Service and Maintenance Manual Model 450A 450AJ 3120749 November 22, 2000 ANSI
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION REVISON LOG May, 1998 July, 1998 September, 1998 July 15, 1999 September 15, 1999 September 19, 2000 November 22, 2000 A-2 - Original Issue - Revised - Revised - Revised - Revised - Revised - Revised – JLG Lift – 3120749
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH 2.33 2.34 2.35 2.36 PAGE NO. Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-79 Semi-Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES (continued) FIGURE NO. 2-39. 2-40. 2-41. 2-42. 2-43. 2-44. 2-45. 2-46. 2-47. 2-48. 2-49. 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. TITLE PAGE NO. Function Control Card Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69 Addco Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Fuel Tank - 16.5 gallons (62.5 liters) 1.3 TIRES 12x16.5 Hydraulic Oil Tank - 28 gallons (106 liters) • Pneumatic - 90 psi (6 Bar) Hydraulic System - • Weight: 128 lbs. (58 kg) Torque Hub - 17 ounces (0.5 liters) 12x16.5 • Foam-Filled NOTE: Torque hubs should be one half full of lubricant. Engine Crankcase (Ford LRG425) - 5 qts. (4.5 L) Engine Crankcase (Deutz F3M1011F) - 6.3 qts. (6 L) • Weight: 328 lbs. (149 kg) 33/1550x16.
SECTION 1 - SPECIFICATIONS Rated Gradeability - 2WD -30% 4WD - 40% 1.6 System Voltage - 12 Volts LUBRICATION Hydraulic Oil Max. Hydraulic System Operating Pressure - 3000 psi (207 bar) Table 1-2.Hydraulic Oil Travel Speed (2WD) - 4.5 mph Hydraulic System Operating Temperature Range Travel Speed (4WD) - 2.25 mph Ground Bearing Pressure (450A) 2 12x16.5 pneu. - 46 psi (3.23 kg/cm ) 12x16.5 FF - 56 psi (3.93 kg/cm2) 33/1550x16.5 pneu. - 35 psi (2.46 kg/cm2) 33/1550x16.5 FF - 50 psi (3.51 kg/cm2) S.
SECTION 1 - SPECIFICATIONS NOTE: Refer to Lubrication Chart for specific lubrication procedures.. 1.8 MAJOR COMPONENT WEIGHTS Table 1-4. Mobil EAL Envirosyn H 46 Specs Type Synthetic Biodegradable ISO Viscosity Grade 46 Specific Gravity .910 Pour Point, Max Table 1-5.Major Component Weights Component LB. KG. 6 ft Platform 160 73 5 ft. Platform 145 66 -44 F (-44 C) 4 ft. Platform 130 59 Flash Point, Min. 500 F (260 C) Jib 230 104 Weight 7.64 lb. per gal. (0.
SECTION 1 - SPECIFICATIONS Figure 1-1.
SECTION 1 - SPECIFICATIONS Table 1-6. Lubrication Chart Interval Components Number/Type Lube Points Capacity Lube 2 Grease Fitting A/R MPG X X 3 Months 150 hrs Hours 6 Months 300 hrs 1 Year 600 hrs 2 Years 1200 hrs Comments Lubrication 1 Swing Bearing - Internal Ball Bearing 2a Swing Bearing - Teeth Spray On A/R OGL 2b End Bearings - Worm Gear* 2 A/R MPG X 3 Wheel Bearings (2WD Only) Repack A/R MPG X 4 Wheel Drive Hub Level/Fill Plug 0.
SECTION 1 - SPECIFICATIONS Table 1-6. Lubrication Chart Interval Components 19 Air Filter - Isuzu Number/Type Lube Points Capacity Lube N/A N/A Replaceable Element 3 Months 150 hrs Hours 6 Months 300 hrs 1 Year 600 hrs 2 Years 1200 hrs X Comments Or as indicated by condition indicator NOTES: KEY TO LUBRICANTS Lubrication intervals are based on machine operation under normal conditions.
