRESENT WHEN DISCONNECTING LPG FUEL LINES. PERFORM THIS STEP IN A WELL VENTILATED AREA. 3. Loosen fuel inlet hose fitting at LPL inlet.
PAGE 136
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. 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.
PAGE 137
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp (MIL) The following components can cause intermittent MIL and no DTC(s): 1. 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. 2. Improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc. 3.
PAGE 138
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a gasoline fuel supply system. Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. Exhaust System Checks 1.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a gasoline fuel supply system. 1. Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes 2. Check intake and exhaust manifolds for casting flash.
PAGE 140
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. 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 1. Check fuel pressure. Refer to LPG Fuel System Diagnosis. 2.
PAGE 141
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Lack of Power, Sluggishness, or Sponginess DEFINITION: Engine delivers less than expected power. There is little or no increase in speed when partially applying accelerator pedal. Preliminary Checks 1. Refer to Important Preliminary Checks. 2. Refer to LPG Fuel system OBD System Check 3. Compare customer's vehicle with a similar unit. Make sure customer has an actual problem.
PAGE 142
SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Ignition System Checks 1. Verify that the spark plugs are correct for use with LPG (R42LTS) 2. Check spark plugs. Remove and inspect plugs for the following conditions: - Wet plugs - Cracks - Wear - Improper gap - Burned electrodes - Heavy deposits 3.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Engine Mechanical Check Action Check 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: Engine has a power variation under a steady throttle or cruise. Vehicle feels as if it speeds up and slows down with no change in accelerator pedal.
PAGE 144
SECTION 3 - CHASSIS & TURNTABLE Table 3-14.
PAGE 145
SECTION 3 - CHASSIS & TURNTABLE Table 3-14.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. Battery Coolant Overflow Air Cleaner Radiator Alternator 6. 7. 8. 9. 10. O2 Sensor Crankshaft Position Sensor Muffler Piston Pump Gear Pump 11. 12. 13. 14. Motor Mount Start/Aux Power Relays Engine Tray Pivot Auxiliary Pump Figure 3-70. GM 3.
PAGE 147
SECTION 3 - CHASSIS & TURNTABLE 15. 16. 17. 18. 19. O2 Sensor Dipstick Control Module Starter Distributor 20. 21. 22. 23. 24. Oil Filter Water Pump Coolant Sensor Pressure Regulator MAP Sensor 25. 26. 27. 28. 29. Mixer PCV Valve Oil Pressure Switch Coil Fuel Filter Figure 3-71. GM 3.
PAGE 148
SECTION 3 - CHASSIS & TURNTABLE 3.17 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS Section Layout This section is organized in the following manner: This section defines diagnostics and recommended troubleshooting procedures associated with EControls, Diesel Governor Control (DGC), and Engine Control Module (ECM) used on industrial engines.
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SECTION 3 - CHASSIS & TURNTABLE List of Abbreviations in this Section AL BP CAN Adaptive Learn Barometric Pressure Controller Area Network LED LPG MAP Light Emitting Diode Liquefied Propane Gas Manifold Absolute Pressure CCP CHT CL CNG DBW DGC DM DMM DST DTC CAN Calibration Protocol Cylinder Head Temperature Closed Loop Compressed Natural Gas Drive-By-Wire Diesel Governor Control Diagnostic Message Digital Multi-Meter (high impedance) Diagnostic Scan Tool Diagnostic Trouble Code MGCP μP Mfg MIL NG OB
PAGE 150
SECTION 3 - CHASSIS & TURNTABLE Fault Code Broadcast All diagnostic trouble codes are broadcast through EDIS for display on a PC. EDIS can acquire the data from the ECU via CAN using the EControls Inc. Proprietary Protocol (ECIPP). Faults may also be acquired over the CAN network through CAN J1939-based scan tools or multi-function display units. Data capture at occurrence of a fault, known in the ECM as fault snapshot (FSS), is available upon DM4 request.
PAGE 151
SECTION 3 - CHASSIS & TURNTABLE The desired action is set by OEM calibration engineers. Table 3-16.
PAGE 152
SECTION 3 - CHASSIS & TURNTABLE Base Fault snapshot variable definitions (CAN NOT be altered) Custom Fault Snapshot variable definitions (User Defined) Base Flight Data Recorder variable definitions (CAN NOT be altered) Custom Flight Data Recorder variable definitions (User Defined) Figure 3-72.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-73. Faults Page with Historic Fault Message Once an active fault has occurred, two sets of data are recorded; fault snapshot and flight data recorder. The fault snapshot (FSS) is a sample of data taken when the fault triggered. Variables included in the FSS are defined in the Snapshot Base and Snapshot Custom Definition fields found on the Faults Page. An FSS is saved with each of the first eight (8) faults the first time the fault becomes active.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-74. Custom Fault Variable Interface Accessing fault information is accomplished through a double left-click of the fault LED in the historic fault list. This produces the Historic Fault Information interface shown in Figure 3-75.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-75. Historic Fault Information Interface Table 3-17. Historic Fault Information Interface Functions Fault Description Message Box Customized text that references the DTC flash code and describes the fault. Fault During Key Cycle Checkbox Informs that the fault occurred during the current key-on event. Fault Caused Engine Shutdown Checkbox Informs that the fault caused the engine to shutdown.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-76. Snapshot Data Interface Figure 3-77. Flight Data Recorder Interface Figure 3-78.
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SECTION 3 - CHASSIS & TURNTABLE 3.18 DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTIONS DTC 116- ECT Higher Than Expected Stage 1 • Engine Coolant Temperature Sensor. Diagnostic Aids • Check Condition-Engine Running. If “ECT High Voltage” fault is also present, follow troubleshooting procedures for that fault as it may have caused “ECT Higher Than Expected 1.
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SECTION 3 - CHASSIS & TURNTABLE DTC 117- ECT/CHT Low Voltage • Engine Coolant Temperature Sensor • Check Condition-Engine Running • Fault Condition-CHT/ECT sensor voltage less than the limit defined in the diagnostic calibration • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp, disable adaptive learn fueling correction during active fault, or any combination thereof as defined in calibration.
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SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-119
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SECTION 3 - CHASSIS & TURNTABLE DTC 118- ECT/CHT High Voltage • Engine Coolant Temperature Sensor • Check Condition-Engine Running • Fault Condition-CHT/ECT sensor voltage higher than the limit defined in the diagnostic calibration • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp, disable adaptive learn fueling correction during active fault, or any combination thereof as defined in calibration.
PAGE 161
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-121
PAGE 162
SECTION 3 - CHASSIS & TURNTABLE DTC 122- TPS1 Signal Voltage Low DBW+ 1 + Motor H-Bridge + tr o -M 1 S P T 1 W B D + 2 W B D d ri -B H e g _ V 5 6 1 E S P T TPS1 3 1 E S P T C M C E R - rtn _ V 5 9 1 h iT n le E /S rw o a tu c A lte ria o d e F itn s o P b k c a 5V_ext 16 te x D 5 + s= V R 2 1 a ri e lS te i rxm DBW- 2 - 12 Serial xmitter 13 Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor 1
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SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-123
PAGE 164
SECTION 3 - CHASSIS & TURNTABLE DTC 123- TPS1 Signal Voltage High + 1 + W B D -2 W B D tr o -M 1 S P T d ri -B H e g t x e _ V 5 6 1 + R E S P T ria e lS C D 5 + = s V 2 1 3 -1 R E S P T i m rx te M C E rtn _ V 5 9 1 le E tu c A h T c ln ia e /S rw to it s o P k c a b d e F n io DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor
PAGE 165
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-125
PAGE 166
SECTION 3 - CHASSIS & TURNTABLE DTC 217- ECT Higher Than Expected 2 Diagnostic Aids • Engine Coolant Temperature Sensor. • Check Condition-Engine Running. • Fault Condition-Engine Coolant Temperature reading or estimate greater than the stage 2 limit when operating at a speed greater than defined in the diagnostic calibration. • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp, disable adaptive learn fueling correction during active fault.
PAGE 167
SECTION 3 - CHASSIS & TURNTABLE DTC 219- RPM Higher Than Max Allowed Governed Speed 1 W B D + tr o -M 1 S P T + 2 W B D rid -B H e g _ V 5 6 1 e t x 2 1 E S P T ta iS rlxm e D 5 + s= V R 3 1 E S P T R rtn _ V 5 9 1 M C E h iT n le E /S rw o a tu c A o lt ria e d e F itn s o P k c a b C DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback • Max Govern Speed
PAGE 168
SECTION 3 - CHASSIS & TURNTABLE DTC 336- Crank Signal Input Noise • Crankshaft Position sensor. • Fault Condition- Electrical noise or irregular crank pattern detected causing x number of crank resynchronization events as defined in diagnostic calibration. The crankshaft position sensor is a magnetic sensor (variable reluctant/magnetic pick-up or Hall effect) installed in the engine block adjacent to a “coded” trigger wheel located on the crankshaft.
PAGE 169
SECTION 3 - CHASSIS & TURNTABLE • Key On, Engine Running • System Mode= “Running” Operate engine at condition that set fault based on fault snapshot Yes No Is crank sensor a VR/ magnetic pick-up? Does DTC 336 reset ? Check wiring and electrical connections between crankshaft position sensor and ECM Yes No Is the wiring OK? Intermittent fault No Repair wireharness Yes Faulty wireharness (twist circuit) No Is wiring between sensor and ECM properly twisted? • Poor system ground • Bad crankshaft
PAGE 170
SECTION 3 - CHASSIS & TURNTABLE DTC 337- Loss of Crank Input Signal Diagnostic Aids • Crankshaft Position sensor. • Check Condition- Key On, Engine On. • Fault Condition- Loss of crankshaft position signal while valid camshaft position signals continue for x number of cam pulses as defined in the diagnostic calibration. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp. • Check crankshaft position sensor is securely connected to harness.
