Service Manual User Manual

ManualsBrandsJLG ManualsSpecial machinery450A_AJ Series II

Service and Maintenance Manual

Models

450A/AJ

Series II

Prior To

S/N 0300160835

P/N - 3121180

December 3, 2012

Summary of content (472 pages)

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Service and Maintenance Manual Models 450A/AJ Series II Prior To S/N 0300160835 P/N - 3121180 December 3, 2012
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. This section contains general safety precautions which must be observed during aerial platform maintenance. 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 machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised A-2 - January 24, 2003 - March 14, 2003 - August 26, 2005 - February 15, 2006 - March 14, 2007 - October 10, 2007 - December 22, 2010 - November 1, 2012 - December 3, 2012 – JLG Lift – 3121180
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 2.5 2.6 TITLE PAGE NO. Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Welding on JLG Equipment . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3121180 TITLE PAGE NO. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.18 3.19 3.20 3.21 3.22 3.23 3.24 iv TITLE PAGE NO. Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. DTC 123- TPS1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 217- ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 219- RPM Higher Than Max Allowed Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 5.3 5.4 5.5 TITLE PAGE NO. Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Variable Pump . . . . . . . . . . . . . . . . . . .
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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. 2-1. 2-2. 2-3. 2-4. 2-5. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 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. 3121180 TITLE PAGE NO. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 3-42. 3-43. 3-44. 3-45. 3-46. 3-47. 3-47. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 3-68. 3-69. 3-70. 3-71. 3-72. 3-73. 3-74. 3-75. 3-76. 3-77. 3-78. 3-79. 3-80. 3-81. 3-82. 3-83. 3-84. 3-85. 3-86. 3-87. 3-88. 3-89. 3-90. 3-91. 3-92. 3-93. 3-94. 3-95. 3-96. viii TITLE PAGE NO. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 3-97. 3-98. 3-99. 3-100. 3-101. 3-102. 3-103. 3-104. 3-105. 4-1. 4-2. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 3121180 TITLE PAGE NO. Faults Page with Active Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 5-43. 6-1. 6-2. 6-3. 6-4. 6-1. 6-1. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7-33. x TITLE PAGE NO. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 7-34. 7-35. 7-36. 7-37. 7-38. 7-39. 7-40. 7-41. 7-42. 7-43. 7-44. 7-45. 7-46. 7-47. 7-48. 7-49. 7-50. 7-50. 7-51. 7-52. 7-53. 7-54. 7-55. 7-56. 7-57. 7-58. 7-59. 7-60. 7-61. 3121180 TITLE PAGE NO. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 1-19 1-20 1-21 1-22 1-23 1-24 1-25 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 3-18 3-19 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 xii TITLE PAGE NO. Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Tires . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Table 1-4. Deutz F3M1011F Fuel Table 1-1. Capacities No. of Cylinders Fuel Tank 17 gallons (64.3 liters) Hydraulic Tank (machines to S/N 0300070586) 28 gallons (106 liters) Hydraulic Tank (S/N 0300070586 & SN 1300000001to Present) 27 gallons (102 liters) 23.6 gal. (89 liters) to the Full line on the sight gauge Drive Hub 23.75 oz. (0.7 liters) Drive Brake 2.7 oz. (0.08 liters) 1.2 TIRES Table 1-2.
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SECTION 1 - SPECIFICATIONS Table 1-6. Caterpillar 3024/C2.2 Fuel Diesel No. of Cylinders 4 BHP 46.5 hp (34 kW) Bore 1.4 SPECIFICATIONS AND PERFORMANCE DATA Reach Specifications 3.307 in. (84 mm) Stroke 3.9370 in. (112 mm) Displacement 134.3 cu. in. (2.2L) Oil Capacity 10 qt. (9.4 L) Compression Ratio 19:1 Firing Order 1-3-4-2 Max. RPM 2800 Max. Platform Height Max. Horizontal Reach Up & Over Height No. of Cylinders 4 BHP Gasoline LP 83 hp @ 3000 rpm 75 hp @ 3000 rpm Bore 4.0 in.
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SECTION 1 - SPECIFICATIONS 1.5 FUNCTION SPEEDS Platform Rotate: Platform level and completely rotated one direction. Rotate opposite direction, record time. Rotate other direction, record time. Table 1-12. Function Speeds (In Seconds) Function Main Lift Up 450A 450AJ 24-28 24-28 Articulating Jib: Platform level and centered with boom. Start with Jib down. Jib up, record time. Jib down, record time.
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SECTION 1 - SPECIFICATIONS Table 1-14. Engine Torque Requirements - Ford Table 1-15. Engine Torque Requirements - Deutz Torque Value ft. lb. Torque Value Nm Oil Drain Plug 15-25 20-34 Spark Plugs 7-15 9-20 Pump Coupling (dry) 26.5 37 Pump Coupling (Loctite 28.5 40 Description #242) Flywheel Torque Value ft. lb. Torque Value Nm Cylinder Head Cover 6 8.5 Cylinder Head Cover 6 8.5 Rocker Arm Adjustment Screw 15 21 Intake Manifold 6 8.5 15 21 28.
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SECTION 1 - SPECIFICATIONS 1.7 LUBRICATION Table 1-18. Mobil DTE 13M Specs Hydraulic Oil Table 1-16. Hydraulic Oil Hydraulic System Operating Temperature Range S.A.E. Viscosity Grade +0° to + 180° F (-18° to +83° C) 10W +0° to + 210° F (-18° to +99° C) +50° to + 210° F (+10° to +99° C ISO Viscosity Grade #32 Specific Gravity 0.877 Pour Point, Max -40°F (-40°C) Flash Point, Min. 330°F (166°C) Viscosity at 40° C 33cSt at 100° C 6.
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SECTION 1 - SPECIFICATIONS 1.9 PRESSURE SETTINGS - PSI (BAR) Table 1-21. Exxon Univis HVI 26 Specs Table 1-24. Pressure Settings Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point SETTING 217°F (103°C) Viscosity PSI BAR Bang-Bang Main Relief 3300 227.5 Steer 2500 172 at 40° C 25.8 cSt Platform Level Up 2800 193 at 100° C 9.
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SECTION 1 - SPECIFICATIONS 4 3 4 5 7,8 1 2A 6 3 4 2B 9,10,11,12,13,14,15 16,17,18,19,20,21 4 Figure 1-2. Operator Maintenance and Lubrication Diagram 1.11 OPERATOR MAINTENANCE 1. Swing Bearing - Internal Ball Bearing NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Diagram. Table 1-25. Lubrication Specifications KEY Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation. 2. A.
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SECTION 1 - SPECIFICATIONS 6. Hydraulic Charge Filter DO NOT OVERGREASE END BEARINGS OR HOUSING OUTER SEAL MAY BLOW AND CAUSE DAMAGE TO EQUIPMENT. 3. Wheel Bearings (2WD Only) Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation. 7. Hydraulic Tank 4. Wheel Drive Hub Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.
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SECTION 1 - SPECIFICATIONS 10. Oil Change w/Filter - Deutz 8. Suction Strainers Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts (4.7 L) Cooler Lube - EO Interval - Every Year or 1200 hours of operation. Comments - Check level daily/Change in accordance with engine manual. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 9. Oil Change w/Filter - Ford 11.
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SECTION 1 - SPECIFICATIONS 13. Oil Change w/Filter - Perkins 17. Fuel Filter - GM Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855) Capacity - 10 Quarts (9.4 L) Lube - EO Interval - Every Year or 600 hours of operation. Comments - Check level daily/Change in accordance with engine manual. 14. Fuel Filter - Ford Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation. 18.
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SECTION 1 - SPECIFICATIONS 21. Fuel Filter (Propane) - GM Engine 4. Push Emergency Stop when engine stops. Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Filter Replacement. 5. Disconnect electrical connection to LPG fuel temperature sensor in auxiliary fuel port of the EPR. 1.12 DRAINING PROPANE REGULATOR OIL BUILD UP (PRIOR TO S/N 0300137808) 6. Remove LPG fuel temperature sensor retainer clip and sensor from regulator body.
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SECTION 1 - SPECIFICATIONS 1.13 PROPANE FUEL FILTER REPLACEMENT 3. Pull filter housing from electric lock off assembly. 4. Remove filter from housing. Removal 5. Locate filter magnet and remove it. 1. Relieve propane fuel system pressure. Refer to 1.14 Propane Fuel System Pressure Relief. 6. Remove and discard housing seal. 2. Disconnect negative battery cable. Slowly loosen and remove filter housing. 8. Remove and discard mounting plate to lock off O-ring seal. 1 7.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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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) TITE TM 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] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 27 8 1.25 36.60 22.
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SECTION 1 - SPECIFICATIONS NOTES: 1-20 – JLG Lift – 3121259
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE Reference the JLG Pre-Delivery and Frequent Inspection Form, and Inspection and Preventative Maintenance Schedule for items requiring inspection. Reference appropriate areas of this manual for servicing and maintenance procedures. General This section provides information needed 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 Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring Complete steps in sequence when disassembling or reassembling a component. 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 SYSTEMS USING DTE 13 OIL SHOULD NOT BE OPERATED AT TEMPERATURES ABOVE 200 DEGREES F (94 DEGREES C) UNDER ANY CONDITION. Hydraulic System 1. Contamination is the primary enemy of a hydraulic system. Contaminants enter the system by using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc.
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SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Measure maximum acceptable cylinder drift using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift Measure platform to ground drift. Lower booms (if equipped) slightly elevated, upper boom fully extended with rated load in the platform and power off. Maximum allowable drift is 2" (5 cm) in 10 minutes. If machine does not pass this test, proceed with the following: Cylinder Drift 1.
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SECTION 2 - GENERAL 2.6 WELDING ON JLG EQUIPMENT NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from machine on an external structure, or component, DO the Following When Welding on JLG Equipment • Disconnect battery. • Disconnect moment pin connection (where fitted). • Ground only to structure being welded. DO NOT Do the Following When Welding on JLG Equipment • Ground on frame and weld on any other area than chassis.
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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 2 - GENERAL AMBIENT AIR TEMPERATURE 120°F(49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) SUMMER GRADE FUEL ENGINE SPECIFICATIONS 70°F(21°C) 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE SPECIFICATIONS 60 F(16 C) 50 F(10 C) 40 F(4 C) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120°F(49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) 70°F(21°C) ENGINE SPECIFICATIONS 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 20°F(-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE SPECIFICATIONS 60 F(16 C) 50 F(10 C) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120°F(49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) 70°F(21°C) ENGINE SPECIFICATIONS 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 20°F(-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & 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 a replacement tire be the same size, ply, and brand as originally installed on the machine. Please 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 Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE 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 (MACHINES BUILT BEFORE S/N 0300071527) Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure bolts are not tightened beyond their specified torque. Roll, Leak, and Brake Testing Always roll and leak test Torque-Hub units before disassembly and after assembly to make sure gears, bearings, and seals are working properly.
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SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Input Sun Gear (17) from Input Carrier SubAssembly (3A). 1. Perform Roll Check, Leak Check and Brake Check if applicable prior to disassembling unit. 7. Remove Input Carrier Sub-Assembly (3A) from Housing (1E). 2. Drain oil and note condition and volume. 8. Remove Output Sun Gear (8) from Output Carrier Sub-Assembly (4A). 3. Remove Input Coupling (9) from Spindle (1A) end of unit. 9.
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SECTION 3 - CHASSIS & TURNTABLE 7. Input Shaft 8. Output Sun Gear 17. Input Sun Gear Figure 3-2.
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SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly 1. Place Carrier (3A) on a press with spline end up. Drive Planet Shaft (3E) out of Carrier (3A). 2. Slide Planet Gear (3F) and two Thrust Washers (3B) out of Carrier (3A). 3. Remove 14 needle Bearings (3C) from bore of Planet Gear (3F). 4. Repeat steps 1 through 3 for remaining planet gears. 3A. 3B. 3C. 3E. 3F. Carrier Thrust Washers Needle Bearings Planet Shaft Planet Gear Figure 3-3.
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SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 3. Slide Planet Gear (4F) and two Thrust Washers (4B) out of Carrier (4A). 1. Using a small diameter punch, drive Roll Pin (4G) which holds Planet Shaft (4E) in Carrier (4A) into Planet Shaft (4E) until it bottoms. 4. Remove 15 needle Bearings (4C) from bore of Planet Gear (4F). 5. Repeat steps 1 through 4 for remaining planet gears. 6. Remove Thrust Washer (4H) from Carrier (4A).
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SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Disassembly 5. Remove “A” position Bearing Cone (1D) from Bearing Cup (1D) in Housing (1E). 1. Place unit on bench with Spindle (1A) end down. 6. Lift Housing (1E) off Spindle (1A). 7. If necessary, press Studs (1N) out of Housing (1E). Locate Housing (1E) on Seal (1B) end. EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN THIS PROCEDURE. 8. Remove “B” position Bearing Cone (1D) from Spindle (1A). 9. Remove Seal (1B) from Spindle (1A). 2.
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SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Disassembly NOTE: This procedure applies only to units with integral input brake (2). NOTE: For this procedure, use Brake Assembly Drawing, which shows proper balloon numbers for individual brake components. In the following instructions, if the number has a “-” between two numbers, it refers to Brake Assembly Drawing only and NOT Torque Hub Assembly Drawing. 1-A. 12. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6.
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SECTION 3 - CHASSIS & TURNTABLE Input Carrier Sub-Assembly SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. 1. Compress Springs (2-13) by installing a minimum of three M4 x 16mm Socket Head Cap Screws (2-11) equally spaced through End Plate (2-7) and into Piston (2-8). Tighten screws incrementally until spring force is removed from Retaining Ring (2-6). 2. Using a small pry bar or screwdriver, pry one end of Retaining Ring (2-6) out of groove in Spindle (1A).
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SECTION 3 - CHASSIS & TURNTABLE 3A. 3B. 3C. 3E. 3F. Carrier Thrust Washers Needle Bearings Planet Shaft Planet Gear Figure 3-7.