SECTION 1 - SPECIFICATIONS 1.9 CRITICAL STABILITY WEIGHTS 1.11 FUNCTION SPEEDS (IN SECONDS) 450A Table 1-7.Critical Stability Weights Component Main Boom Lift Up - 22-38 LB. KG. Ford Engine 339 154 Deutz Engine 441 200 Isuzu Engine 389 176 Tele Out - 20-32 6 ft Platform 160 73 Swing - 85-110 5 ft. Platform 145 66 Rotate (Left & Right) - 16-25 4 ft. Platform 130 59 Bolt-on T/T Cwt. (AJ) 487 221 450AJ 12x16.5 pneu. Tire & Wheel 130 59 Main Boom Lift Up - 22-38 12x16.
SECTION 1 - SPECIFICATIONS the machine serial number is stamped on the left side of the frame. 1.12 SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, xxxxxxx SERIAL NUMBER PLATE SERIAL NUMBER STAMPED ON FRAME Figure 1-2.
Figure 1-3.
SECTION 1 - SPECIFICATIONS This page left blank intentionally.
SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 nent is disconnected, cap or cover all openings to prevent entry of foreign matter. GENERAL This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems. 3.
SECTION 2 - PROCEDURES Bearings Hydraulic System 1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing. 1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system. 2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent.
SECTION 2 - PROCEDURES 3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil. 4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
SECTION 2 - PROCEDURES 2.5 VALVES - THEORY OF OPERATION 2.6 BOOM MAINTENANCE Solenoid Control Valve Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit with the opposite work port opening to reservoir.
SECTION 2 - PROCEDURES g. Using all applicable safety precautions, carefully lift boom assembly clear of turntable and lower to ground or suitable supported work surface. 2. Remove the boom from the turntable as follows: a. Disconnect wiring harness from ground control harness connector. Disassembly of the Main Boom 1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments.
SECTION 2 - PROCEDURES 6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary. 6. Using a suitable lifting device, remove telescope cylinder from boom sections. 7. Using a piece of tape, mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly. 8. Remove hardware securing the front wear pads on base boom section, remove wear pads. 7.
SECTION 2 - PROCEDURES 13. Install wear pads at end of base boom section. Using shims, adjust the adjustable wear pads to zero clearance. Adjust pads alternately side to side, so that fly boom section is centered in base boom section. 14. Retract boom section fully. Using shims, adjust wear pads at aft end of boom section to zero clearance. Adjust pads alternately side to side, so that fly boom section is centered in base boom section. 15. Disconnect auxiliary power source from telescope cylinder.
SECTION 2 - PROCEDURES Cylinders With Dual Counterbalance Valves Slave Level, Lift, and Telescope OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 2.8 CYLINDER REPAIR NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly 1. Using all applicable safety precautions, activate hydraulic system.
SECTION 2 - PROCEDURES Figure 2-4.
SECTION 2 - PROCEDURES 7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable. 4. Place the cylinder barrel into a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8.
SECTION 2 - PROCEDURES 12. Remove the bushing from the piston. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary. 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. 10. Inspect threaded portion of head for damage. Dress threads as necessary. 11.
SECTION 2 - PROCEDURES 15. If applicable, inspect port block fittings and holding valve. Replace as necessary. wear ring into the applicable cylinder head gland groove. 16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary. 17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual.
SECTION 2 - PROCEDURES 7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the solid seal.) NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(See magnified insert in Figure 2-13.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other.
SECTION 2 - PROCEDURES b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews. 18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged. 19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder. 20.