PAGE 171
SECTION 3 - CHASSIS & TURNTABLE DTC 521- Oil Pressure Sender/Switch High Pressure • Engine Oil Pressure • Check Condition- Key on, Engine on (or Engine off ) • Fault Condition- For sender types, oil pressure higher than x psia while engine speed is greater that y RPM. For switch types, oil pressure is indicating high when the engine has been stopped for more than n seconds.
PAGE 172
SECTION 3 - CHASSIS & TURNTABLE Normally Open Switch • Key-On, Engine Off • System Mode= “Stopped” No Does DTC 524 reset ? • Key Off • Disconnect harness from Oil Pressure switch • Check continuity through switch to ground.
PAGE 173
SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3121290 – JLG Lift – 3-133
PAGE 174
SECTION 3 - CHASSIS & TURNTABLE DTC 524- Oil Pressure Low • Engine Oil Pressure. • Check Condition- Key on, Engine on. • Fault Condition- Engine oil pressure lower than expected while engine has been running for a minimum amount of time while engine speed is above some limit as defined in the diagnostic calibration. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, generally configured to derate the engine and trigger an engine shutdown.
PAGE 175
SECTION 3 - CHASSIS & TURNTABLE Normally Open Switch • Key-On, Engine On • System Mode= “Running” • Warm engine at idle to normal operating temperature • Increase RPM above limit set in diagnostic calibration • Key Off • Disconnect harness from Oil Pressure switch • Clear DTC 524 • Key On, Engine On • System Mode= “Running” • Operate engine et idle for at least one minute • Increase RPM above limit set in diagnostic calibration Yes Does DTC 524 reset ? Does DTC 524 reset? Yes • Oil Pressure circuit sh
PAGE 176
SECTION 3 - CHASSIS & TURNTABLE Normally Closed Switch • Key-On, Engine On • System Mode= “Running” • Warm engine at idle to normal operating temperature • Increase RPM above limit set in diagnostic calibration Does DTC 524 reset ? • Key Off • Disconnect harness from Oil Pressure switch • Jumper Oil Pressure signal wire to ground • Clear DTC 524 • Key On, Engine On • System Mode= “Running” • Operate engine et idle for at least one minute • Increase RPM above limit set in diagnostic calibration Yes Does
PAGE 177
SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3121290 – JLG Lift – 3-137
PAGE 178
SECTION 3 - CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low • System voltage to ECM. Battery voltage powers the ECM and must be within limits to correctly operate throttle actuator, power supplies, and other powered devices the ECM controls. • Check Condition- Key on, Engine on. • Fault Condition- Battery voltage to ECM less than x volts while the engine is operating at y RPM or greater as defined in the diagnostic calibration.
PAGE 179
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-139
PAGE 180
SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High • System voltage to ECM. Battery voltage powers the ECM and must be within limits to correctly operate throttle actuator, power supplies, and other powered devices the ECM controls. • Check Condition-Key on, Engine Cranking or Running. • Fault Condition- Battery voltage to ECM greater than x volts while the engine is running as defined in the diagnostic calibration.
PAGE 181
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-141
PAGE 182
SECTION 3 - CHASSIS & TURNTABLE DTC 601- Microprocessor Failure - FLASH • Engine Control Module- Flash Memory. The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. • Check Condition- Key on. • Fault Condition- Internal microprocessor error.
PAGE 183
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-143
PAGE 184
SECTION 3 - CHASSIS & TURNTABLE DTC 604- Microprocessor Failure - RAM • Engine Control Module- Random Access Memory. • Check Condition- Key on. • Fault Condition- Internal ECM microprocessor memory access failure. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle, recommend power derate 2 and low rev limit to reduce possible engine damage and/or overspeed condition.
PAGE 185
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-145
PAGE 186
SECTION 3 - CHASSIS & TURNTABLE DTC 606- Microprocessor Failure - COP • Engine Control Module. The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. • Check Condition- Key on. • Fault Condition- Internal microprocessor error.
PAGE 187
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-147
PAGE 188
SECTION 3 - CHASSIS & TURNTABLE DTC 642- 5 Volt External Low Voltage + 1 + W B D -2 W B D tr o -M 1 S P T d ri -B H e g 6 xt1 e _ V 5 + R E S P T ria e lS C D 5 + s= V 2 1 3 -1 R E S P T i rxm te M C E rtn _ V 5 9 1 le E tu c A h T c ln ia e /S rw to it s o P k c a b d e F n io DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback Diagnostic Aids • Engine C
PAGE 189
SECTION 3 - CHASSIS & TURNTABLE DTC 643- 5 Volt External High Voltage + tr o -M 1 S P T 1 W B D + 2 W B D rid -B H e g 6 1 _ V 5 E S P T a ri e lS xte R D 5 + s= V C 2 1 3 1 E S P T te i rxm M C E R rtn _ V 5 9 1 h iT n le E /S rw o a tu c A lto ria e d e F itn s o P b k c a DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback Diagnostic Aids • Engine C
PAGE 190
SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 • Engine Control Module. The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. • Check Condition- Key on.
PAGE 191
SECTION 3 - CHASSIS & TURNTABLE DTC 1613- Microprocessor Failure - RTI 2 • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
PAGE 192
SECTION 3 - CHASSIS & TURNTABLE SFC 555- RTI 2 Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Does SFC 555 reset with engine idling? Yes Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-152 – JLG Lift – 3121290
PAGE 193
SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things happen within the microprocessor that causes this fault. The ECM will reset itself in the event this fault is set, and MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
PAGE 194
SECTION 3 - CHASSIS & TURNTABLE SFC 556- RTI 3 Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 556 reset with engine idling? Are all circuits ok? Yes Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-154 – JLG Lift – 3121290
PAGE 195
SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D • Engine Control Module. The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase. • Check Condition- Key on.
PAGE 196
SECTION 3 - CHASSIS & TURNTABLE SFC 513- A/D Loss Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 513 reset with engine idling? Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-156 – JLG Lift – 3121290
PAGE 197
SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure - interrupt • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. The ECM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power. It will not self-erase.
PAGE 198
SECTION 3 - CHASSIS & TURNTABLE SFC 512- Invalid Interrupt Key On - Engine Running System Data Mode Check all power and ground circuits to ECM Clear System Fault Yes Does SFC 512 reset with engine idling? Yes Are all circuits ok? Replace ECM with known good part and retest No No Fault is intermittent Repair wiring to ECM and retest 3-158 – JLG Lift – 3121290
PAGE 199
SECTION 3 - CHASSIS & TURNTABLE DTC 1625- CAN J1939 Shutdown Request Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Fault Condition- ECM has received shutdown message from another CAN device and is shutdown on request. • ECM has shutdown engine upon command by an external controller. This is requested and expected behavior.
PAGE 200
SECTION 3 - CHASSIS & TURNTABLE DTC 1626- CAN J1939 Transmit (Tx) Fault Diagnostic Aids • Controller Area Network. • Check Condition- Key On, Engine Off and/or Running. • Fault Condition- ECM CAN transceiver transmit error counts greater than the limit defined in the diagnostic calibration (must be < 125 failures). • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp. • Non-emissions related fault.
PAGE 201
SECTION 3 - CHASSIS & TURNTABLE DTC 1627- CAN J1939 Receive (Rx) Fault Diagnostic Aids • Controller Area Network. • Check Condition- Key On, Engine Off and/or Running. • Fault Condition- ECM CAN transceiver receive error counts greater than the limit defined in the diagnostic calibration (must be < 125 failures). • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp. • Non-emissions related fault.
PAGE 202
SECTION 3 - CHASSIS & TURNTABLE DTC 1628- CAN Address Conflict Failure • CAN device(s). • Check Condition- Key On, Engine on. • Fault Condition- two or more devices on the network that contain the same SA. • Corrective Action(s)- Sound audible warning or illuminate secondary warning lamp. • Non-emissions related fault. The Controller Area Network serves as a communication portal between intelligent devices.
PAGE 203
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-163
PAGE 204
SECTION 3 - CHASSIS & TURNTABLE DTC 1629- J1939 TSC1 Message Receipt Loss DIAGNOSTIC AIDS • Controller Area Network. • Check Condition- Key On, Engine Running. • Fault Condition- ECM is expecting to receive J1939 TSC1 messages and has not received a message for more than n seconds (as defined in the diagnostic calibration). • Corrective Action(s)- Illuminate MIL, sound audible warning or illuminate secondary warning lamp. Govern engine speed at a forced idle. • Non-emissions related fault.
PAGE 205
SECTION 3 - CHASSIS & TURNTABLE DTC 1652- TPS1 Loss of Communications + tr o -M 1 S P T 1 W B D + 2 W B D rid -B H e g _ V 5 6 1 E S P T a ri e lS xte R D 5 + s= V C 2 1 3 1 E S P T te i rxm M C E R rtn _ V 5 9 1 h iT n le E /S rw o a tu c A lto ria e d e F itn s o P b k c a DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback Diagnostic Aids • Throttle
PAGE 206
SECTION 3 - CHASSIS & TURNTABLE DTC 2111- Unable to Reach Lower TPS + 1 + W B D -2 W B D tr o -M 1 S P T d ri -B H e g 6 xt1 e _ V 5 + R E S P T ria e lS C D 5 + s= V 2 1 3 -1 R E S P T i rxm te M C E rtn _ V 5 9 1 le E tu c A h T c ln ia e /S rw to it s o P k c a b d e F n io DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor •
PAGE 207
SECTION 3 - CHASSIS & TURNTABLE 3121290 – JLG Lift – 3-167
PAGE 208
SECTION 3 - CHASSIS & TURNTABLE DTC 2112- Unable to Reach Higher TPS DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor. • Check Condition-Cranking or Running. • Fault Condition-Throttle command is 20% more than actual throttle position. • MIL-On during active fault. • Engine Shut Down.