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SECTION 3 - CHASSIS & TURNTABLE Output Carrier Sub-Assembly UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. 1. Place Spring (4I) in deep counterbore of Output Carrier (4A). 2. Place Washer (4J) on top of Spring (4I). 3. Install Retaining Ring (4K) on snap ring pliers and place on top of Washer (4J). Compress Spring (4I) until Retaining Ring (4K) is seated completely in groove. 4. Apply a liberal coat of grease to bore of one Output Planet Gear (4F). 5.
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SECTION 3 - CHASSIS & TURNTABLE 4A. 4B. 4C. 4E. 4F. 4G. 4H. 4I. 4J. 4K. Output Carrier Thrust Washer Needle Rollers Planet Shaft Planet Gear Roll Pin Thrust Washer Spring Washer Retaining Ring Figure 3-8.
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SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Sub-Assembly 8. Grease large Backup Ring (2-3) and install in largediameter groove at bottom of Piston (2-8). UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. This procedure applies only to units with integral input brake (2). NOTE: For this procedure, use Brake Assembly Drawing, which shows proper balloon numbers for individual brake components.
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SECTION 3 - CHASSIS & TURNTABLE 1-A. 12. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. Spindle Pressure Plug Internal Circlip O-ring Back-up Ring O-ring Back-up Ring Internal Circlip 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. End Plate Piston Stator Spacer Capscrew Rotor Compression Spring Figure 3-8.
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SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Sub-Assembly NOTE: Spray a light film of oil on all component parts during assembly. UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. 1. Press Bearing Cup (1C), position A, into Housing (1E) using appropriate pressing tool (See back of manual). 9. Using retaining ring pliers, install Retaining Ring (1G) into Spindle (1A) groove. Make sure ring is completely seated in groove.
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SECTION 3 - CHASSIS & TURNTABLE 1B. 1C. 1D. 1E. Seal Bearing Cups Bearing Cone Housing 1F. 1G. 1H. Bearing Spacer Retaining Ring Wheel Stud Figure 3-9.
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SECTION 3 - CHASSIS & TURNTABLE Main Assembly 5. Place Input Carrier Sub-Assembly (3A) onto Output Sun Gear (8) splines. NOTE: All components should receive a generous amount of lubricant oil as they are being assembled. 6. Grease O-Ring (19) and insert into groove in Cover Sub-Assembly (6). 1. Place Housing-Spindle Sub-Assembly on table with Spindle (1A) side down. 7. Install Cover Sub-Assembly (6) onto Housing (1E) and install twelve Bolts (14) into Cover (6). Torque bolts to 70-80 in-lbs. 2.
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SECTION 3 - CHASSIS & TURNTABLE 6. 9. 10. 14. 19. Cover Input Coupling Thrust Spacer Cover Bolts O-ring Figure 3-11. Figure 3-11.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-12.
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SECTION 3 - CHASSIS & TURNTABLE 1A Spindle 4E Planet Shaft 1G Retaining Ring - Ext 4C Needle Bearing 12 Pressure Plug 4I Spring 16 O-ring Pipe Plug 4K Retaining Ring - Int 1F Thrust Washer 4G Roll Pin 1E Housing/Ring Gear 4B Thrust Washer 1N Stud 4H Thrust Washer 1C Tapered Bearing - Cup 4J Thrust Washer 1D Tapered Bearing - Cone 17 Sun Gear 1B Lip Seal 8 Sun Gear 3A Carrier 7 Input Shaft 3F Planet Gear 9 Coupling 3E Planet Shaft 6 Cover Subassembly 3C N
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-14.
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SECTION 3 - CHASSIS & TURNTABLE Spindle 4E Planet Shaft Input Brake 4C Needle Bearing Retaining Ring - Ext 4I Spring 12 Pressure Plug 4K Retaining Ring - Int 16 O-ring Pipe Plug 4G Roll Pin 1F Thrust Washer 4B Thrust Washer 1E Housing/ring Gear 4H Thrust Washer 1N Stud 4J Thrust Washer 1C Tapered Bearing - Cup 17 Sun Gear 1D Tapered Bearing - Cone 8 Sun Gear 1B Lip Seal 7 Input Shaft 3A Carrier 9 Coupling 3F Planet Gear 6 Cover Subassembly 3E Planet Shaft
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Figure 3-16.
PAGE 75
Figure 3-17.
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Figure 3-18.
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Figure 3-19.
PAGE 78
Figure 3-20.
PAGE 79
Figure 3-21.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 TORQUE HUB (MACHINES BUILT AFTER S/N 0300071527) 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. Roll and Leak Testing Always roll and leak test Torque-Hubs after assembly to make sure that the unit’s gears and sealants are working properly. The following information briefly outlines what to look for when performing these tests. 2.
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SECTION 3 - CHASSIS & TURNTABLE 7. Turn hub (1G) over and lift it out of flange-support. Remove bearing cup (1E) from counterbore in wide end of hub (1G). UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION. 12. Using retaining ring pliers, remove retaining ring (7B) from groove on input shaft (7A). 8. Turn hub (1G) over onto its small end. Remove two pipe plugs (1J) from side of hub (1G). NOTE: If your unit does not have studs, skip this step. 13.
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SECTION 3 - CHASSIS & TURNTABLE 7. Repeat steps 1-6 to remove and disassemble two remaining cluster gears. 8. At this point carrier disassembly is complete. 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). Assemble Carrier 1. Apply grease to inside of one cluster gear (3F) and line one half of cluster gear with 16 needle rollers (3C). 5.
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SECTION 3 - CHASSIS & TURNTABLE 7. Following cluster gear, place one more thrust washer (3B) onto planet shaft (3E) through opposite planet shaft hole in carrier housing (3A). 8. Use an alignment punch or similar tool to align roll pin holes in carrier housing (3A) and planet shaft (3E). 3121180 9. Drive roll pin (3G) into aligned roll pin holes in carrier housing (3A) and planet shaft (3E). 10. Repeat steps 1 thru 9 to assemble and install two remaining cluster gears. 11.
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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. 5. Place two cover cap bolts (6C) in any two bolt holes 180° apart on cover cap (6B) and tighten bolts. 6. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm) of torque to both bolts (6C). 3. Insert disconnect rod (6E) into cover cap (6B). 3-34 4. Set cover (6A) on table, exterior side up.
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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. 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). NOTE: Make sure cup sits square with counterbore before pressing. 4. Turn hub (1G) over to small end. Press bearing cup (1E) into counterbore in deep end of hub (1G). 8. Press bearing cone (1F) on spindle (1A) in hub (1G). 5.
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SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. Place spacer (1H) on spindle (1A) in hub (1G). 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: Make sure retaining ring is securely seated in groove. 10. Place retaining ring (1I) over spacer onto spindle (1A) in hub (1G). 2.
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SECTION 3 - CHASSIS & TURNTABLE 3. Place internal gear (2) in hub (1G) so its internal splines mesh with external splines of spindle (1A). Oil internal gear (2). 6. Place spring (7C) on smooth end of input shaft (7A). 7. Place other spacer (7D) on smooth end of input shaft (7A). 4. Place thrust washer (11) around spindle (1A) so it rests on bottom of internal gear (2). 5. Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A).
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SECTION 3 - CHASSIS & TURNTABLE 9. With large splined end down, place input shaft subassembly (7) into spindle (1A). 10. Place thrust spacer (9) onto input shaft (7). NOTE: This will hold punch marks in position while installing carrier into hub. 13. 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.
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SECTION 3 - CHASSIS & TURNTABLE 15. Oil all exposed surfaces inside hub (1G). Place thrust washer (11) into counterbore in top of carrier. 18. Place four flat washers (16) on top of bolt holes in cover sub-assembly. 19. Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten. SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALLING O-RING. 16. 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. Place 12 bolts in remaining bolt holes in cover (6) and tighten. 24. 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. 22. 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). 25. Leak test unit at a pressure of 5 psi (34.47 kPa) for 2 to 3 minutes. 23.
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SECTION 3 - CHASSIS & TURNTABLE Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E). 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. If this is done, tools must be ground on all surfaces labeled with a “G” on the tool diagram. 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.4 RE-ALIGNING TORQUE HUB INPUT COUPLING The following procedure applies to torque hubs with integral brakes: Equipment Required 1. Hydraulic power supply (hand pump) capable of producing 200 psi (13.8 bar). 2. Hydraulic fittings to adapt hydraulic supply to brake release port on hub. Procedure 1. Using appropriate fittings, connect a line from hydraulic power supply to brake port. 2. Pressurize brake release port to 155 - 200 psi (10.6 - 13.8 bar) to release brake. 3.
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SECTION 3 - CHASSIS & TURNTABLE Inspection 1. Wash all parts thoroughly in a suitable solvent. 2. Examine needle bearings (8) and (20) in housing (9) and back plate (22 or 27). If needles are free of excessive play and remain in bearing cage, there is no need to replace the bearing. 3. Inspect thrust washer (5) and thrust bearing (6). Surfaces should be free of any signs of wear or fretting. 4. Inspect spider (12) and pivot (13). Conical surfaces should be free of wear and score marks. 5.
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SECTION 3 - CHASSIS & TURNTABLE 1. Snap Ring 2. Shaft Seal 3. Washer 4. Snap Ring 5. Thrust Washer 6. Thrust Bearing 7. Drive Shaft 8. Needle Bearing 9. Housing Assembly 10. Thrust Race 11. Piston Assembly 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Spider Pivot Piston Block Pin Keeper Pin Washer Spring Snap Ring Needle Bearing O-ring Backplate Assembly 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 8. Lubricate thrust race (10) and install in housing assembly. 1. Use filtered system oil to lubricate all critical moving parts before assembly. 2. Install one snap ring (4) in rear groove of drive shaft (7 or 25). Install one thrust washer (5), thrust bearing (6), and second thrust washer (5) on drive shaft (7 or 25). Install second snap ring (4) in front groove on drive shaft. 3. Replace needle bearing (8) in housing (9) if necessary.
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SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE MOTOR Shaft Seal Replacement REMOVAL NOTE: This procedure covers: 1. Remove snap ring (1) and support washer (2). 2WD motors used on GM powered machines. 1 2WD motors used on Caterpillar, Deutz, and Ford powered machines S/N 0300100514 to Present. 2 All 4WD motors. 3 Description Drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston.
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SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT COMPONENTS REMOVAL 1. Use an 11/16" internal hex wrench to remove plug (1) and (2). Inspect new O-rings and sealing area for rust, wear, or contamination. Check springs and poppet for wear. 1. Install orifice poppet (13). 6 9 11 INSTALLATION 2. Install shift spool (12). 2 11/16 in 27 ft.lbs. (37 Nm) 3. Install spring retaining washers on springs (10 and 11). 4. Carefully install centering springs (7, 8, and 9). 5.
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SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil supply to motor. Fill reservoir to proper level and ensure oil supply to motor is Insufficient hydraulic fluid could lead to cavitation that would adequate and lines are unobstructed. cause system noise. Check for air in system. Air trapped in system lines or motor could result in cavitation Ensure system lines and components are purged of air.
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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 10 8 4 12 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 26 24 29 28 22. Screw 23. End Cap 24. O-ring 25. 26. 27. 28. 29. 30. Figure 3-29. End Cap 13. Using an 8 mm internal hex wrench, remove endcap screws (22). Figure 3-30. Valve Plate & Rear Shaft Bearing 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 18. Remove minimum angle stop (29) and servo spring (30) from housing. 20. Turn housing over and remove snap ring (32) retaining shaft seal, and support washer. Remove support washer (33) and carefully pry out shaft seal (34). Discard seal. NOTE: To avoid damaging shaft during seal removal. Install a large sheet metal screw into the chuck of a slide hammer. Drive screw into seal surface and use slide hammer to pull seal. 31 36 35 37 31.
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SECTION 3 - CHASSIS & TURNTABLE Lift here 44 39 45 47 40 48 43 42 49 41 46 53 52 39. 40. 41. 42. 43. Swashplate Servo Piston Piston Seal O-ring Journal Bearings 50 51 Figure 3-34. Swash Plate & Servo Piston 44. 45. 46. 47. 48. 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 RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE SPIRAL RETAINING RING. RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS REMOVED. 28. Turn block over. Using a press, apply pressure on block spring washer (50) to compress block spring enough to safely remove spiral retaining ring (51).
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SECTION 3 - CHASSIS & TURNTABLE SWASHPLATE AND JOURNAL BEARINGS BALL GUIDE AND SLIPPER RETAINER Inspect ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat. Do not reuse. Slipper retainer Inspect running face, servo ball-joint, and swashplate journal surfaces for damage or excessive wear.
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SECTION 3 - CHASSIS & TURNTABLE Assembly SHAFT Inspect motor shaft. Look for damage or excessive wear on output and block splines. Inspect bearing surfaces and sealing surface. Replace shafts with damaged or excessively worn splines, bearing surfaces, or sealing surfaces. SERVO PISTON AND MINIMUM ANGLE STOP Inspect minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace if necessary. 1. Install new O-ring (1) and piston seal (2) to servo piston (3).
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SECTION 3 - CHASSIS & TURNTABLE 3. Install inner block spring washer (4), block spring (5), and outer washer (6) in cylinder block. Using a press, compress block spring enough to expose retaining ring groove. Wind spiral retaining ring (7) into cylinder block. 6. Install journal bearings (13) into housing seats. Use assembly grease to keep bearings seated during assembly. Ensure locating nubs drop into cavities in seats. If reusing bearings, install them in original location and orientation.
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SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) on shaft. 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.
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SECTION 3 - CHASSIS & TURNTABLE 12. Press rear shaft bearing (22) into endcap. Install bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface. 22 2 mm [0.08 in] 23 15. Install endcap (25) on housing with endcap screws (26). Check endcap properly seats on housing without interference. Improper assembly of internal components may prevent endcap from seating properly. Ensure O-rings seat properly when installing endcap. 3 mm [0.