SECTION 2 - PROCEDURES Table 2-1.Cylinder Head and Tapered Bushing Torque Specifications Head Torque Value (Wet) Tapered Bushing Torque Value (Wet) Upper Lift Cylinder 50 ft. lbs. (68 Nm) 9 ft. lbs (12 Nm) Upper Lift Cylinder (AJ) 80 ft. lbs. (109 Nm) 9 ft. lbs (12 Nm) Mid Cylinder 80 ft. lbs. (109 Nm) 9 ft. lbs (12 Nm) Lower Cylinder N/A 9 ft. lbs (12 Nm) E.A.R. Cylinder 30 ft. lbs (41 Nm) 5 ft. lbs. (9 Nm) Tele Cylinder N/A 5 ft. lbs. (9 Nm) Level Cylinder 80 ft. lbs. (109 Nm) 5 ft.
SECTION 2 - PROCEDURES 2. Remove port plugs and drain oil from pump. 8. Lift and remove end cover. 3. Use a permanent marker pen to mark a line across the mounting flange, gear housing and end cover. This will assure proper reassembly and rotation of pump. 9. Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts. 4. Remove key from drive shaft if applicable. 10. Remove rear bearing block from drive and idler shafts. 5.
SECTION 2 - PROCEDURES 14. Turn the mounting flange over, with the shaft seal up, and remove the 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 the oil seal from mounting flange, be careful not to mar or scratch the seal bore. 16. Remove the dowel pins from the gear housing. Do not lose pins. 13. Remove the front bearing block.
SECTION 2 - PROCEDURES Inspect Parts For Wear 1. Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be placed as new items. 2. Check drive shaft spine for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway. No marks or grooves on shaft in seal area, some discoloration of shaft is allowable. 3.
SECTION 2 - PROCEDURES General Information It is important that the relationship of the mounting flange, bearing blocks and gear housing is correct. Failure to properly assemble this pump will result with little or no flow at rated pressure. bore. Uniform pressure must be used to prevent misalignment or damage to the seal. Reverse Shaft Rotation of Pump NOTE: This pump is not bi-rotational, if the shaft rotation must be changed the following procedure must be followed.
SECTION 2 - PROCEDURES 5. Place mounting flange, with shaft seal side down, on a clean flat surface. 6. Apply a light coating of petroleum jelly to the exposed face of the front bearing block. 7. Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E-seal pointing to the intake side of the pump. 11. Install two dowel pins in the holes in the mounting flange or two long dowel pins through gear housing if pump is a multiple section pump. 12.
SECTION 2 - PROCEDURES out of the groove. If this is the case, remove the gear housing and check for proper seal installation. the pump and check for assembly problems, then reassemble the pump. 15. Install the two remaining dowel pins in the rear of the gear housing, if applicable, and place the end cover over the back of the pump. 20. The name plate located on the end cover contains the build date code and the model number. Please refer to this information when corresponding with the J.S.
SECTION 2 - PROCEDURES Placing Pump Back Into Service 2. At the positions indicated on the figure titled Swing Bearing Tolerance Boom Placement. Try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position. 1. If shop test stand is available, the following procedure for testing rebuilt pumps is recommended: 3. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank. a.
SECTION 2 - PROCEDURES TO REMOTE Figure 2-18.
SECTION 2 - PROCEDURES Wear Tolerance Replacement of Swing Bearing 1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Mid/Lower Boom stowed, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. Removal of the swing bearing is as follows: 1. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible. 2.
SECTION 2 - PROCEDURES 3. Apply Tribol Molub-Alloy 936 Open Gear Compound to bearing and worm gear teeth. 4. Grease bearing with Mobilith SHC Bearing Grease. Grease fitting is on inside wall of inner race of bearing. NOTE: If Tribol Molub-Alloy 936 Open Gear Compound or Mobilith SHC Bearing Grease are not available, Multi-Purpose Grease (MPG) can be substituted, however the service interval will be shorter. 5.
SECTION 2 - PROCEDURES 2.12 WORM GEAR Fig 2 Adjusting End Play. Checking Worm Gear End Play NOTE: JLG Industries requires that a annual inspection be performed on the worm gear end play. 1. Using a dial indicator, measure end play of worm gear, by applying side to side movement by hand to platform. 2. If tolerance exceeds 0.010", reduce end play to less than 0.005". Refer to Adjusting End Play. SHIMS Parts Required 7016682 Shim Kit Includes; 3 of 0.005" thick shims 3 of 0.0075" thick shims 3 of 0.