PAGE 209
SECTION 3 - CHASSIS & TURNTABLE DTC 9999- Throttle Actuator Failsafe Spring Failure + tr o -M 1 S P T 1 W B D + 2 W B D rid -B H e g _ V 5 6 1 E S P T a ri e lS xte R D 5 + s= V C 2 1 3 1 E S P T te i rxm M C E R rtn _ V 5 9 1 h iT n le E /S rw o a tu c A lto ria e d e F itn s o P b k c a DBW+ 1 + Motor H-Bridge 2 - TPS1 16 12 Serial xmitter 13 DBW- 5V_ext Vs=+5 VDC TPS SER + TPS SER - 5V_rtn ECM 19 Electronic Throttle Actuator w/Serial Position Feedback Diagnostic Ai
PAGE 210
SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT INDEX 3-170 DESCRIPTION SPN FMI 2 DTC 118: ECT voltage high 110 3 3 DTC 117: ECT voltage low 110 4 4 DTC 116: ECT higher than expected stage 1 110 15 9 DTC 563: Vbat voltage high 168 15 10 DTC 562: Vbat voltage low 168 17 11 DTC 643: Sensor supply voltage 1 high 1079 3 12 DTC 642: Sensor supply voltage 1 low 1079 4 13 DTC 123: TPS1 voltage high 51 3 14 DTC 122: TPS1 voltage low 51 4 29 DTC 524: Oil
PAGE 211
SECTION 3 - CHASSIS & TURNTABLE OUTLET PIPE MUST BE CENTERED WITHIN 1/4" (6.35 MM) MINIMUM CLEARANCE TO EXHAUST VENTURI AROUND VENTURI’S PERIMETER. IF EXHAUST PIPE TOUCHES VENTURI, IT WILL MELT THE HOOD. IF EXHAUST PIPE IS NOT CENTERED, ADJUST MUFFLER OR OUTLET AS NEEDED FOR NECESSARY CLEARANCE. A B D C A. Exhaust Venturi B. 1/4" (6.35 mm) minimum clearance all around. C. 3/4" (19.05 mm) minimum engagement D. Exhaust Pipe Outlet Figure 3-79.
PAGE 212
SECTION 3 - CHASSIS & TURNTABLE A Counterweight installed on turntable. Counterweight A B,C Counterweight mounting bolts (underside of turntable shown). A. Part Number\Actual Weight Stamping B. Apply Loctite #271 to Bolt Threads and to Threads in Counterweight. C. Torque to 285 ft-lb (386 Nm). Figure 3-80.
PAGE 213
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING LINES TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEM. DO NOT USE A LIFTING DEVICE TO LIFT BOOMS UNLESS HOLDING VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILL RESULT IN SEVERE DAMAGE TO BOOM. b. Tag and disconnect boom to control valve hydraulic lines. Use a suitable container to retain residual hydraulic fluid. Cap all hydraulic lines and ports.
PAGE 214
SECTION 4 - BOOM & PLATFORM Main Boom Disassembly Inspection 1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments. 2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down hydraulic system. 3. Carefully disconnect hydraulic hose from retract port of cylinder.
PAGE 215
SECTION 4 - BOOM & PLATFORM Main Boom Assembly Install Boom Assembly 1. Install power track to the attach point on the base boom section. Secure power track with the attaching hardware. 1. Using suitable lifting equipment, position boom assembly on turntable so boom pivot holes in boom and turntable are aligned. 2. Install hydraulic lines and electrical cables in power track. 2. Install boom pivot pin, ensuring location of hole in pivot pin aligns with attach point on upright. 3.
PAGE 216
SECTION 4 - BOOM & PLATFORM 1. Upper Boom 2. Tower Link 3. Upper Upright 4A. Upper Lift Cylinder Master 4B. Upper Lift Cylinder Slave 5. Upper Tower Boom 6. Tower Link 7. Boom 8. Lower Lift Cylinder 9. Lower Upright Figure 4-2.
PAGE 217
SECTION 4 - BOOM & PLATFORM ! ! Figure 4-2.
PAGE 218
SECTION 4 - BOOM & PLATFORM Wear Pads Wear Pads Telescope Cylinder Rod End Wear Pads Figure 4-3.
PAGE 219
SECTION 4 - BOOM & PLATFORM 4.2 ROTARY ACTUATOR Required Tools Basic tools required for assembly and disassembly of the actuator and their intended functions are as follows: Theory of Operation The L20 Series rotary actuator converts linear piston motion to shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03).
PAGE 220
SECTION 4 - BOOM & PLATFORM 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap 5. Exclusion Seal 8. Bolt 9. Cap Seal 10. Cap Ring 11. Rod Seal 12. Piston Seal 13. Bearing Packing 14. Cap Bearing 15. Shaft Bearing 16. Thrust Washer 17. Counterbalance Valve 53. Lock Pin 54. Countersunk Screw Figure 4-4.
PAGE 221
SECTION 4 - BOOM & PLATFORM Disassembly 4. Install end cap (4) removal tools provided with Helac seal kit. 5. Using a metal bar or similar, unscrew end cap (4) by turning it counter clockwise. 6. Remove end cap (4) and set aside. 1. Remove capscrews (54) over end cap lock pins (53). 2. Using a 1/8" (3.18mm) drill bit, drill hole in center of each lock pin to a depth of approximately 3/16" (4.76mm). 3. Remove lock pins using an ”Easy Out” (#2 shown).
PAGE 222
SECTION 4 - BOOM & PLATFORM 7. 8. 4-10 Actuator has timing marks for proper engagement. 9. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet. 10. Mark housing (1) ring gear in relation to piston O.D. gear before removing piston sleeve (3). There should be timing marks on housing ring gear (1), piston (3) and shaft (2). 11. Use a rubber mallet and plastic mandrel to prevent damage when removing piston sleeve (3).
PAGE 223
SECTION 4 - BOOM & PLATFORM 12. Mark piston and housing with a marker where piston gear teeth come out of engagement with housing gear teeth as shown. 15. To remove main pressure seals (13), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove. 13. Remove O-ring (9) and backup ring (10) from end cap (4) and set aside. 16. Remove thrust washers (16), from end cap (4) and shaft (2). 14. Remove wear guides (14) from end cap (4) and shaft (2). 17.
PAGE 224
SECTION 4 - BOOM & PLATFORM 18. 19. 4-12 Remove piston O.D. seal (12). Inspection 1. Clean parts in a solvent tank and dry with compressed air before inspecting. Inspect seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore, and gear teeth for surface finish abnormalities. 2. Inspect thrust washers (16) for rough or worn edges and surfaces. Measure thickness to make sure it is not less than 0.092" (2.34 mm). Remove piston I.D. seal (11).
PAGE 225
SECTION 4 - BOOM & PLATFORM 3. Inspect wear guide condition. Measure thickness not less than 0.123" (3.12 mm). 3121290 Assembly – JLG Lift – 1. Gather all components and tools to one location. 2. Install thrust washer (16) on shaft (2) and end cap (4). 3. Install exclusion seal (5) in groove on shaft (2) and end cap (4) around outside edge of thrust washer (16).
PAGE 226
SECTION 4 - BOOM & PLATFORM 4. Use seal tool in a circular motion to install main pressure seal (13) on shaft (2) and end cap (4). 5. Install wear guide (14) on end cap (4) and shaft (2). 6. 4-14 7. Install outer T-seal (12) by stretching it around groove in a circular motion. Each T-seal has 2 back-up rings (see drawing for orientation). 8. Beginning with inner seal (11), insert one end of backup ring in lower groove and feed the rest in using a circular motion.
PAGE 227
SECTION 4 - BOOM & PLATFORM 10. Insert piston (3) in housing (1) until outer piston seal (12) is touching inside housing bore. 11. Looking from angle shown, rotate piston (3) until marks on piston and housing (1) line up as shown. 12. Using a rubber mallet, tap piston into housing to point where gear teeth meet. 3121290 – JLG Lift – 13. Look from opposite end of housing (1) to see if timing marks line up. When they do, tap piston (3) in until gear teeth mesh together.
PAGE 228
SECTION 4 - BOOM & PLATFORM 15. 16. 4-16 Looking from view shown, use existing timing marks to line up gear teeth on shaft (2) with gear teeth on inside of piston (3). Now tap flange end of shaft with a rubber mallet until gear teeth engage. Install 2 bolts in threaded holes in flange. Using a bar, rotate shaft clockwise until wear guides are seated inside housing bore. – JLG Lift – 17. Coat threads on end of shaft with anti-seize grease to prevent galling. 18.
PAGE 229
SECTION 4 - BOOM & PLATFORM 19. Thread end cap (4) on shaft (2) end. Make sure wear guide stays in place on end cap as it is threaded in housing (1). 21. Place lock pins (53) provided in Helac seal kit in holes with dimple side up. Using a punch, tap lock pins to bottom of hole. 20. Tighten end cap (4) and align holes for lock pins. 22. Insert set screws (54) over lock pins. Tighten to 25 in-lb (2.825 Nm).
PAGE 230
SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve 3. Bolts that come with valve are grade 8 bolts. Install new bolts with a new valve. Apply Loctite #242 to shank of three bolts during installation. 4. Torque 1/4" bolts 110 to 120 in-lb (12.4 to 13.5 Nm). Torque 5/16" bolts 140 in-lb (15.8 Nm). Refer to Figure 4-5., Rotator Counterbalance Valve. 1. Clean actuator surface of contamination and foreign debris including old Loctite. 2.