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SECTION 3 - CHASSIS & TURNTABLE 18. 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. Install seal support washer (28) and snap ring (29). 19. Install remaining plugs and fittings to housing. Refer to drawing below for wrench sizes and installation torques. 5/16 in 63 ft.lbs. (85 Nm) 1/4 in 33 ft.lbs. (45 Nm) 29 28 27 9/16 in 125 ft.lbs. (170 Nm) 27.
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SECTION 3 - CHASSIS & TURNTABLE Initial Start-up Procedures 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). 25. Using a 5/8" wrench, torque plug (40) to 20 ft-lb (27 Nm). 26. Using a 11/16" wrench, torque plugs (41 and 42) to 27 ft-lb (37 Nm). Follow this procedure when starting up a new motor or after reinstalling a motor.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Chassis Torque Values This figure applies to USA built machines prior to S/N 0300107512 and Belgium built machines prior to S/N 1300003222 Ft-Lb Nm A 120 163 B 240 325 C 170 230 D 140 190 E 165 224 F 35 47 Figure 3-47.
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SECTION 3 - CHASSIS & TURNTABLE D E A B C Table 3-10. Chassis Torque Values Ft-Lbs. Nm A 120 163 B 240 325 C 170 230 D 85 115 E 165 224 This figure applies to USA built machines S/N 0300107512 to Present and Belgium built machines S/N 1300003222 to Present Figure 3-47.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE 1. Make sure machine is on a level surface. 2. Center boom over rear axle to make sure cam valve in the rotary coupling is depressed. 11. With turntable centered, adjust bracket with washers to push plunger in 5/16" ± 1/16" (7.9 ± 1.6 mm). 3. Place chocks under tires to ensure machine does not move. Disable machine brakes by disconnecting brake solenoid(s) on brake valve. 4.
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SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction before any further operation. 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.
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SECTION 3 - CHASSIS & TURNTABLE 6 7 2 TO REMOTE Motor Hydraulic Lines Not Shown 4 Inner Race 1 Outer Race 5 9 8 3 Figure 3-48.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly 5. Lift directly up and remove pinon and gear assembly (10, 16, 17, 34, 18 - 22) from housing (4). Refer to Figure 3-49., Swing Bearing Drive. 6. Disassemble pinion and gear assembly using a press. Support worm gear (20) on press wIth pinion (10) facing down, allowing room for pinion to be pressed out of gear. Press pinon out of bearing (22), spacer (21), and worm gear (20). 1. Clean area around swing motor (1) to prevent any dirt from entering system. 2.
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SECTION 3 - CHASSIS & TURNTABLE 33 1 34 35,36 2 4 3 5 6 29 30, 32 27 26 25 22, 33 21 7 20 28 19 18 15 9 8 10 16 17, 34 14 13 12 11 Figure 3-49.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 14. Place gear cap assembly over pinion assembly and install shims set aside in step 6. Refer to Figure 3-49., Swing Bearing Drive. 1. Press bearing cup (17) in cap (12). 15. Install eight 3/8" 12 point screws (11) and torque to 60 ft-lb (81 Nm). 2. Place bearing cup (33) in housing (4). 16. Install 2 small screws (8). 3. Put face seal (18) and O-ring (19) on hub of worm gear (20). 17. Install seal (28) in worm cap (26) at hex end of worm. 4.
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SECTION 3 - CHASSIS & TURNTABLE IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED TO TIGHTEN BEARING ATTACHMENT BOLTS, CHECK TORQUE SETTING ACCURACY OF TOOL BEFORE USE. 7. Tighten bolts to an initial torque of 130 ft-lb (176 Nm) following torque sequence shown in Figure 3-50., Swing Bearing Torque Sequence. Tighten to a final torque of 190 ft-lb (257 Nm) following same sequence. 3 17 7 Check Frame To Bearing Bolts 9 7 11 3 1.
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SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance Check Turntable To Bearing Bolts 1. Fully retract boom and elevate to 70 degrees (full elevation).Try and insert a 0.0015" feeler gauge between bolt head and hardened washer at positions shown in Figure 3-52., Swing Bearing Feeler Gauge Check. TURNTABLE REF. SWING BEARING MEASURING POINT FRAME REF. Figure 3-53. Swing Bearing Tolerance Measuring Point 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.10 SWING MOTOR • Before you disassemble motor or any of its components read this entire section. It provides important information on parts and procedures to service 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.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Swing Motor Troubleshooting Trouble Oil Leakage Significant loss of speed under load Cause 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.
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SECTION 3 - CHASSIS & TURNTABLE Removal Refer to Figure 3-55., Swing Motor Removal and Installation. 1. Thoroughly clean area around swing motor to prevent dirt from entering system. 2. Tag and disconnect hydraulic lines to swing motor. Cap or plug all openings. 3. Secure worm gear shaft so it does not pull out any when removing swing motor. Failure to do so could damage worm gear seals. • Remove motor, drain fluids, and take it to a clean work surface. • Clean and dry motor before disassembly.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly and Inspection Refer to Figure 3-56., 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.
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SECTION 3 - CHASSIS & TURNTABLE 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. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set. 6.
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SECTION 3 - CHASSIS & TURNTABLE 2. Remove rotor set (8) and wearplate (9), together to retain rotor set in its assembled form, maintaining same rotor vane to stator contact surfaces. Drive link (10) may come away from coupling shaft (12) with rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work drive link out of rotor and wearplate. Inspect rotor set in its assembled form 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 2. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 5. 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. If housing is defective in these areas, discard housing assembly. 3.
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SECTION 3 - CHASSIS & TURNTABLE 7. 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. 3-80 – JLG Lift – 8.
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SECTION 3 - CHASSIS & TURNTABLE 20 18 8 25 16 8C 8E 15 14 19 14 8B 13 4 8A 8D 17 12 4 10 9 4 8 4 7 5 4 3 6 4 2 1 1. 2. 3. 4. 5. Bolt End Cover Seal Ring Seal Ring Commutator 6. Commutator Ring 7. Manifold 8. Rotor Set 8A. Rotor 8B. Stator Half 8C. Stator Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 11. Thrust Bearing 12. 13. 14. 15. 16. Coupling Shaft Inner Bushing Thrust Washer Thrust Bearing Seal 17. 18. 19. 20. 21.
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SECTION 3 - CHASSIS & TURNTABLE Assembly Refer to Figure 3-56., 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).
PAGE 133
SECTION 3 - CHASSIS & TURNTABLE 6. Install thrust washer (14) and thrust bearing (15). 3. 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. 4. Place housing (18) assembly into a soft jawed vise with coupling shaft bore down, clamping against mounting flange. NOTE: Motor requires one thrust washer (14) with thrust bearing (15). Coupling shaft is seated 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). O U T E R B E A R I NG ( 1 9 ) I S N O T L U B R I C A T E D B Y S Y S T E M HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH RECOMMENDED GREASE. NOTE: Coupling shaft (12) will be flush or just below housing wear surface when properly seated with coupling shaft (12).
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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. 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. 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. 3-86 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.
PAGE 138
SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Assembly 4. Assemble six vanes, or as many vanes that readily assemble in stator vane pockets. A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled using the following procedures: 1. 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 139
SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Assembly 9. Grasp output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link, and rotor to seat rotor and assembled vanes into stator, creating necessary clearance to assemble seventh or full complement of seven vanes. Assemble seven vanes using minimum force.
PAGE 140
SECTION 3 - CHASSIS & TURNTABLE 3.11 SEMI-TRACK Normal Wear The semi-track option is available in soft or hard tracks and provides increased traction in rough terrain. Testing With both sides installed, drive machine slowly in both directions to check track does not catch or hit any part of machine. Test machine until it can be driven at top speed and on side slopes without tracks hitting.
PAGE 141
SECTION 3 - CHASSIS & TURNTABLE Figure 3-57.
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SECTION 3 - CHASSIS & TURNTABLE D C B C E A Figure 3-58.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Motor Adapter Setscrew Mounting Gasket Coupling Shaft Seal Stator Cap Assembly Spring Ball 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Seat Needle Bearing Washer Screw Retaining Ring Gear Idler Shaft Drive Pin Dowel Pin Gasket 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. O-ring Gear Housing I.D. Label Gasket Gear Housing Beta Plug Screw Drive Shaft Plastic Plug Plastic Plug A. Torque 96 to 120 inch-pounds (11 to 13.5 Nm) B.
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SECTION 3 - CHASSIS & TURNTABLE 3.12 GENERATOR Overload Protection Every 250 hours Check drive belt for proper 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. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-60.
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SECTION 3 - CHASSIS & TURNTABLE 3.13 FORD EFI ENGINE • Inspect ECM grounds for cleanliness, tightness, and proper location. Performing Diagnostics • Inspect fuel system for adequate fuel level, and fuel quality (concerns such as proper octane, contamination, winter/summer blend). 1. Verify complaint and determine if it is a deviation from normal operation. 2. Once complaint is verified, preliminary checks can be done.
PAGE 147
SECTION 3 - CHASSIS & TURNTABLE Table 3-13.
PAGE 148
SECTION 3 - CHASSIS & TURNTABLE ENGINE COOLANT TEMPERATURE (ECT) SENSOR HEATED OXYGEN SENSOR The Engine Coolant Temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5-volt signal to the ECT sensor through resistors in the ECM and measures the voltage.
PAGE 149
Figure 3-61.
PAGE 150
SECTION 3 - CHASSIS & TURNTABLE Intake Air Temperature (IAT) Sensor Engine Control Module (ECM) The intake air temperature (IAT) sensor is a thermistor which changes resistance based on temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5volt signal to the sensor and monitors signal voltage.
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SECTION 3 - CHASSIS & TURNTABLE ECM Inputs/Outputs Throttle Position (TP) Sensor Inputs—Operating Conditions The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body, which is built into the electronic governor. The ECM monitors signal line voltage and calculates throttle position. The TP sensor signal changes as the throttle valve angle is changed, At a closed throttle position, TP sensor output is low.
PAGE 152
SECTION 3 - CHASSIS & TURNTABLE 3.14 CIRCUIT TESTING TOOLS Fuel System FUEL INJECTOR DO NOT USE A TEST LIGHT TO DIAGNOSE ENGINE ELECTRICAL SYSTEMS UNLESS SPECIFICALLY INSTRUCTED. A TEST LIGHT CAN PUT AN EXCESSIVE LOAD ON AN ECM CIRCUIT AND CAUSE COMPONENT DAMAGE. ONLY USE A DIGITAL VOLTMETER WITH AN INPUT IMPEDANCE OF AT LEAST 10 MEGOHMS FOR VOLTAGE MEASUREMENTS. Electrostatic Discharge Damage Electronic components used in the ECM are often designed to carry very low voltage.
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SECTION 3 - CHASSIS & TURNTABLE HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-62.
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SECTION 3 - CHASSIS & TURNTABLE FUEL METERING SYSTEM PURPOSE FUEL PUMP ELECTRICAL CIRCUIT The basic function of the air/fuel metering system is to control air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve. When key is first turned “ON,” the ECM energizes the fuel pump relay for two seconds to build up fuel pressure quickly.
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SECTION 3 - CHASSIS & TURNTABLE ELECTRONIC GOVERNOR AND THROTTLE BODY OPEN LOOP AND CLOSED LOOP OPERATION In the 2.5L EFI industrial engine, throttle control is achieved by using an electronic governor controlled by the engine control module (ECM). The ECM operates in the following two modes: • Open loop • Closed loop When the engine is first started, the system is in “open loop” operation. In open loop, the ECM ignores the heated oxygen sensor (HO2S) signal.
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SECTION 3 - CHASSIS & TURNTABLE 3.15 DEUTZ ENGINE CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor provides a signal used by the Engine Control Module (ECM) to calculate the ignition sequence. The sensor initiates reference pulses which the ECM uses to calculate RPM and crank-shaft position. NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions. Checking Oil Level 1.
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SECTION 3 - CHASSIS & TURNTABLE Changing Oil Filter Replacing Fuel Filter 1. Wipe area around filter to clean any dirt from area. 2. Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off. MAKE SURE THERE ARE NO OPEN FLAMES OR SPARKS IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM. 1. Wipe area around filter to clean any dirt from area. 2. Undo fuel filter cartridge and spin off. 3. Catch any escaping fuel. 4.
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SECTION 3 - CHASSIS & TURNTABLE 3.16 DEUTZ EMR 2 (S/N 85332 TO PRESENT) 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. Engine sensors provide control unit electronics with information of the current condition of engine and preconditions (throttle position etc.).
PAGE 159
Figure 3-65.
PAGE 160
Figure 3-66.
PAGE 161
Figure 3-67.
PAGE 162
Figure 3-68.
PAGE 163
SECTION 3 - CHASSIS & TURNTABLE Figure 3-69.
PAGE 164
SECTION 3 - CHASSIS & TURNTABLE Figure 3-70.
PAGE 165
Figure 3-71.
PAGE 166
Figure 3-72.
PAGE 167
Figure 3-73.
PAGE 168
Figure 3-74.
PAGE 169
Figure 3-75.
PAGE 170
SECTION 3 - CHASSIS & TURNTABLE 3.17 GM ENGINE GENERAL MAINTENANCE • Check ground and platform control stations to ensure all warning indicator lights are functioning. Drive Belt Maintenance Checking/Filling Engine Oil Level 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.
PAGE 171
SECTION 3 - CHASSIS & TURNTABLE Changing Engine Oil 1. Loosen worm gear clamp on coolant line running into EPR as shown below and remove hose from EPR. Place a rag under hose to prevent coolant from running onto engine/machine. ALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE OIL WHEN ENGINE IS WARM FROM OPERATION AS OILS WILL FLOW FREELY AND CARRY AWAY MORE IMPURITIES. To change oil: 1. Start engine and run until it reaches normal operating temperature. 2. Stop engine. 3.
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SECTION 3 - CHASSIS & TURNTABLE 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.