SECTION 2 - PROCEDURES 3. Crack the bleeder screw at the bottom of the cylinder. 2.14 JIB 4. Operate the drive function until no air is coming out of the bleeder valve. Removal 1. Place the Jib in a horizontal position and support the complete assembly with adequate blocking. 5. Close the bleeder valve. 2. Remove the Platform as follows: 6. Engage the hubs and repeat steps 1 thru 5 for the opposite side of the machine. a. Disconnect the electrical connectors going into the platform control box. 7.
SECTION 2 - PROCEDURES 4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block. 12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. 5. Carefully activate SWING control lever and position boom over right side of machine. 13. Have an assistant check to see that right front wheel remains locked in position off of ground. 6.
SECTION 2 - PROCEDURES 2.17 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE 1. With the turntable centered, adjust the bracket with the washers to push the plunger in 5/16" ± 1/16". WASHER BRACKET LOCKOUT VALVE Figure 2-25. Ring Gear/Cover Carrier Disassembly 2. The ideal adjustment is 3/8". Do not push the plunger in more that 3/8". The extra adjustment is needed for the turntable bearing play. 2.18 TORQUE HUB (PRIOR TO S/N 39594) Ring Gear/Cover Disassembly 1.
SECTION 2 - PROCEDURES 6. Remove the carrier (8) along with the sun gear (28). 5. Repeat steps 2 thru 4 for the remaining two planet gears. 7. Remove the input shaft (29). Take out the bottom thrust washer (27). 6. Remove the bearing needles (13) and the thrust spacer (14) from the planet gear (11). 8. Take off the thrust washer (30) from the spindle counterbore. Hub-Spindle Disassembly 9. Remove the internal gear (31) from the spindle (21). NOTE: If your unit does not have studs, then skip step 1.
SECTION 2 - PROCEDURES Figure 2-27.
SECTION 2 - PROCEDURES Figure 2-28.
SECTION 2 - PROCEDURES 6. Place the assembled planet gear (11), large end towards the roll pin onto the planet shaft (10). 5. With the housing still in the stud fixture, with a seal pressing fixture, press the seal (34) with the closed face up into the small diameter of the housing. 7. Push the planet shaft (10) through until it reaches the other side of the planet gear (11).
SECTION 2 - PROCEDURES 10. Install carrier sub-assembly with sun gear (28) onto input shaft (29) and into internal gear (31). Rotate the carrier to insure that the timing is correct. 6. Remove thrust washer (11) from the counterbore in top of carrier (3A). 7. Remove input gear (8) from the middle of carrier sub-assembly. 11. Place second washer (27) into the counterbore of the carrier(8). 12.
SECTION 2 - PROCEDURES Figure 2-29.
SECTION 2 - PROCEDURES 3. Set hub (1G), small end/spindle facing down, up on something that will support the hub’s flange while it lifts hub up so spindle is not resting on anything. Carefully press or hammer spindle (1A) down out of hub (1G). Carrier Disassembly NOTE: When you remove the needle rollers from the cluster gears, discard the old needle rollers and use new ones during re-assembly.
SECTION 2 - PROCEDURES 2. Place one spacer (3D) inside cluster gear (3F) so that it rests on top of the needle rollers. 3. Line the remaining half of cluster gear (3F) with 16 needle rollers. 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). 3120749 – JLG Lift – 5. Place one thrust washer (3B) onto the end of planet shaft (3E) inside carrier.
SECTION 2 - PROCEDURES 8. Use an alignment punch or similar tool to align the roll pin holes in carrier housing (3A) and planet shaft (3E). 2. Place the o-ring (6G) onto the cover cap (6B) so that it rests against the flange of the cover cap. 3. Insert disconnect rod (6E) into cover cap (6B). 9. Drive roll pin (3G) down into the aligned roll pin holes in carrier housing (3A) and planet shaft (3E). 10. Repeat steps 1 thru 9 to assemble and install the two remaining cluster gears. 4.