PAGE 231
SECTION 4 - BOOM & PLATFORM NOTE: Retorque all bolts on rotator if any rotator bolts are replaced. A B C D E Torque to 50 ft-lb (68 Nm) Loctite #242 Torque to 480 ft-lb (650 Nm) Check torque every 150 hours of operation Torque to 85 ft-lb (115 Nm) Figure 4-6.
PAGE 232
SECTION 4 - BOOM & PLATFORM 2. 4.3 POWERTRACK MAINTENANCE Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. Remove Link NOTE: Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different. 1. 4-20 Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a T20 torx bit, remove 8-32 x 0.500 screw from one side.
PAGE 233
SECTION 4 - BOOM & PLATFORM 5. REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 3. To remove a link, rivets holding links together must be removed. Use a right-angle pneumatic die grinder with a ¼” ball double cut bur attachment. 4. insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed. 3121290 After grinding it may be necessary to use a center punch with a hammer to remove rivet.
PAGE 234
SECTION 4 - BOOM & PLATFORM 6. 4-22 Insert flat head screwdriver between links. Twist and pull links apart. – JLG Lift – 7. Remove link from other section of powertrack using screwdriver.
PAGE 235
SECTION 4 - BOOM & PLATFORM Install New Link 1. 2. Spread half-shear (female) end of new link and slide cutout end of track section into it. Use a screwdriver if necessary. 3. After new link is installed round half-shears do not fit properly in cut-outs. Squeeze cut-out end of new link into half-shear (female) end of track section.
PAGE 236
SECTION 4 - BOOM & PLATFORM 4. 5. 4-24 Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will rotate into cut-outs. 6. Push pin through center hole then slide washer on pin. 7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed. Parts shown below connect new link to powertrack.
PAGE 237
SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed properly. Correct 1. 2. Pull up on other end of round bar and slide new poly roller on bar. Incorrect Install new 8-32 x 0.500 self-threading torx head screw in end of new aluminum round bar. Torque to 18-20 inlb (2-2.25 Nm).
PAGE 238
SECTION 4 - BOOM & PLATFORM 3. Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in-lb (2-2.25 Nm). Replace Fixed End Brackets REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove rivets as shown in link removal instructions on page 4-20. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head.
PAGE 239
SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. 3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. Replace Moving End Brackets REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-20. Repeat on other bracket if replacing it.
PAGE 240
SECTION 4 - BOOM & PLATFORM 2. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. Install center pin with snap ring in new bracket. Correct 3. 4-28 Install radius pins and snap rings in original locations. Repeat with other moving end if replacing it. – JLG Lift – 4. Incorrect Make sure both brackets rotate correctly.
PAGE 241
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 O-RING LUBRICATION 2. Hold fitting over hydraulic oil container and brush an even film of oil around entire O-ring in fitting. Make sure O-ring is completely saturated. 3. Turn over fitting repeat previous step to O-ring on other side of fitting. Make sure entire O-ring is coated with hydraulic oil.
PAGE 242
SECTION 5 - HYDRAULICS Dip Spray NOTE: This method works best with Face Seal O-rings, but will work for all O-ring fitting types. This method requires a pump or trigger spray bottle. Tools needed: • Small leak proof container 1. Fill spray bottle with hydraulic oil. 2. Hold fitting over suitable catch can. 3. Spray entire O-ring surface with medium coat of oil. • Sponge cut to fit inside container • Small amount of hydraulic oil to saturate sponge. 1.
PAGE 243
SECTION 5 - HYDRAULICS 5.2 HYDRAULIC CYLINDERS 1. Tower Lift 2. Main Lift 3. Master 4. Telescope 5. Slave (Platform Level) 6. Jib Lift 7. Axle Lockout 8. Steer Figure 5-1.
PAGE 244
SECTION 5 - HYDRAULICS 5. Tower Lift Cylinder Mark cylinder head and barrel with a center punch for realignment. Remove eight cylinder head cap screws. DISASSEMBLY Refer to Figure 5-5. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2.
PAGE 245
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Locking Compound Locking Primer Not Used Capscrew Tapered Bushing 6. 7. 8. 9. 10. Bushing Head Barrel Rod Piston 11. 12. 13. 14. 15. Ring Washer Socket Head Bolt Tube Spacer Not Used Wear Ring 16. 17. 18. 19. 20. Wear Ring Backup Ring Backup Ring O-Ring O-Ring 21. 22. 23. 24. 25. Seal Wiper T-Seal Cartridge Valve O-Ring Plug Figure 5-5.
PAGE 246
SECTION 5 - HYDRAULICS 8. Remove cap screws from tapered bushing. 7. 9. Insert cap screw in threaded holes in outer piece of tapered bushing. Progressively tighten cap screw(s) until bushing is loose on piston. Inspect threaded portion of piston for damage. Dress threads as necessary. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. Remove bushing from piston. 9. Inspect cylinder head inside diameter for scoring or other damage.
PAGE 247
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal in cylinder head gland groove. Figure 5-10. Wiper Seal Installation 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head. Figure 5-8.
PAGE 248
SECTION 5 - HYDRAULICS 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 8. Carefully thread piston on cylinder rod hand tight. Ensure O-ring and back-up rings are not damaged or dislodged. NOTE: 9. Piston and mating end of rod must be free of oil when installing tapered bushing. Thread piston onto rod until it aligns with spacer end. Install tapered bushing.
PAGE 249
SECTION 5 - HYDRAULICS Main Lift Cylinder DISASSEMBLY PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. Refer to Figure 5-17. 6. Clamp barrel securely. Pull rod assembly from barrel. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
PAGE 250
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod End Cap Piston Head 6. 7. 8. 9. 10. Hex Nut Tube Spacer Not Used Cartridge Valve O-Ring Plug 11. 12. 13. 14. 15. Setscrew Setscrew Wear Ring Seal O-Ring 16. 17. 18. 19. 20. Wear Ring O-Ring Seal Wiper Locking Compound 21. Locking Primer 22. Locking Compound 23. Bushing Figure 5-17.
PAGE 251
SECTION 5 - HYDRAULICS CLEANING AND INSPECTION 11. 1. Clean all parts in approved cleaning solvent. 2. Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary. 4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary. 5.
PAGE 252
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: Carefully install assembled head (5) on rod. Make sure wiper and rod seals are not damaged or dislodged. Push head along rod to rod end. 4. Carefully slide spacer on rod to marked position. Apply locking compound to setscrew. Tighten setscrew. 5. Insert new O-ring (15) in piston (4) groove. Install seal (14) on center of piston. Install wear rings (13) on each end of piston. Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.
PAGE 253
SECTION 5 - HYDRAULICS 4. Master Cylinder (450 A/AJ) Without Arctic Package 450A Refer to Figure 5-25. 450AJ refer to Figure 5-26. Mark cylinder head and barrel with a center punch for realignment. Unscrew cylinder head with pin-face spanner wrench. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
PAGE 254
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Barrel Rod Not Used Piston 5. 6. 7. 8. Head Not Used Not Used Bushing 9. 10. 11. 12. Seal Wear Ring O-Ring O-Ring 13. 14. 15. 16. Backup Ring Seal O-Ring Wiper 17. 18. 19. 20. Retaining Ring O-Ring Retainer Spacer Figure 5-25.
PAGE 255
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Not Used Piston Bushing 6. 7. 8. 9. 10. Not Used Not Used O-Ring Retaining Ring Wiper 11. 12. 13. 14. 15. O-Ring Seal Backup Ring O-Ring O-Ring 16. 17. 18. 19. 20. Wear Ring Seal Retainer Not Used Not Used 21. Not Used 22. Not Used 23. Head Figure 5-26.
PAGE 256
SECTION 5 - HYDRAULICS 6. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Remove retainer from end of rod. 8. Unscrew and remove piston assembly. 9. 450A only. Remove spacer. 10. NOTE: Lubrication is not required with nickel plated pins and bearings. Install pin in composite bushing dry. Remove head assembly from rod. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 2.
PAGE 257
SECTION 5 - HYDRAULICS IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. 2. Place new wiper in cylinder head with flat side facing in. Use a soft mallet to seat wiper in cylinder head groove. 3. Install retainer in cylinder head groove. 4. Install O-ring in cylinder head groove. 5.
PAGE 258
SECTION 5 - HYDRAULICS 4. Master Cylinder (450 A/AJ) With Arctic Package 450A Refer to Figure 5-25. 450AJ refer to Figure 5-26. Mark cylinder head and barrel with a center punch for easy reassembly. Remove eight cylinder head retainer cap screws. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 259
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Locking Compound Locking Primer Bolt Tapered Bushing 5. 6. 7. 8. Composite Bushing Piston Ring Washer Head 9. Barrel 10. Rod 11. Bolt 101. Lock Ring 102. 103. 104. 105. Wear Ring Backup Ring O-Ring O-Ring 106. 107. 108. 109. Wiper Seal Backup Ring Seal Figure 5-35.
PAGE 260
SECTION 5 - HYDRAULICS 6. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 6. Inspect piston surface for damage, scoring, and distortion. Dress piston surface or replace piston as needed. 7. Loosen and remove cap screws attaching tapered bushing to piston. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 8. Insert cap screws in threaded holes in outer piece of tapered bushing.
PAGE 261
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: 5. Install washer ring on rod. Carefully install cylinder head assembly head on rod. Do not damaged or dislodge wiper and rod seals. Push head to rod end. 6. Place a new O-ring and back-up rings in inner piston diameter groove. Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new seal in cylinder head groove. Figure 5-38.