PAGE 173
SECTION 3 - CHASSIS & TURNTABLE EPR Assembly Low Pressure Regulator (LPR) The EPR assembly is a combination Low Pressure Regulator and a Voice Coil Assembly. The Voice coil is an electronic actuator controlled by an internal microprocessor. The microprocessor provides output data to the ECM and receives input data over a CAN BUS connection. The internal microprocessor receives electrical signals from the Fuel Pressure Sensor FPS and the Fuel Temperature Pressure FTP and communicates the data to the ECM.
PAGE 174
SECTION 3 - CHASSIS & TURNTABLE Air Fuel Mixer Electronic Throttle Control (ETC) The air valve mixer is an air-fuel metering device and is completely self-contained. The mixer is an air valve design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load. The mixer is mounted in the air stream ahead of the throttle control device. When the engine begins to crank, it draws in air with the air valve covering the inlet, negative pressure begins to build.
PAGE 175
SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Heated Exhaust Gas Oxygen Sensor To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control Unit (ECM). The ECM is a 32 bit controller which receives input data from sensors fitted to the engine and fuel system and then outputs various signals to control engine operation.
PAGE 176
SECTION 3 - CHASSIS & TURNTABLE Gasoline Fuel Pump Fuel Filter The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by an electric fuel pump. The fuel pump receives a signal from the ECM to prime the fuel system for approximately 2 seconds prior to start. Priming the fuel system provides for a quicker start when the engine begins to crank.
PAGE 177
SECTION 3 - CHASSIS & TURNTABLE Propane Fuel System Leak Test 6. Locate filter magnet (4) and remove it. 7. Remove and discard housing seal (3). 8. If equipped, remove and discard retaining bolt seal. 9. Remove and discard mounting plate to lock off O-ring (9). PROPANE IS EXTREMELY FLAMMABLE. NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PROPANE FUEL SYSTEM LEAKS. Installation Always inspect propane fuel system for leaks after performing service.
PAGE 178
SECTION 3 - CHASSIS & TURNTABLE Electronic Pressure Regulator (EPR) Assembly Replacement INSTALLATION The EPR assembly consists of two separate components. The Voice Coil Section is not serviceable and can only be replaced as an assembly. The pressure regulator section is serviceable and is detailed in this section. DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQUID PIPE THREAD SEALANT WHEN INSTALLING FITTINGS. CHECK ALL O-RINGS ON VAPOR AND WATER FITTINGS FOR ANY DAMAGE. REPLACE IF NECESSARY.
PAGE 179
SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control Replacement PRESSURE REGULATOR SECTION REMOVAL 1. Remove EPR. Refer to EPR Removal Procedure. See Figure 3-89. 2. Remove six (6) regulator to voice coil screws using the special tool. Separate regulator from actuator. REMOVAL 1. Disconnect negative battery cable. 2. Remove air intake duct. DO NOT REMOVE SECONDARY DIAPHRAGM RETAINING PLATE AND DIAPHRAGM OR ACTUATOR SECTION WARRANTY WILL BE VOID. 3.
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SECTION 3 - CHASSIS & TURNTABLE 2. Install two quad seals one seal at a time so seal does not roll. Seal must sit flat on throttle body. MIXER REPLACEMENT See Figure 3-90. REMOVAL 1. Remove Throttle control device. Refer to Electronic Throttle Body Replacement. 2. Remove four (4) throttle control device to mixer adapter bolts. 3. Remove discard mixer to adapter gasket. INSTALLATION COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY. 1.
PAGE 181
SECTION 3 - CHASSIS & TURNTABLE Vapor Hose Replacement Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL 1. Disconnect hose clamps using hose clamp pliers. REMOVAL 2. Remove the vapor hose from each fitting. 1. Disconnect negative battery cable. INSTALLATION 2. Disconnect the O2 sensor electrical connector. 3. Using an O2 Sensor socket, remove the O2 Sensor and discard. THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS.
PAGE 182
SECTION 3 - CHASSIS & TURNTABLE 3.20 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is for diagnosing a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify vehicle has sufficient quantity of fuel and liquid fuel is being delivered to the LPR. Ensure LPG tank manual shut off valve is fully opened and excess flow valve has not been activated.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-14. 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? -- Gotothe 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 3-14. LPF Fuel System Diagnosis STEP 15 ACTION 1. Turn ignition OFF. 2. Close LPG tank manual shut-off valve. VALUE(S) YES NO -- 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. Was fuel present when fitting was loosened? 16 1. Turn OFF ignition. 2. Connect test light to chassis ground and probe pin A of LPL connector. 3.
PAGE 185
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 186
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 187
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Exhaust System Checks Action 1. Check exhaust system for a possible restriction: - Inspect exhaust system for damaged or collapsed pipes - Inspect muffler for signs of heat distress or internal failure. 2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis Hard Start DEFINITION: Engine cranks OK, but does not start for a long time. Engine does eventually run or may start, but immediately dies.
PAGE 188
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Exhaust System Checks Action 1. Check exhaust system for a restriction: - Inspect exhaust system for damaged or collapsed pipes. - Inspect muffler for signs of heat distress or internal failure. 2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in GM Base Engine Service Manual.
PAGE 189
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 190
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 191
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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.
PAGE 192
SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 193
SECTION 3 - CHASSIS & TURNTABLE Table 3-16.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-16.
PAGE 195
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 Oil Drain Valve Muffler Piston Pump 11. 12. 13. 14. 15. Gear Pump Motor Mount Start/Aux Power Relays Engine Tray Pivot Auxiliary Pump Figure 3-92. GM 3.
PAGE 196
SECTION 3 - CHASSIS & TURNTABLE 16. 17. 18. 19. 20. O2 Sensor Dipstick Control Module Starter Distributor 21. 22. 23. 24. 25. Oil Filter Water Pump Coolant Sensor Pressure Regulator MAP Sensor 26. 27. 28. 29. 30. Mixer PCV Valve Oil Pressure Switch Coil Fuel Filter Figure 3-93. GM 3.
PAGE 197
SECTION 3 - CHASSIS & TURNTABLE 3.21 PERKINS ENGINE GENERAL MAINTENANCE Engine Oil Level - Check Replacing the Engine Crankcase Breather HOT OIL AND COMPONENTS CAN CAUSE SEVERE BURNS. DO NOT ALLOW HOT OIL OR COMPONENTS TO CONTACT SKIN. KEEP PARTS CLEAN FROM CONTAMINANTS. CONTAMINANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENT LIFE. NOTE: Perform this maintenance with engine stopped. 1.Maintain oil level between “ADD” mark (Y) and “FULL” mark (X) on oil level gauge (1).
PAGE 198
SECTION 3 - CHASSIS & TURNTABLE 1 * 2 3 8 7 6 5 ** 4 * Torque to 10 ft-lb (13.5 Nm) ** Torque to 21 ft-lb (28.5 Nm) 1. 2. 3. 4. Dipstick Crankcase Breather Coolant Sensor Oil Pressure Sensor 5. 6. 7. 8. Oil Drain Valve Oil Filter Speed Sensor Fuel Filter Figure 3-95.
PAGE 199
SECTION 3 - CHASSIS & TURNTABLE NOTE: Do not drain oil when engine is cold. As oil cools, suspended waste particles settle on bottom of oil pan and not removed with oil. Drain crankcase with engine stopped. Drain crankcase with oil warm. This draining method allows waste particles suspended in oil to be drained correctly. Failure to follow this procedure will allow waste particles to recirculate through engine lubrication system with new oil.
PAGE 200
SECTION 3 - CHASSIS & TURNTABLE Setting Actuator NOTE: During this procedure it’s very important to keep control linkage pushed against stop. 1. Remove bolt from control linkage 3. Once adjustments are made to align spherical rod end bearing with control linkage bolt hole, lengthen actuator linkage by continuing to turn spherical rod end and threaded rod 2-2½ turns (1-1¼ turns of spherical rod end and 1-1¼ turns of threaded rod.) This will provide 1/8" (3 mm) preload. 2.
PAGE 201
SECTION 3 - CHASSIS & TURNTABLE Speed Sensor Installation 1. Remove radiator and reservoir caps. NOTE: A new speed sensor comes with two hex nuts. 1. Remove one hex nut from speed sensor and discard it. 2. Install speed sensor in housing until it contacts flywheel. 2. Fill radiator to top. Allow coolant to settle and add coolant as necessary to top off radiator. 3. Reinstall radiator cap. 3. Back off sensor 1/4 to 3/4 turn. Ensure sensor flats are vertical and tighten nut. 4.
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SECTION 3 - CHASSIS & TURNTABLE 6. Remove fill cap and fill coolant recovery reservoir to cold level line. Put fill cap back on reservoir when done. 7. Start engine and run it long enough to bring coolant to operating temperature. Turn off engine. REMOVING RADIATOR CAP WITH COOLANT HOT AND UNDER PRESSURE CAN CAUSE SEVERE INJURIES. ALLOW ENGINE AND COOLING SYSTEM TO COOL BEFORE REMOVING RADIATOR CAP. 8. Make sure coolant reaches hot level line on coolant recovery reservoir. Add coolant as needed.
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SECTION 3 - CHASSIS & TURNTABLE 3.23 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 CCP CHT CL CNG DBW DGC DM DMM DST DTC DVOM ECI ECIPP ECM ECT ECU EDIS EGO EMWT EPR ERWT ETB ETC FDR FMI FO FP FPP FRP FRT FSS FT GCP HDGCP HEGO HO2S IAC IAT ICAV IVS LDGCP 3-154 Adaptive Learn Barometric Pressure Controller Area Network 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 S
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SECTION 3 - CHASSIS & TURNTABLE Fault Code Broadcast • Byte 7: Manifold Absolute Pressure 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 multifunction display units. Diagnostic Trouble Codes Numeric diagnostic trouble codes assigned to faults in this manual are cross-referenced to SAE.
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SECTION 3 - CHASSIS & TURNTABLE Diagnostic Calibration Configuration and Corrective Actions Table 2 identifies configuration options and corrective actions available for configuration of each fault. Each fault within the DGC is capable of being uniquely configured in the engines diagnostic calibration to cause one or more corrective actions while a given fault is active. The desired action is set by OEM calibration engineers. Table 3-18.
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SECTION 3 - CHASSIS & TURNTABLE Fault/Diagnostic Trouble Code Interaction All fault and diagnostic information is managed through the Faults page. Interaction includes viewing fault messages, downloading fault data (fault snapshot and flight data recorder), erasing faults from memory, and defining variables for fault data logging. Faults are separated into two categories, Active and Historic.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-98. 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 3-99. 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 3-100.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-100. Historic Fault Information Interface Table 3-19. 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 3-101. Snapshot Data Interface Figure 3-102.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-103. Clear Faults Prompt 3.24 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 3-164 – JLG Lift – 3121180
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3-166 – JLG Lift – 3121180
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SECTION 3 - CHASSIS & TURNTABLE DTC 122- TPS1 Signal Voltage Low DBW+ 1 + Motor H-Bridge 2 - 1 W B D + tr o -M 1 S P T d ri -B H e g _ V 5 6 1 e t x 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 lte ria o d e F itn s o P b k c a TPS1 + 2 W B D 2 1 E S P T ta le iS m rx 16 C 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 1.
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SECTION 3 - CHASSIS & TURNTABLE 3-168 – JLG Lift – 3121180
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SECTION 3 - CHASSIS & TURNTABLE DTC 123- TPS1 Signal Voltage High + 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 e xt D 5 + = s V R C 2 1 a lS ri e 3 1 E S P T te i m rx M C E R - rtn _ V 5 9 1 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 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
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SECTION 3 - CHASSIS & TURNTABLE 3-170 – JLG Lift – 3121180
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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.
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SECTION 3 - CHASSIS & TURNTABLE DTC 219- RPM Higher Than Max Allowed Governed Speed + 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 lS ria e 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 o i 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 G
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SECTION 3 - CHASSIS & TURNTABLE DTC 336- Crank Signal Input Noise • Crankshaft Position sensor. • Check Condition- Key On, Engine On. • Fault Condition- Electrical noise or irregular crank pattern detected causing x number of crank resynchronization events as defined in diagnostic calibration. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp and disable adaptive fueling correction for remainder of key-cycle.
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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
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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.
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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.
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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.
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SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3-178 – JLG Lift – 3121180
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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.
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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
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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
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SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3-182 – JLG Lift – 3121180
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SECTION 3 - CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low • System voltage to ECM. • Check Condition- Key on, Engine on. • Fault Condition- Battery voltage to ECM less than x volts while the engine is operating at y RPM or greater as defined in the diagnostic calibration. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle.
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SECTION 3 - CHASSIS & TURNTABLE 3-184 – JLG Lift – 3121180
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SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High • System voltage to ECM. • Check Condition-Key on, Engine Cranking or Running. • Fault Condition- Battery voltage to ECM greater than x volts while the engine is running as defined in the diagnostic calibration. • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle.
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SECTION 3 - CHASSIS & TURNTABLE 3-186 – JLG Lift – 3121180
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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.
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SECTION 3 - CHASSIS & TURNTABLE 3-188 – JLG Lift – 3121180
PAGE 239
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 240
SECTION 3 - CHASSIS & TURNTABLE 3-190 – JLG Lift – 3121180
PAGE 241
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.