PAGE 262
SECTION 5 - HYDRAULICS 13. APPLY JLG THREAD LOCKING COMPOUND P/N 0100011 TO TAPERED BUSHING BOLTS WHEN REBUILDING MASTER, SLAVE, LIFT, OR TELESCOPE CYLINDERS. TIGHTEN TO SPECIFIED TORQUE. 10. Install bolts in tapered bushing using JLG Thread Locking Compound P/N 0100011. Torque to 5 ft-lb (6.7 Nm). Position cylinder barrel in suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. 14.
PAGE 263
SECTION 5 - HYDRAULICS 5. Telescope Cylinder Use a strap wrench to remove cylinder end cap. Refer to Figure 5-45. DISASSEMBLY PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. 6. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Clamp barrel securely. Pull rod assembly from barrel.
PAGE 264
SECTION 5 - HYDRAULICS 1. 2. 3. 3A. 4. Thread Locking Compound Thread Locking Primer Barrel End Cap Rod 5. 6. 7. 8. 9. Piston Spacer Lock Nut Cylinder Head O-Ring Plug 10. 11. 12. 13. 14. O-Ring Counter-Balance Valve 90° Adapter O-Ring (450AJ Only) Bolt 15. Counter-Balance Valve Block 16. Setscrew (450A Only) 101. Wear Ring 102. Seal 103. O-Ring 104. Wear Ring 105. O-Ring 106. Seal 107. Wiper Seal 108. Backup Ring Figure 5-45.
PAGE 265
SECTION 5 - HYDRAULICS CLEANING AND INSPECTION 1. 13. Clean all parts thoroughly with approved cleaning solvent. Inspect rod bearings for excessive wear or damage. Replace as needed. a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation. 2. Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. 3. Inspect threaded portion of rod for excessive damage.
PAGE 266
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: 1. 3. Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Slide End Cap on rod with threads facing open end of rod. 4. Apply a light film of hydraulic oil to all components before assembly. Carefully install assembled head on rod. Make sure wiper and rod seals are not damaged or dislodged. Push head along rod to rod end. 5. Install O-ring inside spacer (450AJ only). Carefully slide spacer on rod to marked position.
PAGE 267
SECTION 5 - HYDRAULICS 5. Slave (Platform Level) Cylinder Without Arctic Pkg Refer to Figure 5-53. (450A) or Figure 5-54. (450 AJ). Mark cylinder head and barrel with a center punch for realignment. Unscrew cylinder head with pin-face spanner wrench. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
PAGE 268
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Not Used Head Piston 6. 7. 8. 9. 10. Not Used Not Used Bushing Seal O-Ring 11. 12. 13. 14. 15. Wear Ring O-Ring Backup Ring Seal Wiper 16. 17. 18. 19. 20. Retaining Ring O-Ring Not Used Not Used Not Used 21. 22. 23. 24. 25. Retainer Not Used Cartridge Valve Cartridge Valve Plug 26. Plug 27. Not Used 28. O-Ring Figure 5-53.
PAGE 269
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Not Used Piston Head 6. 7. 8. 9. 10. Not Used Not Used Bushing Seal O-Ring 11. 12. 13. 14. 15. Wear Ring O-Ring Backup Ring Seal Wiper 16. 17. 18. 19. 20. Retaining Ring O-Ring Not Used Not Used Not Used 21. 22. 23. 24. 25. Retainer Not Used Cartridge Valve Cartridge Valve Plug 26. Plug 27. Not Used 28. O-Ring Figure 5-54.
PAGE 270
SECTION 5 - HYDRAULICS 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 8. Remove retainer from end of rod. 9. Unscrew and remove piston assembly. 10. NOTE: Lubrication is not required with nickel plated pins and bearings. Install pin in composite bushing dry. Remove head assembly from rod. CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning solvent. 2.
PAGE 271
SECTION 5 - HYDRAULICS IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. 2. Place new wiper in cylinder head with flat side facing inside. Use a soft mallet to seat wiper in cylinder head groove. 3. Install retainer in cylinder head groove. 4. Install O-ring in cylinder head groove. 5.
PAGE 272
SECTION 5 - HYDRAULICS 5. Platform Level (Slave) Cylinder With Arctic Package Refer to Figure 5-63. Mark cylinder head and barrel with a center punch for reassembly. Remove eight cylinder head retainer cap screws from cylinder barrel. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 273
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Locking Compound Locking Primer Socket Head Bolt Tapered Bushing Composite Bushing 6. 7. 8. 9. 10. Head Rod Barrel Ring Washer Piston 11. Vented Counterbalance Valve 12. Non-Vented Counterbalance Valve 13. Socket Head Bolt 101. Lock Ring 102. Wear Ring 103. Backup Ring 104. O-Ring 105. O-Ring 106. Wiper 107. Seal 108. Backup Ring 109. Seal Figure 5-63.
PAGE 274
SECTION 5 - HYDRAULICS 1. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 2. Loosen and remove cap screws attaching tapered bushing to piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 3. Insert cap screws in threaded holes in outer piece of tapered bushing.
PAGE 275
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. Figure 5-68. Wiper Seal Installation 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head. Figure 5-66.
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SECTION 5 - HYDRAULICS 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 11. Remove cylinder rod from holding fixture. 8. Carefully thread piston on cylinder rod hand tight. Ensure O-ring and back-up rings are not damaged or dislodged. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. (See Figure 2-28. Piston Seal Kit Installation.
PAGE 277
SECTION 5 - HYDRAULICS 5. Jib Lift Cylinder (AJ Only) Without Arctic Package Refer to Figure 5-76. Mark cylinder head and barrel with a center punch for reassembly. Unscrew cylinder head with spanner wrench. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 278
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Rod Not Used Not Used Not Used Head 7. 8. 9. 10. 11. 12. Piston Bushing Bushing Not Used Cartridge Valve Not Used 13. 14. 15. 16. 17. 18. Not Used Bushing Sleeve Nut Retainer Wiper 19. 20. 21. 22. 23. 24. Seal O-Ring Backup Ring O-Ring O-Ring O-Ring 25. 26. 27. 28. 29. Plug Not Used Not Used O-Ring Seal 30. Not Used 31. Retaining Ring 32. Wear Ring Figure 5-76.
PAGE 279
SECTION 5 - HYDRAULICS 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 11. Inspect seal and O-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary. 8. Remove retainer from end of rod. 12. 9. Remove nut, sleeve, and bushing. Inspect cylinder head outside diameter for scoring or other damage, ovality, and tapering. Replace as needed. 13.
PAGE 280
SECTION 5 - HYDRAULICS ASSEMBLY 5. Refer to Figure 5-76. NOTE: Place new O-rings and back-up ring in outside diameter cylinder head grooves. Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal in cylinder head gland groove. Figure 5-79. Cylinder Head Seals Figure 5-78.
PAGE 281
SECTION 5 - HYDRAULICS 14. Remove cylinder rod from holding fixture. 15. Position cylinder barrel in suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. 16. Clamp barrel securely and support rod. Insert piston end into barrel cylinder. Do not damage or dislodge piston O-rings and backup ring. 17. Continue pushing rod into barrel. Screw in cylinder head. Torque to 368 ft-lb (500 Nm).
PAGE 282
SECTION 5 - HYDRAULICS 5. Jib Lift Cylinder (AJ Only) With Arctic Package Refer to Figure 5-85. Mark cylinder head and barrel with a center punch for easy realignment. Remove eight cylinder head retainer cap screws from cylinder barrel. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 283
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Locking Compound Locking Primer Bolt Tapered Bushing Bushing 6. 7. 8. 9. 10. Bushing Head Barrel Rod Ring Washer 11. 12. 13. 14. 15. O-Ring Plug Piston Socket Head Bolt Cartridge Valve Backup Ring 101. 102. 103. 104. 105. Backup Ring Ring, Metallic Seal Ring, Wear Ring, Wear O-Ring 106. 107. 108. 109. O-Ring Seal Wiper T-Seal Figure 5-85.
PAGE 284
SECTION 5 - HYDRAULICS 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 8. Loosen and remove cap screws attaching tapered bushing to piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 9. Insert cap screws in threaded holes in outer piece of tapered bushing.
PAGE 285
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal in applicable cylinder head gland groove. Figure 5-90. Wiper Seal Installation 1. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head. Figure 5-88.
PAGE 286
SECTION 5 - HYDRAULICS 4. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 5. Carefully thread piston on cylinder rod hand tight. Ensure O-ring and back-up rings are not damaged or dislodged. NOTE: Piston and mating end of rod must be free of oil when installing tapered bushing. 6. Thread piston on rod until tight. Install tapered bushing.
PAGE 287
SECTION 5 - HYDRAULICS 5. Steer Cylinder Unscrew cylinder head with hook spanner on rod end to be pulled. DISASSEMBLY Refer to Figure 5-98. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. 3. Operate hydraulic power source and extend cylinder.
PAGE 288
SECTION 5 - HYDRAULICS 1. 2. 3. Barrel Rod Cylinder Head 4. 5. 6. Wiper Rod Seal Bearing 7. 8. 9. O-Ring Backup Ring O-Ring 10. Piston Seal 11. Wear Ring 12. Composite Bushing Figure 5-98.
PAGE 289
SECTION 5 - HYDRAULICS CLEANING AND INSPECTION 8. Remove wear ring (11) from piston. 9. Remove seal (10) from piston. Do not damage piston groove. NOTE: Piston seal is a combination-type seal. If seal separates it cannot be reused. 1. Clean all parts in an approved cleaning solvent. 2. Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite™ or equivalent. Replace rod if necessary. 3.
PAGE 290
SECTION 5 - HYDRAULICS ASSEMBLY NOTE: 1. Apply a light film of hydraulic oil to all components before assembly. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE INSTALLING CYLINDER ROD AND PISTON. Position cylinder barrel in a suitable holding fixture. 9. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER CYLINDER OPERATION. 2. Install Rod Seal (5) in Cylinder Head (3). 3. Press-in Bearing (6). 4. Install Wiper (4). 5.