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SECTION 3 - CHASSIS & TURNTABLE 3-192 – JLG Lift – 3121180
PAGE 243
SECTION 3 - CHASSIS & TURNTABLE DTC 642- 5 Volt External Low Voltage + 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 2 1 E S P T ta le iS m rx te x R D 5 + = s V 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 e o lt ria d e F itn s o P b k c a 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 Diagnostic Aids • Engine Co
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SECTION 3 - CHASSIS & TURNTABLE DTC 643- 5 Volt External High Voltage + 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 2 1 + R E S P T lte iS m rx a C D 5 + = s V 3 -1 R E S P T 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 o i M C E 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 Co
PAGE 245
SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 • Engine Control Module. • Check Condition- Key on. • Fault Condition- Internal microprocessor error. • MIL- On until code is cleared by technician. • Adaptive- Disabled for the remainder of the key-on cycle. • Closed Loop- Enabled. • Power Derate (level 2 until fault is cleared manually). The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 246
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 3-196 – JLG Lift – 3121180
PAGE 247
SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121180 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 248
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 3-198 – JLG Lift – 3121180
PAGE 249
SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D • Engine Control Module. • Check Condition- Key on. • Fault Condition- Internal microprocessor error. • MIL- On until code is cleared by technician. • Adaptive- Disabled for the remainder of the key-on cycle. • Closed Loop- Enabled. • Power Derate (level 2 until fault is cleared manually). 3121180 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 250
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 3-200 – JLG Lift – 3121180
PAGE 251
SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure interrupt • Engine Control Module • Check Condition- Key on • Fault Condition- Internal microprocessor error • MIL- On until code is cleared by technician • Adaptive- Disabled for the remainder of the key-on cycle • Closed Loop- Enabled • Power Derate (level 2 until fault is cleared manually) 3121180 The ECM has checks that must be satisfied each time an instruction is executed.
PAGE 252
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 3-202 – JLG Lift – 3121180
PAGE 253
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 254
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).
PAGE 255
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).
PAGE 256
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 257
SECTION 3 - CHASSIS & TURNTABLE 3121180 – JLG Lift – 3-207
PAGE 258
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.
PAGE 259
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 d ri -B H e g _ V 5 6 1 2 1 E S P T ta le iS m rx te x R D 5 + = s V 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 e o lt ria d e F itn s o P b k c a 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 • Throttle Actuator (with s
PAGE 260
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 t x e _ V 5 6 1 2 1 + R E S P T lte iS m rx a C D 5 + = s V 3 -1 R E S P T 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 o i M C E 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 • C
PAGE 261
SECTION 3 - CHASSIS & TURNTABLE 3121180 – JLG Lift – 3-211
PAGE 262
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 263
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 d ri -B H e g _ V 5 6 1 E S P T a lS ri e te x R D 5 + = s V C 2 1 3 1 E S P T te i m rx M C E R - rtn _ V 5 9 1 h iT n le E /S rw o a tu c A e o lt ria 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 Diagno
PAGE 264
SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT INDEX 3-214 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 265
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 3-104.
PAGE 266
SECTION 3 - CHASSIS & TURNTABLE B,C B,C A B,C A B,C B,C A. Part Number\Actual Weight Stamping B. Apply Loctite #271 to Bolt Threads and to Threads in Counterweight. C. Torque to 400 ft-lb (542 Nm). Typical Four Places. Figure 3-105.
PAGE 267
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE 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. CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING LINES TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEM. b. Tag and disconnect hydraulic lines from boom to control valve. Use a suitable container to retain any residual hydraulic fluid. Cap all hydraulic lines and ports.
PAGE 268
SECTION 4 - BOOM & PLATFORM Disassembly of Main Boom 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 269
SECTION 4 - BOOM & PLATFORM Assembly of Main Boom Installation of 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 into power track. 2. Install boom pivot pin, ensuring location of hole in pivot pin aligns with attach point on upright. 3.
PAGE 270
SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. 7. 8. 9. Upper Boom Tower Link Upper Upright Upper Lift Cylinder Upper Tower Boom Tower Link Boom Lower Lift Cylinder Lower Upright Figure 4-2.
PAGE 271
SECTION 4 - BOOM & PLATFORM Figure 4-2.
PAGE 272
SECTION 4 - BOOM & PLATFORM Figure 4-3.
PAGE 273
SECTION 4 - BOOM & PLATFORM Figure 4-4.
PAGE 274
SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR Assembly and Testing Theory of Operation See Figure 4-6., Rotator Assembly - Cutaway Fluid entering Port P2 under pressure will bear on the piston (4) and force piston sleeve (3) upwards. The lefthanded spline of piston sleeve (3) will combine with righthanded spline of shaft (2A) and cause rapid counterclockwise rotation of shaft and flange (2B) (looking down). Fluid entering Port P1 will reverse rotation.
PAGE 275
SECTION 4 - BOOM & PLATFORM 1. Housing & Ring Gear 2A. Shaft 2B. Flange 2C. Bearing Tube 3. Piston Sleeve 4. Piston 5. End Cap 6. Locknut 7. Capscrew 9. Piston Seal 11. Piston Seal 14. O-ring 15. O-ring 16. Exclusion Seals 17. Piston Bearing 18. Radial Bearing 19. Radial Bearing 20. Thrust Bearing 21. O-ring 22. O-ring P1 Pressure Port P2 Pressure Port Figure 4-6.
PAGE 276
SECTION 4 - BOOM & PLATFORM If actuator is not equipped with grease fittings, coat thrust bearings (20) with grease before sliding on shaft and end cap. NOTE: End caps on 60K and larger actuators may need to be installed with actuator in a vertical position. Shaft is installed by again aligning punched timing marks. Temporarily taping threaded portion of shaft will help installation past shaft seals (masking tape works well).
PAGE 277
SECTION 4 - BOOM & PLATFORM 4.3 ROTARY ACTUATOR (S/N 0300130812 AND 1300006433 TO PRESENT) Theory of Operation Required Tools Basic tools required for assembly and disassembly of the actuator and their intended functions are as follows: The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation.
PAGE 278
SECTION 4 - BOOM & PLATFORM PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1. Screw 103.2 . Washer 106.1. Port Plug 106.2. Port Plug 109 . Lock Pin 113. Capscrew SEALS 200. T-Seal 202. T-Seal 204. O-ring 205. Cup Seal 207. Backup Ring 304.1. Wiper Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 420.1 Bushing 420.2 Bushing 421.1 Bushing Figure 4-7.
PAGE 279
SECTION 4 - BOOM & PLATFORM PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1. Screw 103.2 . Washer 106.1. Port Plug 106.2. Port Plug 109 . Lock Pin 113. Capscrew SEALS 200. T-Seal 202. T-Seal 204. O-Ring 205. Cup Seal 207. Backup Ring 304.1. Wiper Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 420.1 Bushing 420.2 Bushing 421.1 Bushing Figure 4-8.
PAGE 280
SECTION 4 - BOOM & PLATFORM Disassembly 1. Remove capscrews (113) over end cap lock pins (109). 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). 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. 3. Remove lock pins using an ”Easy Out” (#2 shown). 6. Remove end cap (4) and set aside.
PAGE 281
SECTION 4 - BOOM & PLATFORM 7. Remove stop tube if included. Stop tube is an available option to limit actuator rotation. 9. Use a felt marker to clearly indicate timing marks between shaft and piston before removing shaft, (2). This will greatly simplify timing during assembly. 8. Actuator has timing marks for proper engagement. 10. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet.
PAGE 282
SECTION 4 - BOOM & PLATFORM 11. Mark housing (1) ring gear in relation to piston O.D. gear before removing piston (3). There should now be timing marks on housing (1) ring gear, piston (3) and shaft (2). 12. Use a rubber mallet and plastic mandrel to prevent damage when removing piston (3). 13. Mark piston and housing with a marker where piston gear teeth come out of engagement with housing gear teeth as shown. 14. Remove O-ring (204) and backup ring (207) from end cap (4) and set aside. 15.
PAGE 283
SECTION 4 - BOOM & PLATFORM 16. To remove main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove. 19. Remove piston O.D. seal (202). 20. Remove piston I.D. seal (200). 17. Remove thrust washers (304), from end cap (4) and shaft (2). 18. Remove wiper seal (304.1) from groove in end cap (4) and shaft (2).
PAGE 284
SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect wear guide condition and measure thickness (not less than 0.123" or 3.12 mm). 1. Clean all parts in a solvent tank and dry with compressed air before inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth. Assembly 2. Inspect thrust washers (304) for rough or worn edges and surfaces.
PAGE 285
SECTION 4 - BOOM & PLATFORM 2. Install thrust washer (304) on shaft (2) and end cap (4). 3. Install wiper seal (304.1/green 0-ring) in groove on shaft (2) and end cap (4) around outside edge of thrust washer (304). 4. Use seal tool in a circular motion to install main pressure seal (205) on shaft (2) and end cap (4). 3121180 – JLG Lift – 5. Install wear guide (302) on end cap (4) and shaft (2). 6. Install inner T-seal (200) in piston (3) using a circular motion. 7.
PAGE 286
SECTION 4 - BOOM & PLATFORM 9. Repeat for outer seal (202). 12. Using a rubber mallet, tap piston into housing to point where gear teeth meet. 10. Insert piston (3) into housing (1) as shown, until outer piston seal (202) is touching inside housing bore. 11. Looking from angle shown, rotate piston (3) until marks on piston and housing (1) line up as shown.
PAGE 287
SECTION 4 - BOOM & PLATFORM 13. Look from opposite end of housing (1) to see if timing marks are lining up. When they do, tap piston (3) in until gear teeth mesh together. Tap piston into housing until it bottoms out. 15. Looking from the 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. 14. Install shaft (2) into piston (3). Be careful not to damage seals.
PAGE 288
SECTION 4 - BOOM & PLATFORM 18. Coat threads on end of shaft with anti-seize grease to prevent galling. 21. Tighten end cap (4). In most cases original holes for lock pins will line up. 19. Install 0-ring (204) and back-up ring (207) in inner seal groove on end cap (4). 22. Place lock pins (109) provided in Helac seal kit in holes with dimple side up. Using a punch, tap lock pins to bottom of hole. 20. Thread end cap (4) on shaft (2) end.
PAGE 289
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 the shank of three bolts during installation. Refer to Figure 4-9., Rotator Counterbalance Valve. 1. Clean actuator surface of any contamination and foreign debris including old Loctite. 2. Make sure new valve has O-rings in counterbores of valve to seal it to actuator housing. 4. Torque 1/4" bolts 110 to 120 in-lb (12.4 to 13.5 Nm).
PAGE 290
SECTION 4 - BOOM & PLATFORM NOTE: Retorque all bolts on rotator if any rotator bolts are replaced. A,B,D E C,D 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 4-10.
PAGE 291
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 CYLINDER REPAIR -USA MANUFACTURED ONLY NOTE: Following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA OR CONTAMINATION MAY DAMAGE EQUIPMENT. Figure 5-2. Cap Screw Removal 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
PAGE 292
SECTION 5 - HYDRAULICS 3 8 20 3 10 19 6 16 7 13 14 12 5 18 17 11 1,2,15 7 4 1684129 C 1. 2. 3. 4. 5. Loctite #242 Locking Primer Bushing Bushing Head 6. 7. 8. 9. 10. Barrel Rod/Piston O-Ring Plug Not Used Wear Ring 11. 12. 13. 14. 15. Washer Ring Backup Ring Wear Ring O-Ring Bolt 16. 17. 18. 19. 20. T-Seal Wiper Seal Rod Seal Bleeder Valve Counterbalance Valve Figure 5-3.
PAGE 293
SECTION 5 - HYDRAULICS 17 14 1 17 14 16 5 7 10 11 6 9 4 24 20 19 13 25 22 12 2 17 1684243 E 1. 2. 3. 4. 5. Barrel Rod Not Used Head Piston 6. 7. 8. 9. 10. Locknut Retaining Ring Not Used Wiper Seal 11. 12. 13. 14. 15. O-Ring Backup Ring O-Ring Valve Cartridge Not Used 16. 17. 18. 19. 20. Bleeder Bearing Not Used O-Ring Seal 21. 22. 23. 24. 25. O-Ring O-Ring Not Used Wear Ring Retaining Ring Figure 5-4.
PAGE 294
SECTION 5 - HYDRAULICS 3 4 9 8 1 5 7 5 CYLINDER ROD CAN SLIDE OUT OF CYLINDER IF BLEEDER SCREW IS LOOSENED. 6 2 1684465 B 1. 2. 3. 4. 5. Barrel Rod Plug Pilot Piston Wear Ring 6. 7. 8. 9. Wiper Rod Seal Bleeder Valve Cartridge Figure 5-5.
PAGE 295
SECTION 5 - HYDRAULICS 6 26 8 6 10 27 4 5 12 18 13 20 24 25 13 15 16 19 23 17 7 2,3,22 14 1,2,21 9 6 6 1684165 A 1. 2. 3. 4. 5. Loctite #242 Locking Primer Loctite RC609 Bolt Tapered Bushing 6. 7. 8. 9. 10. Composite Bushing Head Barrel Rod O-Ring Plug 11. 12. 13. 14. 15. Not Used Piston Wear Ring Washer Ring Backup Ring 16. 17. 18. 19. 20. Wear Ring Backup Ring O-Ring O-Ring Setscrew 21. 22. 23. 24. 25. Bolt Wiper Seal T-Seal Spacer Tube 26. Valve Cartridge 27.
PAGE 296
SECTION 5 - HYDRAULICS 5 21 3 1 22 8 4 12 20 10 20 12 14 15 14 13 16 19 6 18 9 17 1 23 2 7 5 1683760 D 1. 2. 3. 4. 5. Loctite #242 Locking Primer #7471 Bolt Tapered Bushing Composite Bushing 6. 7. 8. 9. 10. Head Rod Barrel Ring Washer Piston 11. 12. 13. 14. 15. Not Used Lock Ring Wear Ring Backup Ring O-Ring 16. 17. 18. 19. 20. O-Ring Wiper Seal Backup Ring Seal 21. Valve Cartridge 22. Valve Cartridge 23. Bolt Figure 5-7.
PAGE 297
SECTION 5 - HYDRAULICS 8 17 8 1 18 9 21 14 15 4 10 20 12 5 29 22 13 2 8 8 1. 2. 3. 4. 5. Barrel Rod Not Used Piston Head 6. 7. 8. 9. 10. Not Used Not Used Bearing Seal O-Ring 11. 12. 13. 14. 15. Not Used O-Ring Backup Ring Seal Wiper 16. 17. 18. 19. 20. Not Used Valve Cartridge Valve Cartridge Not Used O-Ring 1684240 C 21. 22. 23. 24. 25. Retaining Ring O-Ring Not Used Not Used Not Used 26. 27. 28. 29. Not Used Not Used Not Used Retaining Ring Figure 5-8.
PAGE 298
SECTION 5 - HYDRAULICS 8 8 27 13 13 10 6 18 19 25 19 18 5 14 16 20 22 17 9 21 23 3,4,24 12 1,3,26 11 7 7 1. 2. 3. 4. 5. Loctite #242 Not Used Locking Primer Loctite RC609 Bolt 6. 7. 8. 9. 10. Tapered Bushing Bushing Bushing Bushing Barrel 11. 12. 13. 14. 15. Rod Ring Washer O-Ring Plug Piston Not Used 16. 17. 18. 19. 20. Backup Ring Backup Ring Seal Wear Ring Wear Ring 21. 22. 23. 24. 25. 1683959 B O-Ring O-Ring Seal Wiper T-Seal 26. Bolt 27. Valve Cartridge Figure 5-9.
PAGE 299
SECTION 5 - HYDRAULICS 8 8 1 11 11 29 17 16 23 15 14 14 7 6 19 18 28 20 22 21 31 24 2 9 9 1684242 B 1. 2. 3. 4. 5. 6. Barrel Rod Not Used Not Used Not Used Head 7. 8. 9. 10. 11. Piston Bearing Bearing Not Used Valve Cartridge 12. 13. 14. 15. 16. Not Used Not Used Bushing Sleeve Nut 17. 18. 19. 20. 21. Retaining Ring Wiper Seal O-Ring Backup Ring 22. 23. 24. 25. 26. O-Ring O-Ring O-Ring Not Used Not Used 27. 28. 29. 30. 31.
PAGE 300
SECTION 5 - HYDRAULICS 23 1 23 11 10 9 6 20 21 13 14 20 12 13 4 15 7 17 16 5 18 19 3 22 2 23 23 1. 2. 3. 4. 5. Barrel Rod End Cap Piston Head 6. 7. 8. 9. 10. Hex Nut Tube Spacer Not Used Valve Cartridge 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 Loctite #242 1684155 B 1684154 B 21. Locking Primer 22. Loctite 23. Bushing Figure 5-11.
PAGE 301
SECTION 5 - HYDRAULICS 6 6 1 25 11 10 19 14 9 7 20 12 26 24 23 21 8 29 27 22 2 6 6 1684244 E 1. 2. 3. 4. 5. Barrel Rod Not Used Not Used Not Used 6. 7. 8. 9. 10. Bearing Piston Head Nut Retaining Ring 11. 12. 13. 14. 15. Seal O-Ring Not Used Spacer Not Used 16. 17. 18. 19. 20. Not Used Not Used Not Used Wear Ring Seal 21. 22. 23. 24. 25. O-Ring Backup Ring O-Ring Wiper Valve Cartridge 26. 27. 28. 29. O-Ring O-Ring Not Used Retaining Ring Figure 5-12.
PAGE 302
SECTION 5 - HYDRAULICS 6 24 6 8 25 24 5 15 23 15 10 18 4 19 13 16 11 17 19 7 1,2,12 21 22 9 6 6 1. 2. 3. 4. 5. Loctite #242 Locking Primer Loctite RC609 Bolt Tapered Bushing 6. 7. 8. 9. 10. Bushing Head Barrel Rod Piston 11. 12. 13. 14. 15. Ring Washer Bolt Tube Spacer Not Used Wear Ring 16. 17. 18. 19. 20. Wear Ring Backup Ring Backup Ring O-Ring O-Ring 1684070 E 21. 22. 23. 24. 25. Seal Wiper T-Seal Valve Cartridge O-Ring Plug Figure 5-13.
PAGE 303
SECTION 5 - HYDRAULICS 6 10 6 1 10 16 12 19 14 11 7 20 24 15 23 21 17 8 30 18 26 2 6 6 1. 2. 3. 4. 5. Barrel Rod Not Used Not Used Not Used 6. 7. 8. 9. 10. Bearing Piston Head Not Used Valve Cartridge 11. 12. 13. 14. 15. Nut Retaining Ring Not Used Spacer O-Ring 16. 17. 18. 19. 20. Seal O-Ring Backup Ring Wear Ring Seal 21. 22. 23. 24. 25. 1684239 D O-Ring Not Used O-Ring Wiper Not Used 26. 27. 28. 29. 30. O-Ring Not Used Not Used Not Used Retaining Ring Figure 5-14.
PAGE 304
SECTION 5 - HYDRAULICS 6 6 10 8 4 5 13 20 12 24 25 15 18 15 13 16 23 2, 3, 22 17 19 7 14 1, 2, 21 9 6 6 16844170 A 1. 2. 3. 4. 5. Loctite #242 Locking Primer Loctite RC609 Capscrew Tapered Bushing 6. 7. 8. 9. 10. Composite Bushing Head Barrel Rod O-Ring Plug 11. 12. 13. 14. 15. Not Used Piston Wear Ring Washer Ring Backup Ring 16. 17. 18. 19. 20. Wear Ring Backup Ring O-Ring O-Ring Setscrew 21. 22. 23. 24. 25. Bolt Wiper Seal T-Seal Spacer Tube Figure 5-15.
PAGE 305
SECTION 5 - HYDRAULICS 5 9 5 3 1 2 4 12 20 6 20 12 14 15 14 16 19 13 8 18 7 17 1 2 21 10 5 5 1. 2. 3. 4. 5. Loctite #242 Locking Primer Bolt Tapered Bushing Composite Bushing 6. 7. 8. 9. Piston Ring Washer Head Barrel 10. 11. 12. 13. Rod Not Used Lock Ring Wear Ring 14. 15. 16. 17. Backup Ring O-Ring O-Ring Wiper 1683773 E 18. 19. 20. 21. Seal Backup Ring Seal Bolt Figure 5-16.
PAGE 306
SECTION 5 - HYDRAULICS 8 1 8 9 19 18 14 5 15 4 10 12 23 13 21 2 8 8 1684241 C 1. 2. 3. 4. 5. Barrel Rod Not Used Piston Head 6. 7. 8. 9. 10. Not Used Not Used Bearing Seal O-Ring 11. 12. 13. 14. 15. Not Used O-Ring Backup Ring Seal Wiper 16. 17. 18. 19. 20. Not Used Not Used O-Ring Retaining Ring Not Used 21. O-Ring 22. Not Used 23. Retaining Ring Figure 5-17.
PAGE 307
SECTION 5 - HYDRAULICS 5 4 7 12 3 8 9 10 1 10 9 8 3 12 7 4 2 5 11 13 1. 2. 3. 4. Barrel Rod Cap Ring Washer 5. 6. 7. 8. Bolt Not Used Wiper Backup Ring 1683614 C 9. 10. 11. 12. O-Ring Wear Ring Wear Ring Seal 13. T-Seal 14. Loctite #242 (Not Shown) 15. Locking Primer (Not Shown) Figure 5-18.
PAGE 308
SECTION 5 - HYDRAULICS 11 12 3 9 7 10 8 1 8 10 7 9 3 12 11 2 6 13 1. 2. 3. 4. Barrel Rod Cylinder Head Anti-Seize 1684412 A 5. 6. 7. 8. Not Used Wear Ring Backup Ring Wear Ring 9. 10. 11. 12. O-Ring O-Ring Wiper Seal 13. T-Seal Figure 5-19.
PAGE 309
SECTION 5 - HYDRAULICS 1 6 7 3 15 14 18 7 6 14 3 12 13 13 18 15 12 2 9 10 9 1684246 B 1. 2. 3. 4. 5. 6. Barrel Rod Head Not Used Not Used Wiper 7. 8. 9. 10. 11. 12. Seal Not Used Wear Ring Seal Not Used Backup Ring 13. 14. 15. 16. 17. 18. O-Ring O-Ring O-Ring Not used Not Used Retaining Ring Figure 5-20.
PAGE 310
SECTION 5 - HYDRAULICS 1684095 E 1684140 E 1. 2. 3. 4. 5. Barrel Rod Piston Head Tube Spacer 6. 7. 8. 9. 10. Valve Bolt O-Ring Plug Setscrew Locknut 11. 12. 13. 14. 15. Retaining Ring Wear Ring Cap Seal O-Ring Wear Ring 16. 17. 18. 19. 20. O-Ring Rod Seal Wiper Loctite #242 Not Used 21. 22. 23. 24. 25. Not Used Not Used Wear Pad Bolt Adapter Figure 5-21.
PAGE 311
SECTION 5 - HYDRAULICS 18 5 1 5A 7 25 9 6 26 8 14 4 16 20 19 13 27 23 2 1684262 C 1. 2. 3. 4. 5. Barrel Rod Not Used Head Valve Block 6. 7. 8. 9. 10. Piston Seal O-Ring Spacer Not Used 11. 12. 13. 14. 15. Not Used Not Used O-Ring Seal Not Used 16. 17. 18. 19. 20. Wiper Not Used Bolt O-Ring O-Ring 21. 22. 23. 24. 25. Not Used Not Used O-Ring Not Used Setscrew 26. Wear Ring 27. Retaining Ring Figure 5-22.
PAGE 312
SECTION 5 - HYDRAULICS USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. 9. With barrel clamped securely, apply pressure to rod pulling device and carefully withdraw complete rod assembly from cylinder barrel. Figure 5-24. Tapered Bushing Removal 15. Screw piston CCW by hand and remove piston from cylinder rod. 16. Remove and discard piston O-rings, seal rings, and backup rings. 17.
PAGE 313
SECTION 5 - HYDRAULICS 10. Inspect threaded portion of head for damage. Dress threads as necessary. 11. Inspect seal and O-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary. 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. 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. 1.
PAGE 314
SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into applicable cylinder head gland groove. Install new wear ring into applicable cylinder head gland groove. 6. If applicable, correctly place a new O-ring and backup rings in the inner piston diameter groove. Figure 5-27. Poly-Pak Piston Seal Installation Figure 5-30. Piston Seal Kit Installation 7. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 8.
PAGE 315
SECTION 5 - HYDRAULICS 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. (See Figure 2-28. Piston Seal Kit Installation.) Table 5-1. Cylinder Head and Tapered Bushing Torque Specifications Description Head Torque Value (Wet) 13. Position cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
PAGE 316
SECTION 5 - HYDRAULICS IF CYLINDER IS TEST PRIOR TO INSTALLATION ON MACHINE, USE EXTREME CARE TO INSURE OUTER END OF ROD IS SUPPORTED. USE A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS TO SUPPORT OVERHANGING WEIGHT OF EXTENDING ROD. 5.2 5. Clamp mounting flange in a protected jaw vise with pump shaft facing down. 6. Loosen four metric hex head bolts. 7. Remove pump from vise and place on clean work bench, remove the four hex head bolts and spacers if applicable.
PAGE 317
SECTION 5 - HYDRAULICS 10. Remove rear bearing block from drive and idler shafts. 13. Remove front bearing block. 14. Turn mounting flange over, with shaft seal up, and remove retaining ring with proper snap ring pliers. 11. Remove idler shaft from bearing block. 12. Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item. 15. Remove oil seal from mounting flange, be careful not to mar or scratch seal bore. 16.
PAGE 318
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 placed as new items. 5. Inspect bearing blocks for excessive wear or scoring on surfaces in contact with gears. Inspect bearings for excessive wear or scoring. 6. Inspect area inside gear housing. A clean ”wipe” on the inside surface of the intake side is normal. There should not be excessive wear, deep scratches, or gouges. 2.
PAGE 319
SECTION 5 - HYDRAULICS General Information FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR NO FLOW AT RATED PRESSURE. RELATIONSHIP OF MOUNTING FLANGE, BEARING BLOCKS, AND GEAR HOUSING MUST BE CORRECT. Reverse Shaft Rotation of Pump NOTE: Pump is not bi-rotational. Use the following procedure if shaft rotation direction is changed.
PAGE 320
SECTION 5 - HYDRAULICS 6. Apply a light coating of petroleum jelly to exposed face of front bearing block. 7. Insert drive end of drive shaft through bearing block with seal side down and open side of E-seal pointing to 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. 12. Apply a light coating of petroleum jelly in grooves on both sides of gear housing. Coat new O-rings and install in grooves. 8.
PAGE 321
SECTION 5 - HYDRAULICS 14. Install two remaining dowel pins in rear of gear housing, if applicable, and place end cover over back of pump. 19. Name plate located on end cover contains build date code and model number. Please refer to this information when corresponding with the J.S. Barnes Service Department. Table 5-3.Hydraulic Pump Bolt Torque Chart Torque Values, Black Oxide End Cover Torque Values, Zinc Plated End Cover Pump Series Thread Size W-600 M 8 x 1.25 18-21 ft.lb. 24-30 Nm 16-18 ft.lb.
PAGE 322
SECTION 5 - HYDRAULICS Placing Pump Back Into Service 1. 5.3 If shop test stand is available, the following procedure for testing rebuilt pumps is recommended: 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. c. Intermittently load pump to 500 P.S.I. for three minutes. d. Intermittently load pump to 1000 P.S.I. for three minutes. e.
PAGE 323
SECTION 5 - HYDRAULICS Removal and Installation of FNR and NFPE Modules SHIM ADJUSTABLE STYLE 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 324
SECTION 5 - HYDRAULICS 1. System Pressure Gauge Port M2 2. System Pressure Port B 3. System Pressure Port A 4. System Pressure Gauge Port M1 5. Servo Pressure Gauge Port M5 6. Case Drain Port L2 (non-feedback) 7. Case Drain Port L2 8. Servo Pressure Gauge Port L4 9. Case Drain Port L1 10. Case Drain Port L1 (non-feedback) 11. Charge Pressure Gauge 12. Charge Pump Inlet Port S Figure 5-34.