PAGE 291
SECTION 5 - HYDRAULICS ASSEMBLY Axle Lockout Cylinder Refer to Figure 5-106., Axle Lockout Cylinder. Refer to Figure 5-106., Axle Lockout Cylinder. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. PISTON CAN FALL OUT OF HOUSING AND CAUSE INJURY OR DAMAGE TO EQUIPMENT. BE CAREFUL WHEN REMOVING AXLE CYLINDER. OPENING BLEED VALVE CAN CAUSE PISTON TO FALL OUT OF HOUSING. 1. Open bleed valve (8).
PAGE 292
SECTION 5 - HYDRAULICS FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE. CYLINDER ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED. 1. 2. 3. 4. 5. Barrel Rod Plug Pilot Piston Wear Ring 6. 7. 8. 9. Wiper Rod Seal Bleeder Cartridge Valve Figure 5-106.
PAGE 293
SECTION 5 - HYDRAULICS 5.3 HYDRAULIC PUMP (GEAR) 7. Remove pump from vise and place on clean work bench. Remove four hex head bolts and spacers if applicable. 8. Lift and remove end cover. 9. Carefully remove gear housing and place on work bench. Make sure rear bearing block remains on drive and idler shafts. Disassembly NOTE: The following general instructions also apply to multiple section gear pumps.
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SECTION 5 - HYDRAULICS 10. Remove rear bearing block from drive and idler shafts. 13. Remove front bearing block. 11. Remove idler shaft from bearing block. 14. Turn mounting flange over, with shaft seal up. Remove retaining ring with snap ring pliers. 12. Remove drive shaft from mounting flange. 15. Remove oil seal from mounting flange. Do not mar or scratch seal bore. 16. Remove dowel pins from gear housing. Do not lose pins. 17. Remove and discard seals from both bearing blocks.
PAGE 295
SECTION 5 - HYDRAULICS Inspect Parts For Wear 1. Clean and dry all parts thoroughly before inspection. It is not necessary to inspect seals. They will be replaced. 2. Check drive shaft spine for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway. No marks or grooves on shaft in seal area, some discoloration of shaft is allowable. 3. Inspect drive gear shaft and idler gear shafts at bearing points and seal area for rough surfaces and excessive wear. 3121290 – JLG Lift – 4.
PAGE 296
SECTION 5 - HYDRAULICS General Information 2. Install retaining ring in groove in seal bore of mounting flange. 3. Place front and back bearing blocks on a clean surface with E-seal grooves facing up. Apply a light coating of petroleum jelly in the grooves. Coat E-seal and backup with petroleum jelly. This helps keep seals in place during reassembly 4. Place E-seals, flat side out, into grooves in both bearing blocks.
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SECTION 5 - HYDRAULICS 5. Place mounting flange, with shaft seal side down, on a clean flat surface. 6. 7. 10. Apply a light coating of petroleum jelly to exposed face of front bearing block. Place rear bearing block over drive and idler gear shafts with seal side up and open end of E-seal facing intake side of pump. 11. Install two dowel pins in mounting flange holes or two long dowel pins through gear housing if pump is a multiple section pump.
PAGE 298
SECTION 5 - HYDRAULICS 13. Gently slide gear housing over rear bearing block assembly. Slide housing down until it engages dowel pins. Press firmly in place with hands, do not force or use any tool. Check intake port in housing is on same side as open end of E-seal, and marked lines on mounting flange and gear housing are aligned. NOTE: Rear bearing block surface should be slightly below gear housing face.
PAGE 299
SECTION 5 - HYDRAULICS Placing Pump Back Into Service 1. 5.4 If shop test stand is available, use the following procedure for testing rebuilt pumps: a. Mount pump on test stand. Make sure proper level of clean oil is available in reservoir. Check suction line for leaks and obstructions. b. Start pump and run for three minutes at zero pressure. VARIABLE PUMP Ports and Pressure Gauges Proper servicing of pumps and motors requires pressure measured and monitored at various hydraulic circuit points.
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SECTION 5 - HYDRAULICS SHIM ADJUSTABLE STYLE Remove and Install FNR and NFPE Modules 1. Clean pump and module housings. 2. Remove four screws retaining module to pump housing (4 mm Int. Hex). Remove module from housing. 3. Remove O-rings from the control ports. Examine ports for cleanliness. 4. Clean sealing surfaces. 5. Replace locator pin. 6. Install new O-rings. 7. Replace screws. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).
PAGE 301
SECTION 5 - HYDRAULICS 1. System Pressure Gauge Port M2 7. Case Drain Port L2 2. System Pressure Port B 8. Servo Pressure Gauge Port L4 3. System Pressure Port A 9. Case Drain Port L1 4. System Pressure Gauge Port M1 10. Case Drain Port L1 (non-feedback) 5. Servo Pressure Gauge Port M5 11. Charge Pressure Gauge 6. Case Drain Port L2 (non-feedback) 12. Charge Pump Inlet Port S Figure 5-108.
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SECTION 5 - HYDRAULICS Plug/ Fitting # Torque lb. ft.
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SECTION 5 - HYDRAULICS 5. Install new O-ring on valve plug. Reinstall poppet, spring, and plug (with shims and O-ring) into pump housing. Torque to 40-100 ft-lb (55-135 Nm). Shaft Seal and Shaft Replacement SCREW ADJUSTABLE STYLE 1. Retaining Ring 1. Lock Nut 2. O-Ring 3. Plug 4. Spring T-Seal 5. Poppet 2. Seal Carrier Assembly Figure 5-111. Shaft Seal Removal A lip type shaft seal is used in Series 42 pumps. Seal and shaft can be replaced without major unit disassembly.
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SECTION 5 - HYDRAULICS 1. NOTE: Position pump with shaft facing up. If unit is positioned horizontally when shaft is removed, cylinder block could move out of place, making shaft installation difficult. 2. Remove retaining ring from housing. 3. Pull out seal carrier assembly. 4. Remove O-ring from seal carrier. To install a new shaft only, go to step 8. 5. Place seal carrier in an arbor press with shaft bearing side down and press out old seal.
PAGE 305
SECTION 5 - HYDRAULICS Charge Pump NOTE: Disassemble charge pump to inspect and clean, or change auxiliary shaft drive coupling. 1. Remove auxiliary pump if necessary. 2. Remove screws retaining charge pump cover to pump housing (Torx T). Seven screws are used with “no pad” or SAE “A” auxiliary mounting pad charge pump cover, and six screws are used with SAE “B” auxiliary mounting pad charge pump cover. Remove charge pump cover, gasket, and cover locating pins. 3.
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SECTION 5 - HYDRAULICS 5.5 NOTE: HYDRAULIC COMPONENT START-UP The goal at hydrostatic system start up is to preserve the designed life span of the system. Use the following start-up procedure when a new pump or motor is installed or a system is restarted after a pump or motor has been removed and reinstalled. THE FOLLOWING PROCEDURE MAY REQUIRE MACHINE TO BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING PROCEDURE. TO PREVENT INJURY.
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SECTION 5 - HYDRAULICS 5.6 MAIN VALVE BLOCK PRESSURE SETTING PROCEDURES 5.7 PLATFORM VALVE BLOCK PRESSURE SETTING PROCEDURES NOTE: Refer to Figure 5-115., Main Control Valve. NOTE: Refer to Figure 5-116., Platform Control Valves. Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating machine until hydraulic system has warmed to normal operating temperatures. Cold temperatures have a significant impact on pressure readings. JLG Industries Inc.
PAGE 308
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. M2 - Proportional Main Pressure Test Port Swing Relief Valve Swing Solenoid: Bottom - Left, Top - Right Main Dump Solenoid Lift Solenoid: Bottom - Down, Top - Up Steer Solenoid: Bottom - Right, Top - Left 7. 8. 9. 10. 11. 12. Flow Control Solenoid Lower Lift Solenoid: Bottom - Down, Top - Up Telescope Solenoid: Bottom - In, Top - Out Flow Control M1 - Telescope Pressure Test Port Telescope Relief Valve 13. 14. 15. 16. 17. 18. 19.
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SECTION 5 - HYDRAULICS . 1. Rotate Solenoid Valve Assy. Bottom Solenoid - Right Top Solenoid - Left 2. Level Solenoid Valve Assy. Bottom Solenoid - Down Top Solenoid - Up 3. Jib Solenoid Valve Assy. Bottom Solenoid - Down Top Solenoid - Up 4. Flow Control Valve 5. M3 - Jib Pressure Test Port 6. Jib Relief Valve* 7. 8. 9. 10. 11. 12. 13.
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SECTION 5 - HYDRAULICS NOTES: 5-70 – JLG Lift – 3121290
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SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM speed, and max.-speed for all boom, drive, and steering functions. 6.1 INTRODUCTION WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS. AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/ ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
PAGE 312
SECTION 6 - JLG CONTROL SYSTEM & " ( ) * # ! " # ! " $ - ./0 $ # %& # ' + , Figure 6-2.
PAGE 313
SECTION 6 - JLG CONTROL SYSTEM Connect JLG Control System Analyzer 1. Using Analyzer Connect four pin end of cable supplied with hand-held or wireless analyzer to controller module on platform box or at controller module inside ground control box. Connect other end of cable to analyzer. NOTE: Cable has a keyed four pin connector at each end. It cannot be connected backwards. 1. Power up Control System by turning lower key to platform or ground position and pulling both emergency stop buttons out.
PAGE 314
SECTION 6 - JLG CONTROL SYSTEM If ENTER is selected at the HELP: PRESS ENTER display, and a fault is present, the analyzer display scrolls the fault across the screen. If no fault is detected, the display shows: HELP: EVERYTHING OK. If powered up at the ground station, the display shows: GROUND OK. If ENTER Pressing ENTER with any of the above displayed menus, displays additional sub-menus within the selected menu.