PAGE 325
SECTION 5 - HYDRAULICS Plug/ Fitting # Torque lb. ft. Nm N/A N/A 11/16 20-35 27-47 9/16 70-100 95-135 N/A 1 Servo Gauge Port M4 2 3 4 Case Drain Port L1 N/A 5 Charge Pressure Gauge M3 N/A N/A 6 Charge Pump Inlet Port S 85 115 7 Case Drain Port L2 N/A N/A 8 Port N N/A N/A System Gauge M1 & M2 N/A N/A 9 85 115 11 11/16 20-35 27-47 12 9/16 70-100 95-135 13 11/16 20-35 27-47 10 System Ports A&B 14 Servo Gauge M5 15 11/16 N/A N/A 20-35 27-47 Figure 5-35.
PAGE 326
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 5-37. Shaft Seal Components Figure 5-36. Screw Adjustable Charge Relief Valve Components 1.
PAGE 327
SECTION 5 - HYDRAULICS 1. Position pump with shaft facing up. NOTE: If the unit is positioned horizontally when the shaft is removed, the 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 328
SECTION 5 - HYDRAULICS Charge Pump 7. Lubricate gerotor assembly with clean hydraulic oil before assembly. Disassemble charge pump to inspect and clean, or change auxiliary shaft drive coupling. 8. Install gerotor drive pin into hole in drive coupling. Apply grease or petroleum jelly to keep in place. 1. Remove auxiliary pump, if necessary. 2. Remove screws retaining charge pump cover to pump housing (Torx T).
PAGE 329
SECTION 5 - HYDRAULICS 1. Cover Retaining Screw 2. O-Ring 3. Geroter Cover 4. Geroter Assembly 5. Drive Coupling 6. Geroter Cover Locating Pin 7. Charge Pump Cover Locating Pin 8. Geroter Drive Pin 9. Gasket Figure 5-40.
PAGE 330
SECTION 5 - HYDRAULICS 5.4 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS Inlet line from reservoir to pump must be filled prior to start-up. Check inlet line for properly tightened fittings, restrictions, and air leaks. From a hydrostatic component standpoint, the goal at system start up is to put into functional operation, the hydrostatic system in such a way as to preserve the designed life span of the system.
PAGE 331
SECTION 5 - HYDRAULICS Install a 1000 psi (60 bar) pressure gauge in charge pressure gauge port to monitor charge pressure during start-up. It is recommended the external control input signal, (electrical connections for EDC), be disconnected at pump control until after initial start-up. This ensures pump remains in its neutral position. DO NOT START ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION (0 DEGREES SWASHPLATE ANGLE).
PAGE 332
SECTION 5 - HYDRAULICS 5.5 PRESSURE SETTING PROCEDURE Articulating Jib Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating machine until hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures. 1.
PAGE 333
SECTION 5 - HYDRAULICS . 1. 2. 3. 4. 5. 6. Check Valve Load Shuttle Load Shuttle Main Dump Swing Steer 7. 8. 9. 10. 11. 12. Upper Lift Proportional Dump Directional Pilot Telescope Lower Lift Flow Regulator 13. Bang Bang Relief 14. Proportional Main Relief 15. Steer Relief 16. Load Shuttle (Steer) 17. Lift Down Relief 18. Swing Relief Figure 5-41.
PAGE 334
SECTION 5 - HYDRAULICS A B C 18-20 ft. lbs. (24.5 - 27.2 Nm) 4-5 ft. lbs. (5.4 - 6.8 Nm) 25-27 ft. lbs. (34 - 36.7 Nm) Figure 5-42.
PAGE 335
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. Jib Up Jib Down Jib Up/Down Relief Rotate - Left Rotate - Right Level Up Level Down 8. 9. 10. 11. 12. Level Up Relief Level Down Relief Level Up Pilot Check Level Down Pilot Check Pressure Compensated Regulator NOTE: Torque valves and cartridges 18 to 20 ft-lb (24.5 to 27.2 Nm). Torque solenoid coils 4 to 5 ft-lb (6.5 to 9.5 Nm). Figure 5-43.
PAGE 336
SECTION 5 - HYDRAULICS NOTES: 5-46 – JLG Lift – 3121180
PAGE 337
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, THE CONTROLLER MUST BE PROGRAMMED FOR PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATING THE TILT SENSOR. AVOID PRESSURE-WASHING ELECTRICAL AND ELECTRONIC COMPONENTS. IF PRESSURE-WASHING AREAS CONTAINING ELECTRICAL OR ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
PAGE 338
SECTION 6 - JLG CONTROL SYSTEM Figure 6-2.
PAGE 339
SECTION 6 - JLG CONTROL SYSTEM 6.2 CONNECT JLG CONTROL SYSTEM ANALYZER MACHINE SETUP CALIBRATIONS (view only) 1. Connect four pin end of cable supplied with analyzer to controller module located on platform box or at controller module inside ground control box. Connect remaining end of cable to analyzer. NOTE: Cable has a keyed four pin connector at each end. It cannot be connected backwards.
PAGE 340
SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-3.
PAGE 341
SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Use UP or DOWN arrow key to enter second digit of password which is 33271. Continue using arrow keys until all remaining digits of password is shown. Pressing ENTER with any above displayed menus show sub-menus within the selected menu. In some cases, such as DRIVE, the next level is parameter or information to be changed.
PAGE 342
SECTION 6 - JLG CONTROL SYSTEM Figure 6-4.
PAGE 343
SECTION 6 - JLG CONTROL SYSTEM 6.5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER Once you have gained access to level 1, and a personality item is selected, press UP or DOWN arrow keys to adjust its value, for example: 6.6 MACHINE SETUP When a machine digit item is selected, press UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2 = LIFT DOWN PERSONALITIES: DRIVE ACCEL 1.0s There is a minimum and maximum value for efficient operation.
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6-8 DRIVE: ACCEL X.XS TO MENU: MACHINE SETUP STEER: MAX SPEED X% PERSONALITIES: DRIVE MENU: PERSONALITIES RIGHT TRACK: ELEV R MAX X% RIGHT TRACK: CREEP F MAX X% RIGHT TRACK: CREEP R MAX X% LEFT TRACK: MIN REVERSE X% LEFT TRACK: MAX REVERSE X% LEFT TRACK: ELEV F MAX X% LEFT TRACK: ELEV R MAX X% LEFT TRACK: CREEP F MAX X% LEFT TRACK: CREEP R MAX X% DRIVE: MIN REVERSE X% DRIVE: MAX REVERSE X% – JLG Lift – DRIVE: ELEV.
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3121180 – JLG Lift – UPPER TELESCOPE: MIN OUT X% UPPER TELESCOPE: MAX OUT X% TOWER LIFT: MIN DOWN X% TOWER LIFT: MAX DOWN X% TOWER TELESCOPE: MAX OUT X% TOWER TELESCOPE: MIN OUT X% TOWER TELESCOPE: MAX IN X% TOWER TELESCOPE: MIN IN X% TOWER TELESCOPE: DECEL X.XS TOWER TELESCOPE: ACCEL X.XS PERSONALITIES: TOWER TELESCOPE BASKET LEVEL: MAX DOWN X% BASKET LEVEL: MIN DOWN X% BASKET LEVEL: MAX UP X% BASKET LEVEL: MIN UP X% BASKET LEVEL: DECEL X.XS BASKET LEVEL: ACCEL X.
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6-10 – JLG Lift – ENGINE: 5=CAT. 3024C ENGINE: 6=CAT. 3044C MODEL NUMBER: 5=800A MODEL NUMBER: 6=800S GEN SET/WELDER: 1=BELT DRIVE SOFT TOUCH: 1=YES GEN SET/WELDER: 2=HYD.
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Figure 6-6. Analyzer Flow Chart, Prior to Version 5.
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6-12 – JLG Lift – Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 NOTE: Some screens may not be available depending upon machine configuration.
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Figure 6-8. Analyzer Flow Chart, Version 5.
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6-14 TO: MENU: CALIBRATIONS MENU: MACHINE SETUP FROM: MENU: PERSONALITIES – JLG Lift – GEN SET CUTOUT: MOTION ENABLED GEN SET CUTOUT: MOTION CUTOUT GEN SET/WELDER: NO GEN SET/WELDER: BELT DRIVE CABLE SWITCH: YES CABLE SWITCH: NO FLYWHEEL TEETH: 133 TEETH FLYWHEEL TEETH: 110 TEETH FUNCTION CUTOUT: DRIVE CUT E&T LOAD SYSTEM: SPECIAL 1 FUNCTION CUTOUT: DRIVE CUTOUT FUNCTION CUTOUT: BOOM CUTOUT FUNCTION CUTOUT: NO TILT: 3 DEGREES + CUT TILT: 4 DEGREES + CUT TILT: 3 DEGREES TILT: 4 DEGREES
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3121180 – JLG Lift – TRANSPORT SWITCHES: OPEN TRANSPORT MODE: OUT OF TRANSPORT END OF STROKE PROXIMITY: OPEN TOWER LIFT PROXIMITY:CLOSED FUEL SELECTION STATUS:GAS AMBIENT TEMPERATURE:XXXC FUEL LEVEL SENSOR: OK STARTER CRANK TIME: XX S ENGINE SPEED ACTUAL: XXXX RPM ENGINE SPEED TARGET: XXXX RPM PLATFORM LEVEL: UP XXX% PLATFORM ROTATE: RIGHT XXX% MAIN TELESCOPE: IN XXX% TOWER TELESCOPE: IN XXX% TOWER LIFT: XXX% DOWN JIB LIFT: UP PLATFORM CONTROL VALVE: OFF FUNCTION SPEED: PUMP POT XXX% CREEP SWITCH: CLOSED
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6-16 1 MENU: SERVICE MODE 1 TEST UMS? NO CALIBRATIONS: TILT SENSOR 1 FORD ENGINE: DISABLE RS-485? 1 TILT SENSOR: CALIBRATE? Figure 6-11. Analyzer Flow Chart, Version 6.X Software - Sheet 1 of 3 S GO TO PAGE 6-18 LEVEL UP CRKPT: 1 CALIBRATE? PLAT.
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SECTION 6 - JLG CONTROL SYSTEM A DIAGNOSTICS: DRIVE/STEER B DIAGNOSTICS: BOOM FUNCTIONS C DIAGNOSTICS: ENGINE D DIAGNOSTICS: SYSTEM E DIAGNOSTICS: DATALOG F DIAGNOSTICS: VERSIONS JOYSTICK DRIVE: FORWARD XXX% JOYSTICK LIFT: MAIN UP XXX% START SEQUENCE: NOT ACTIVE GROUND MODULE: BATTERY: XX:XV DATALOG: ON: XXXh XXm GROUND MODULE SOFTWARE: XX.XX JOYSTICK STEER: LEFT XXX% JOYSTICK SWING: LEFT XXX% BATTERY VOLTAGE: XX.
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SECTION 6 - JLG CONTROL SYSTEM G PERSONALITIES: DRIVE H PERSONALITIES: LEFT TRACK I PERSONALITIES: RIGHT TRACK J PERSONALITIES: MAIN LIFT K PERSONALITIES: SWING L PERSONALITIES: TOWER LIFT M PERSONALITIES: MAIN TELESCOPE DRIVE: ACCEL X.XS LEFT TRACK: ACCEL X.XS RIGHT TRACK: ACCEL X.XS MAIN LIFT: ACCEL X.XS SWING: ACCEL X.XS TOWER LIFT: ACCEL X.XS MAIN TELESCOPE: ACCEL X.XS DRIVE: DECEL X.XS LEFT TRACK: DECEL X.XS RIGHT TRACK: DECEL X.XS MAIN LIFT: DECEL X.XS SWING: DECEL X.
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SECTION 6 - JLG CONTROL SYSTEM 6.7 MACHINE PERSONALITY SETTINGS NOTE: Adjust personality settings within range for optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION DRIVE PERSONALITY 0.1s to 5.0s 1.5 DECELeration 0.1s to 3.0s 1.5 MINimum speed 0 to 35% 30 MAXimum speed 0 to 100% 50 REVerse MINimum speed 0 to 35% 30 REVerse MAXimum speed 0 to 100% 50 ELEVATED MAXimum speed 0 to 50% 38 CREEP MAXimum speed 0 to 50% 40 800 to 2900 1800 ACCELeration 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION SWING PERSONALITY 0.1 to 5.0s 2.0 DECELeration 0.1 to 3.0s 1.5 MINimum LEFT speed 0 to 50% 32 MAXimum LEFT speed 0 to 100% 58 CREEP maximum LEFT speed 0 to 65% 40 MINimum RIGHT speed 0 to 50% 38 MAXimum RIGHT speed 0 to 100% 58 CREEP maximum RIGHT speed 0 to 65% 40 800 to 2900 1400 ACCELeration 0.1 to 5.0 2.0 DECELeration 0.1 to 3.0 1.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION JIB LIFT PERSONALITY 0.1 to 5.0 3.0 DECELeration 0.1 to 3.0 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S 1 MARKET: 2 0 1 2 3 4 5 ANSI USA ANSI EXPORT CSA CE AUSTRALIA JAPAN 0 ENGINE: 3* * Engine selections vary depending on model selection.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit GLOW PLUG: 5 ENGINE SHUTDOWN: 6 TILT: 7* * Certain market selections will limit tilt options. Number Description 0 NO GLOW PLUGS: No glow plugs installed. 1 W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description GEN SET CUTOUT: 12* 0 MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / Welder Menu selection is not 0. 1 MOTION CUTOUT: Motion cutout in platform mode only. H & T LIGHTS: 13 0 NO: No head and tail lights installed. 1 YES: Head and tail lights installed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description GROUND ALARM: 18* 0 NO: No ground alarm installed. * Certain market selections will alter default setting. 1 DRIVE: Travel alarm sounds when the drive function is active (Option). 2 DESCENT: Descent alarm sounds when lift down is active (Option). 3 MOTION: Motion alarm sounds when any function is active (Option).
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit ENGINE: 3* * Engine selections vary depending on model selection. Number 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit ENGINE SHUTDOWN: 7 Number 0 DISABLED: No engine shutdown. 1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI. TILT: 8* * Certain market selections will limit tilt options and alter default setting.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit Number GEN SET CUTOUT: 13* * Only visible if Gen Set / Welder Menu selection is not 0. 0 MOTION ENABLED: Motion enabled when generator is ON. 1 MOTION CUTOUT: Motion cutout in platform mode only. H & T LIGHTS: 14 0 NO: No head and tail lights installed. 1 YES: Head and tail lights installed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit Number FUNCTION CUTOUT: 18* * Only visible under certain market selections. * Certain market selections will limit function cutout options or alter default setting. 0 NO: No drive cutout. 1 BOOM CUTOUT: Boom function cutout while driving above elevation. 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit ENGINE: 3* * Engine selections vary depending on model selection. Number 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit STARTER LOCKOUT: 6 Number 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit GEN SET/WELDER: 12 Number 0 NO: No generator installed. 1 BELT DRIVE: Belt driven setup. GEN SET CUTOUT: 13* * Only visible if Gen Set / Welder Menu selection is not 0. 0 MOTION ENABLED: Motion enabled when generator is ON. 1 MOTION CUTOUT: Motion cutout in platform mode only. H & T LIGHTS: 14 0 NO: No head and tail lights installed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Number 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Number 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 the Ground Module. 1 PROPULSION: Drive coils are energized from the Propulsion Module.
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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.
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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.
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SECTION 6 - JLG CONTROL SYSTEM 6.8 SYSTEM TEST 3. Pull out Emergency Stop switch and start engine. The Control System Incorporates a built-in system test to check system components and functions. Test from Platform 1. Position Platform/Ground select switch to Platform. 4. The analyzer screen should read: 2. Plug analyzer into connector at base of platform control box. 5. Use arrow button to reach SYSTEM TEST and press Enter.
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Figure 6-14.
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SECTION 6 - JLG CONTROL SYSTEM Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the engine. 1. Set Platform/Ground select switch to Ground. 2. Plug analyzer into connector inside Ground control box. 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 6-15.
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Figure 6-15.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer RUNNING 3121180 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).
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer TEST ALL INPUTS? TESTS COMPLETE 3121180 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
PAGE 384
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description ENGINE: START ACTIVE/NOT ACTIVE Displays status of the engine start circuit AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL NUMBER = 7 or 8) BATTERY XX.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description SYSTEM: 3121180 GM BATTERY XX.XV Ground module battery voltage PM BATTERY XX.XV Platform module battery voltage AMB. TEMP XXXC Ambient temperature FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) 6-50 Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) Description HI TILTED - NO/YES Displays status of hi tilt input.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) osc axle p sw OP/CL Oscillating axle pressure switch status. (Displayed if OSCILLATING AXLE = 1) sky welder YES/NO Status of Sky Welder selected during boom sensor calibration.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) MOMENT: 6-52 Description Displayed if MODEL NUMBER = 7 or 8 (LB-IN) ACTUAL XXXXXXXX Current moment value (LB-IN) OVER XXXXXXXX Current over moment setpoint. (LB-IN) UNDER XXXXXXXX Current under moment setpoint.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Diagnostics Parameters Diagnostics Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Parameter Value (Displayed on Analyzer 2nd Line) ENVELOPE: Displayed if MODEL NUMBER = 7 or 8 LENGTH XXXX.X Current indicated boom length in inches. ANGLE 1 XX.X Current indicated boom angle 1 in degrees. ANGLE 2 XX.X Current indicated boom angle 2 in degrees. A/D LNGTH XXXXX Current indicated boom length in A/D counts.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949 Fault Flash Code None Communicated (Displayed on Analyzer) Fault Description No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949 2/3 Flash code 2/3 indicates problems with boom function selection. LIFT/SWING JOYSTICK FAULTY Lift or swing joystick center tap is out of valid range or wiper is wireoff. LIFT/SWING LOCKED JOYSTICK MOVED BEFORE EMS/FSW Platform upper lift or swing was selected before and during footswitch closure.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949 3/2 Flash code 3/2 indicates that a contactor did not open when energized. NOT REQUIRED 3/3 Flash code 3/3 indicates that a driver is short-circuit. 6 ADD DRIVER FAULTS 3/5 Flash code 3/5 indicates a brake pressure problem. NOT REQUIRED 7 4/2 Flash code 4/2 indicates that the engine is over temperature.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault None Description Priority No flash code is indicated for the following help messages. They are intended to hint at a possible problem if vehicle is not behaving as expected.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 2/2 Description Flash code 2/2 indicates problems with drive & steer selection. Except where noted, these faults are not reported during 2 second power-up sequence. DRIVE LOCKED – JOYSTICK MOVED BEFORE FOOTSWITCH Drive selected before and during footswitch closure.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 2/5 Description Flash code 2/5 indicates a function is prevented due to a cutout. BOOM PREVENTED – DRIVE SELECTED Priority 4 A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 3/3 Description Priority Flash code 3/3 indicates a driver problem. All driver faults are detected in a similar manner. Open circuit faults are detected when analog feedback reads too high and output is commanded off. Short to ground is detected when analog feedback reads low and output is commanded on.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description LP LOCK SHORT TO BATTERY Machines with dual-fuel engines ONLY. LP START ASSIST SHORT TO GROUND Machines with dual-fuel engines ONLY. LP START ASSIST OPEN CIRCUIT Machines with dual-fuel engines ONLY. LP START ASSIST SHORT TO BATTERY Machines with dual-fuel engines ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description HEAD TAIL LIGHT OPEN CIRCUIT Machines with headlights option configured ONLY HEAD TAIL LIGHT SHORT TO BATTERY Machines with headlights option configured ONLY BASKET UP OVERRIDE SHORT TO GROUND Machines with electronic leveling systems ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description LIFT DOWN AUX VALVE OPEN CIRCUIT Machines with gravity lift down ONLY. TOWER LIFT APU SHORT TO GROUND 1250AJP ONLY. TOWER LIFT APU OPEN CIRCUIT 1250AJP ONLY. TOWER LIFT APU SHORT TO BATTERY 1250AJP ONLY. MAIN LIFT ENABLE SHORT TO GROUND 1250AJP ONLY.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 3/4 Description Priority Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All driver faults are detected in a similar manner. Open circuit faults are detected when analog feedback reads too high and output is commanded off.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 4/3 Description Priority Flash code 4/3 indicates engine problems. These faults are not reported during 2 second power-up sequence except where noted. 9 HIGH ENGINE TEMP Occurs when engine temperature is above 117 degrees Celsius for Ford and 130 degrees Celsius for Deutz engines.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 4/5 Description Flash code 4/5 indicates problems with the S-D CAN based PVG valves currently used on the 1250AJP only. MAIN LIFT PVG COMMUNICATIONS CAN communications lost with Main Lift PVG valve. tower lift pvg communications CAN communications lost with Tower Lift PVG valve.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description MAIN LIFT PVG VALVE COMMAND IMPROPER Main boom lift pvg valve received invalid control system command. TOWER LIFT PVG VALVE COMMAND IMPROPER Tower boom lift pvg valve received invalid control system command.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 6/6 Description Flash code 6/6 indicates problems with the CAN bus. Priority 10 PLATFORM CAN COMMUNICATIONS Ground module or platform module not receiving CAN messages. This is LOST probably due to wiring problems between platform and ground modules. BLAM CAN COMMUNICATIONS LOST Machines with a BLAM ONLY.
PAGE 408
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 8/3 Description Flash code 8/3 indicates problems with the Basket Leveling system. Priority 10 BASKET LEVELING CRACKPOINT UP Only occurs on machines with electronic leveling systems.
PAGE 409
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 8/4 Description Priority Flash code 8/4 indicates problems with the envelope system. Only occur on machines with envelope control. 10 BOOM ANGLE SENSOR DISAGREEMENT The boom angle sensors are reporting angles that differ too greatly. An EMS cycle is required.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 8/5 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE 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 The horizontal force is out of the allowed range.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 8/6 Description Flash code 8/6 indicates steering system problem. An EMS cycle is required except as noted. Priority 10 RESTRICTED TO TRANSPORT – OSC Only occurs on machines with electrically released oscillating axles configAXLE PRESS SW DISAGREEMENT ured.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description REAR LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears. REAR RIGHT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition clears.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 9/9 Description Flash code 9/9 indicates problems with the controller or the user disabling safety systems from Access Level 0.
PAGE 415
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 1300000001 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault 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: 6-80 – JLG Lift – 3121180
PAGE 417
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 operating problems. If a problem develops which is not presented in this section or not corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any maintenance. 7.
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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 OFF before testing continuity. Figure 7-2. Resistance Measurement • Disconnect component from circuit before testing. • Test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance).
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement 7.2 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: Do NOT apply dielectric grease to the following connections: • Main Boom Rotary sensor connections (on Celesco Sensor). • LSS Modules connections, • Deutz EMR 2 ECM connection.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.3 AMP CONNECTOR Assembly Check wedge lock is in the open, or as-shipped position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on AMP connections for the following reasons: • To prevent oxidation at mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts are inserted, close wedge lock to its locked position. Release locking latches by squeezing them inward (See Figure 7-8.). 4. Slide wedge lock into housing until flush with housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Wedge Lock 1. Insert a 3/16" (4.8 mm) wide screwdriver blade between mating seal and one of the red wedge lock tabs. 2. Pry wedge lock to the open position. 3. While rotating wire back and forth over a half turn (1/4 turn in each direction), gently pull wire until contact is removed. NOTE: Wedge lock should never be removed from housing for contact insertion or removal.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly A A B B C C D Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind contact barrel. 2. Hold connector with rear grommet facing you. 1. Remove wedgelock (A) using needlenose pliers or a hook shaped wire to pull wedge straight out. NOTE: Hold rear seal in place. Removing contact may displace seal. 3.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A B C C Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool over wire of contact to be removed. 2. Hold connector with rear grommet facing you. 2.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 1300000979. Figure 7-20.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870144G Figure 7-21.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 1300000979. Figure 7-22.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870144G Figure 7-23.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built from S/N 1300000979 to S/N 1300002604. Figure 7-24.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-25.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built from S/N 1300000979 to S/N 1300002604. Figure 7-26.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-27.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built from S/N 1300000979 to S/N 1300002604. Figure 7-28.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-29.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM WORK LIGHTS OPTION #1 GREEN RED BLACK 10/3 RED BLACK RED 20 AMP PLATFORM WORK LIGHTS OPTION #2 GREEN BLACK RED BLACK GREEN STROBE LIGHT 10/3 15 15 AMP YEL/RED 2-37 3 ORN 55-52 YEL/RED 2-10 TAN 5-1 TAN 6-1 BROWN 15-1 BROWN 16-1 YELLOW 55-16 YELLOW 55-17 TOWER UP TOWER DOWN TOWER TELE IN TOWER TELE OUT CRAB STEER COORDINATED STEER START SWITCH AUX POWER WHT/YEL 48-1 BRN/ORN 53-1 ENGINE SPEED TWO SPEED HORN SOFT TOUCH OVERIDE HEAD/TA
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GROUND CONTROL BOX 30 AMP TO BATTERY NEG.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS WHT/YEL 48-12(12) GLOW PLUGS REGULATOR GLOW PLUG SOL. D+ WHT/YEL 48-10 (12) START SOL. STARTER MOTOR CAT ENGINE 400S, 450A/AJ B+ 14 GA. FUSE LINK WHT/YEL 48-12(12) SPEED PICKUP STARTER MOTOR SOL. FLYWHEEL SPEED PICKUP W START SOL. GLOW PLUG SOL. 14 GA. FUSE LINK FAN MOTOR STARTER MOTOR FLYWHEEL FUSIBLE LINK RED 1-1(10) STARTER MOTOR SOL. GLOW PLUGS 87 THROTTLE ACTUATOR COOLANT TEMP.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS RECTIFER ALTERNATOR WITH PLUG CONNECTOR P WHT/YEL 48-3 WHT/YEL 48-13 (8) GLOW PLUGS GLOW PLUG SOL.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS WHT/LT GRN LT GRN/RED LT GRN/WHT BLK/LT GRN EGO 1 EGO 2 EGO 3 EGO 4 TPS 1 TPS 2 MAP AUX ANA PDI FPP 1 FPP2/1VS AUX ANA PD2 AUX ANA PD3 CAN1 TERM + CAN1 + CAN1 CAN2 CAN2 + CAN2 TERM + 5V EXT 1 5V EXT CRANK + CRANK CAM + CAM ROAD SPEED + ROAD SPEED KNOCK1 + KNOCK1 KNOCK2 + KNOCK2 SPK COIL 1A SPK COIL 1B SPK COIL 2A SPK COIL 2B SPK COIL 3A SPK COIL 3B SPK COIL 4A SPK COIL 4B 1AT ECT LP TEMP AUX DIG 1 AUX DIG 2 AUX DIG 3 VSW AUX ANA PU1 AUX ANA PU2 AUX ANA
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BLK/YEL BLK/LT GRN PNK/DK GRN DR GRN/WHT EGO 2 D C B A BLK/WHT BLK/LT GRN PNK/DK GRN DR GRN/ORN D C B A TAN/WHT BLK/LT GRN LT GREEN LT GRN/RED YEL/GRY BLK/LT GRN 4 3 2 1 EGO 1 A B C ECT BOSCH TMAP CONNECTOR 2 LT BLUE OIL PRESS.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 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 Figure 7-39.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-40.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-41.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-42.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-43.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-44.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-45.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-46.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-47.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-48.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-49.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS + Hydraulic Drawing 1283460 Description Figure 7-50.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-51.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-52.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-53.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-54.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-55.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-56.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-57.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-58.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-59.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-60.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-61.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-54 – JLG Lift – 3121180
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3121180 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 813058 JLG Deutschland GmbH Max-Planck-Str.