PAGE 315
SECTION 6 - JLG CONTROL SYSTEM Adjust Parameters Press ENTER to select the ACCESS LEVEL menu. Using UP or DOWN the password, 3. Once you have gained access to level 1, and a personality item arrow keys, enter first digit of is selected, press UP or DOWN adjust its value, for example: arrow keys to Using RIGHT arrow key, position cursor right one space to enter the second digit of the password. Use UP or DOWN arrow key to enter second digit of the password which is 33271.
PAGE 316
SECTION 6 - JLG CONTROL SYSTEM There is a setting that JLG strongly recommends you do not change. This setting is so noted below: Machine Setup ELEVATION CUTBACK When a machine digit item is selected, press UP DOWN or CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFORMANCE OF YOUR MACHINE. arrow keys to adjust its value, for example: AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
PAGE 317
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION ACCEL Table 6-1. Analyzer Abbreviations MEANING ABBREVIATION MEANING ACCELERATE GND ACT ACTIVE GRN GREEN A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE AMB.
PAGE 318
SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION S/C MEANING SHORT CIRCUIT SEL SELECTOR SN SERIAL NUMBER SPD STOW STOWD SW SPEED STOWED STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ.
PAGE 319
SECTION 6 - JLG CONTROL SYSTEM MENU: HELP:PRESS ENTER HELP: (001) EVERYTHING OK LOG:(xxx) x:xxxxxxxxxxx MENU: DIAGNOSTICS TO MENU: SYSTEM TEST DIAGNOSTICS: DRIVE/STEER DIAGNOSTICS: BOOM FUNCTIONS JOYSTICK DRIVE: FORWARD XXX% JOYSTICK LIFT: MAIN UP XXX% JOYSTICK STEER: LEFT XXX% LIFT OUTPUT: MAIN UP XXX% DRIVE OUTPUT: FORWARD XXX% LIFT UP COMMANDED:XXXXMA TO DIAGNOSTICS: ENGINE DRIVE FORWARD: COMMANDED:XXXXMA BRAKES STATUS: LOCKED LIFT DOWN COMMANDED:XXXXMA DRIVE REVERSE: COMMANDED:XXXXMA C
PAGE 320
SECTION 6 - JLG CONTROL SYSTEM From DIAGNOSTICS: BOOM FUNCTIONS DIAGNOSTICS: ENGINE DIAGNOSTICS: SYSTEM DIAGNOSTICS: UMS START SEQUENCE: NOT ACTIVE GROUND MODULE: BATTERY: XX.XV CHASSIS TILT ANGLE: XX.X BATTERY VOLTAGE: XX.XV PLATFORM MODULE: BATTERY: XX.XV UMS TO TURNTABLE ANGLE: XX.X COOLANT TEMPERATURE:XXXF AMBIENT TEMPERATURE:XXXF UMS INCLINATION ANGLE: XX.X ELECTRIC FAN OUTPUT: OFF PLATFORM SELECT KEYSWITCH: OPEN CHASSIS TILT X-AXIS: XX.
PAGE 321
SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: UMS DIAGNOSTICS: LOAD DIAGNOSTICS: CAN STATISTICS DIAGNOSTICS: 1 CALIBRATION DATA DIAGNOSTICS: DATALOG DIAGNOSTICS: VERSIONS CAPACITY LENGTH SWITCH: CLOSED CAN STATISTICS RX/SEC: X CALIBRATION DATA 1 LOAD ZERO: DATALOG: ON: XXXh XXm GROUND MODULE SOFTWARE: XX.XX CAPACITY ANGLE SWITCH: CLOSED CAN STATISTICS TX/SEC: X CALIBRATION DATA 1 LOAD 500LB: DATALOG: ENGINE: XXXh XXm GROUND MODULE COST. DATA:XX.
PAGE 322
SECTION 6 - JLG CONTROL SYSTEM FROM MENU: DIAGNOSTICS MENU: SYSTEM TEST SYSTEM TEST: ACTIVATE? MENU: ACCESS LEVEL ACCESS LEVEL: CODE XXXXXX MENU: PERSONALITIES PERSONALITIES: DRIVE PERSONALITIES: STEER PERSONALITIES: LEFT TRACK PERSONALITIES: RIGHT TRACK DRIVE: ACCEL X.XS STEER: MAX SPEED XXX% LEFT TRACK: ACCEL X.XS RIGHT TRACK: ACCEL X.XS DRIVE: DECEL X.XS LEFT TRACK: DECEL X.XS RIGHT TRACK: DECEL X.
PAGE 323
SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES: RIGHT TRACK PERSONALITIES: MAIN LIFT PERSONALITIES: SWING PERSONALITIES: TOWER LIFT PERSONALITIES: MAIN TELESCOPE PERSONALITIES: TOWER TELESCOPE MAIN LIFT: ACCEL X.XS SWING: ACCEL X.XS TOWER LIFT: ACCEL X.XS MAIN TELESCOPE: ACCEL X.XS TOWER TELESCOPE: ACCEL X.XS MAIN LIFT: DECEL X.XS SWING: DECEL X.XS TOWER LIFT: DECEL X.XS MAIN TELESCOPE: DECEL X.XS TOWER TELESCOPE: DECEL X.
PAGE 324
SECTION 6 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MACHINE SETUP MENU: CALIBRATIONS 1 MODEL NUMBER: 600S MARKET: CE ENGINE: PERKINS ECM FLYWHEEL TEETH: 133 TEETH GLOW PLUG: IN-CYLINDER STARTER LOCKOUT: DISABLED ENGINE SHUTDOWN: ENABLED TILT: 5 DEGREES JIB: NO 4 WHEEL STEER: NO STOUCH/SKYGUARD: NO GEN SET/WELDER: NO GEN SET CUTOUT: MOTION ENABLED H & T LIGHTS: NO CABLE SWITCH: NO LOAD SYSTEM: NO LOAD SENSOR: 4 UNDER PLATFORM FUNCTION CUTOUT: NO GROUND ALARM: MOTION DRIVE: 4
PAGE 325
SECTION 6 - JLG CONTROL SYSTEM NOTE: Adjust personality settings within range for optimum machine performance. Table 6-2. Personality Ranges/Defaults FUNCTION DRIVE PERSONALITY 0.0s to 5.0s 1.0 DECELeration 0.0s to 3.0s 0.5 MINimum speed 1 to 35% 30 MAXimum speed 1 to 100% 60 REVerse MINimum speed 1 to 35% 30 REVerse MAXimum speed 1 to 100% 60 ELEVATED MAXimum speed 1 to 100% 38 CREEP MAXimum speed 1 to 90% 38 800 to 2900 1800 ACCELeration 0.0 to 5.0 1.0 DECELeration 0.
PAGE 326
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION SWING PERSONALITY 0.0 to 5.0s 2.0 DECELeration 0.0 to 3.0s 1.5 MINimum LEFT speed 1 to 50% 32 MAXimum LEFT speed 1 to 100% 66 CREEP maximum LEFT speed 1 to 65% 51 MINimum RIGHT speed 1 to 50% 38 MAXimum RIGHT speed 1 to 100% 61 CREEP maximum RIGHT speed 1 to 65% 51 800 to 2900 1400 ACCELeration 0.0 to 5.0 2.0 DECELeration 0.0 to 3.0 1.
PAGE 327
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION JIB LIFT PERSONALITY 0.0 to 5.0 3.0 DECELeration 0.0 to 3.0 0.
PAGE 328
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.
PAGE 329
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Numb er ENGINE: 3* * Engine selections vary depending on model selection. 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1) 4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1) 5 CAT. 3024C: CAT 3024C Diesel (Tier 2) 6 CAT.
PAGE 330
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Numb er STARTER LOCKOUT: 6 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow. 1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished. 0 DISABLED: No engine shutdown.
PAGE 331
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Numb er STOUCH/SKYGUARD: 11 0 None: No soft touch or SkyGuard system installed. 1 SOFT TOUCH - Soft touch only installed. 2 SKYGUARD - Skyguard only installed. 3 BOTH(CUTOUT) - Soft Touch and Skyguard installed. 0 NO: No generator installed. 1 BELT DRIVE: Belt driven setup.
PAGE 332
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Numb er LOAD SENSOR: 17* * Only visible if Load Sensor Menu selection is not 0 and under certain market selections. * Certain market selections will limit load sensor options. 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module. 1 4 UNDER PLATFORM: Use the EIM for load sensing.
PAGE 333
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Numb er LEVELING MODE: 22* * Only visible on 800S models. 0 ALL FUNCTIONS: Platform level with all functions. 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only. DRIVE CONTROL: 23 0 NORMAL: Drive coils are energized from Ground Module. 1 PROPULSION: Drive coils are energized from Propulsion Module.
PAGE 334
SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
PAGE 335
SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
PAGE 336
SECTION 6 - JLG CONTROL SYSTEM 6.8 SYSTEM TEST 3. Pull out Emergency Stop switch and start engine. 4. Analyzer screen should read: 5. Use arrow button to reach SYSTEM TEST and press Enter. Analyzer prompts to activate system test. Press Enter to activate. 6. Follow flow path in Figure 6-11., System Test Flow Chart - Platform Tests and go through component tests. Press ESC key during any part of test to return to main menu without completing all tests or wait until all tests are complete.
PAGE 337
Figure 6-11.
PAGE 338
SECTION 6 - JLG CONTROL SYSTEM Test From Ground Station 1. Set Platform/Ground select switch to Ground. 2. Plug analyzer into connector inside Ground control box. 3. 6-28 4. The analyzer screen should read: 5. Use arrow button to reach SYSTEM TEST. Press Enter. Analyzer will prompt you asking if you want to activate system test. Press Enter again to activate. 6. Follow flow path in Figure 6-12., System Test Flow Chart - Ground Station Tests and go through component tests.
PAGE 339
Figure 6-12.
PAGE 340
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer RUNNING 6-30 Description Initial display when system test is run; certain “critical” checks are made. Problems that can be reported include below messages. ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
PAGE 341
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TESTING VALVES Description Indicates valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils. NOTE: In platform mode, the footswitch must be closed. NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if TOWER TELE=NO. Jib valves are not tested if JIB = NO.
PAGE 342
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TEST ALL INPUTS? TESTS COMPLETE 6-32 Description Prompts whether to check every operator input. If ESC is pressed or clicked, system test ends. If ENTER is pressed or clicked, each operator input is prompted for in turn. In platform mode every platform switch and joystick is tested. In ground mode every ground switch is tested.
PAGE 343
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 344
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 345
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 346
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 347
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 348
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 349
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
PAGE 350
SECTION 6 - JLG CONTROL SYSTEM Figure 6-13.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer None Description Priority No flash code indicated for the following help messages. They indicate a possible problem if vehicle is not operating as expected. 1 EVERYTHING OK “Normal” help message in platform mode GROUND MODE OK “Normal” help message in ground mode FSW OPEN A drive or boom function has been selected but footswitch is open.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 2/2 (Continued) Fault Displayed on Analyzer Description D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt range around these values where fault may be indicated. WAITING FOR FSW TO BE OPEN Footswitch closed when platform mode was selected.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 2/5 (Continued) Fault Displayed on Analyzer Description DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL Ground module needs to use RS232 backup communications link to BLAM module but an analyzer is connected.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 3/3 (Continued) Fault Displayed on Analyzer Description Priority LEFT FORWARD DRIVE PUMP OPEN Machines with chassis module ONLY. CIRCUIT LEFT REVERSE DRIVE PUMP SHORT Machines with chassis module ONLY. TO GROUND LEFT REVERSE DRIVE PUMP SHORT Machines with chassis module ONLY. TO BATTERY LEFT REVERSE DRIVE PUMP OPEN CIRCUIT Machines with chassis module ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer Description 3/3 (Continued) MAIN LIFT PILOT PRESSURE FAILURE 1250AJP ONLY. NO MAIN LIFT PILOT PRESSURE 1250AJP ONLY. MAIN LIFT PILOT PRESSURE SWITCH FAILURE 1250AJP ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 3/3 (Continued) Fault Displayed on Analyzer Description TOWER LIFT APU VALVE STUCK OPEN 1250AJP ONLY. TOWER LIFT ENABLE STUCK OPEN 250AJP ONLY. TOWER LIFT ENABLE SHORT TO GROUND 250AJP ONLY. Priority TOWER LIFT ENABLE OPEN CIRCUIT 250AJP ONLY. TOWER LIFT ENABLE SHORT TO BATTERY 250AJP ONLY. TOWER TELESCOPE APU SHORT TO 250AJP ONLY. GROUND TOWER TELESCOPE APU OPEN CIR- 250AJP ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 3/3 (Continued) Fault Displayed on Analyzer Description PVG VALVE OPEN CIRCUIT 1250AJP ONLY. PVG VALVE SHORT TO BATTERY 1250AJP ONLY. FOX SPARE OUTPUT SHORT TO GROUND Fox machines ONLY. FOX SPARE OUTPUT SHORT TO BATTERY Fox machines ONLY. Priority FOX SPARE OUTPUT OPEN CIRCUIT Fox machines ONLY. HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 3/4 (Continued) Fault Displayed on Analyzer Description Priority JIB LEFT SHORT TO GROUND JIB LEFT OPEN CIRCUIT JIB RIGHT SHORT TO BATTERY JIB RIGHT SHORT TO GROUND JIB RIGHT OPEN CIRCUIT PLATFORM CONTROL VALVE SHORT TO BATTERY Machines with electronic basket leveling ONLY. PLATFORM CONTROL VALVE SHORT TO GROUND Machines with electronic basket leveling ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer Description 4/3 (Continued) ECM CAN COMMUNICATION LOST Engine is configured to have a CANBUS controlled engine and JLG system does not detect an ECM. This fault can be the result of power lost to ECM or a break in CANBUS communications connection from ECM to JLG system. 4/4 Flash code 4/4 indicates problems with battery supply. Not reported during 2 second power-up.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 4/5 (Continued) Fault Displayed on Analyzer Description MAIN LIFT PVG VALVE STUCK RETRACTED Main boom lift pvg valve spool stuck in retracted position. TOWER LIFT PVG VALVE STUCK RETRACTED Tower boom lift pvg valve spool stuck in retracted position. TOWER TELESCOPE PVG VALVE STUCK RETRACTED Tower boom telescope pvg valve spool stuck in retracted position.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 4/5 (Continued) Fault Displayed on Analyzer Description MAIN LIFT PVG VALVE WIRING INCORRECT Power wire for main lift pvg valve not wired to that valve. TOWER LIFT PVG VALVE WIRING INCORRECT Power wire for tower lift pvg valve not wired to that valve. TOWER TELESCOPE PVG VALVE WIRING INCORRECT Power wire for tower telescope pvg valve not wired to that valve.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer 8/3 Description Priority Flash code 8/3 indicates problems with the Basket Leveling system. 10 BASKET LEVELING CRACKPOINT UP Only occurs on machines with electronic leveling systems.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer 8/4 Description Flash code 8/4 indicates problems with the envelope system. Only occur on machines with envelope control. BOOM ANGLE SENSOR DISAGREEMENT The boom angle sensors are reporting angles that differ too greatly. An EMS cycle is required. BOOM LENGTH SWITCH FAILED The boom length switch inputs are reporting the same state. An EMS cycle is required.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer 8/5 Description Priority Flash code 8/5 indicates problems with the moment or load pin system. Only occur on machines with moment or load pin control. An EMS cycle is required. 10 MOMENT PIN HORIZONTAL FORCE The horizontal force is out of the allowed range. OUT OF RANGE MOMENT PIN VERTICAL FORCE OUT OF RANGE The vertical force is out of the allowed range.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 8/6 (Continued) Fault Displayed on Analyzer Description RT REAR STEER LT STB OR OC A short to battery or open circuit has been detected on right rear steer left valve. RT REAR STEER LT STG A short to ground has been detected on right rear steer left valve. LT REAR STEER RT STB OR OC Left rear steer right valve short to battery or open circuit.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Fault Displayed on Analyzer 9/9 Description Priority Flash code 9/9 indicates problems with the controller or the user disabling safety systems from Access Level 0. 11 PLATFORM MODULE SOFTWARE UPDATE REQUIRED Platform module code is too old to support the EIM or BPE load sensor and machine is configured to use one of these two sensors. PM code must be updated to a newer version.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions Flash Code 9/9 (Continued) Fault Displayed on Analyzer Description BLAM SENSOR SUPPLY OUT OF RANGE HIGH Supply voltage for boom angle sensors is above expected range. An EMS cycle is required. BLAM SENSOR SUPPLY OUT OF RANGE LOW Supply voltage for boom angle sensors is below expected range. An EMS cycle is required.
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SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-60 – JLG Lift – 3121290
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL Polarity This section contains basic electrical information and schematics for locating and correcting most electrical problems. If a problem develops which is not presented in this section or corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any additional maintenance.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS • To prevent oxidation at mechanical joint between male and female pins. Current Measurement • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with external seals. 1.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Dielectric Grease Application AMP Seal Before following these instructions, refer to excluded connector types (See Exclusions below). 1. Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors. 2. Apply dielectric grease to the female contact (fill it approximately ½ full; see example below) 3. Leave a thin layer of dielectric grease on connector face. 4.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON/PHOENIX CONTACT M12 AMP Mate-N-Lok This connector uses gold contact material to resist corrosion and an O-ring seal for moisture integrity. Low-force contacts cannot displace dielectric grease to achieve electrical contact. Once contaminated, replacement of female contacts is required. The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 connector system.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Connector Assembly Plug and header assembly colors are mechanically keyed to mate only with identical colors. 1. Check wedge lock is in the open, or as-shipped, position. Figure 7-13. AMP Connector Figure 7-15. AMP Connector Assembly Contact Assembly 1.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 4. After all contacts are inserted, close wedge lock to its locked position. Release locking latches by squeezing them inward. NOTE: Wedge lock should never be removed from housing for insertion or removal of contacts. Figure 7-17. Close Wedge Lock 5. Slide wedge lock in housing until flush with housing. Figure 7-19.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly 1. Grasp crimped contact (1) about 25mm behind contact barrel. 2. Hold connector with rear grommet (2) facing you. 3. Push contact straight into connector grommet (3) until a click is felt. A slight tug confirms it is locked in place. 4. 1. Remove wedgelock (1) using needle-nose pliers or a hook shaped wire to pull wedge straight out. 2.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly 1. Grasp contact (1) about 25mm behind contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool (1) over wire of contact to be removed. 2. Hold connector with rear grommet (2) facing you. 2. Push tool in the insert cavity (2) until it engages contact and resistance is felt. 1 2 1 Figure 7-22. HD/HDP Contact Installation 3.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001141989E - 1/5 Figure 7-29.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001141989E 3/5 Figure 7-30.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001141989E - 4 of 5 Figure 7-31. GM 3.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001141989E 5/5 Figure 7-33.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792780F 1/3 Figure 7-35.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792780F 2/3 Figure 7-37.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-38.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792780F 3/3 Figure 7-39.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-24 – JLG Lift – 3121290
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3121290 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65813058 JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG Latino Americana Ltda. Rua Eng.