SECTION 2 - PROCEDURES 5. Place two of the cover cap bolts (6C) into any two bolt hoes that are 180° apart on the cover cap (6B) and tighten bolts. 8. Place the two remaining bolts (6C) into the bolt holes in the disconnect cap (6D), and tighten the bolts. 6. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of torque to both bolts (6C). 9. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of torque to both bolts (6C). 7.
SECTION 2 - PROCEDURES Hub-Spindle Sub-Assembly NOTE: Make sure the cup sits square with the counterbore before pressing. 4. Turn hub (1G) over onto its small end. Press bearing cup (1E) down into the counterbore in the deep end of the hub (1G). 1. Set hub (1G) onto its large end. Press bearing cup (1C) into the counterbore in the small end of the hub (1G). 5. Set hub (1G) onto its large end. Place bearing cone (1D) into bearing cup (1C). 2. Press the nine studs (1N) into the stud holes in hub (1G).
SECTION 2 - PROCEDURES 7. Oil spindle, then lower hub (1G), small end down, onto spindle (1A). 10. Place retaining ring (1I) over the spacer onto spindle (1A) in hub (1G). 8. Press bearing cone (1F) onto spindle (1A) in hub (1G). Main Assembly BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING 1. Grease o-ring (5) and place it into the counterbore in hub (1G). NOTE: O-ring may be stretched or pinched together to make it fit the counterbore exactly. 9.
SECTION 2 - PROCEDURES 2. Oil all exposed surfaces inside hub (1G). 5. Stand input shaft (7A) on its splined end. Place one spacer (7D) onto the smooth end of input shaft (7A). 3. Place internal gear (2) into hub (1G) so that its internal splines mesh with the external splines of spindle (1A). Oil internal gear (2). 6. Place one spring (7C) onto the smooth end of input shaft (7A). 4. Place thrust washer (11) around spindle (1A) so it rests on the bottom of the internal gear (2). 7.
SECTION 2 - PROCEDURES 8. Using retaining ring pliers, insert retaining ring (7B) into the groove on input shaft (7A) by compressing the spring and spacers together. 9. With large splined end down, place input shaft subassembly (7) into spindle (1A). 10. Place thrust spacer (9) onto input shaft (7). 11. Set carrier sub-assembly (3) on a flat work surface so the large ends of cluster gears (3F) face up. Locate the punch marks on the face of each cluster gear (3F) and position them at 12 o’clock.
SECTION 2 - PROCEDURES 12. With "X" marked side facing up, place the ring gear (4) around cluster gears (3F). NOTE: This will hold the punch marks in position while installing the carrier into the hub. 13. Place the carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning the "X" marked shoulder bolt hole in the ring gear (4) over one of the shoulder bolt holes in the hub. Mark the location of shoulder bolt holes on the outside of ring gear and hub. 14.
SECTION 2 - PROCEDURES 17. Place cover sub-assembly (6) onto ring gear (4), aligning the pipe plug holes according to the alignment prior to disassembly. 23. Turn hub (1G) over onto its side. Insert coupling (14) into the end of the spindle (1A). 24. Roll test the unit in both clockwise and counterclockwise directions. Perform the 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. 25.
SECTION 2 - PROCEDURES 25 1 3 2 4 5 6 7 8 9 10 11 12 14 12 14 15 16 17 18 19 22 21 23 24 25 1. 2. 3. 4. 5. 6. 7. 8. 9. Housing Gasket Torque Pin Ball Bearing Retaining Ring Seal Spring Retainer Small Compression Spring Large Compression Spring 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Primary Disc Rotating Disc Not Used Stationary Disc Piston Back-up Ring O-ring Back-up Ring 19. 20. 21. 22. 23. 24. 25. O-ring Bleeder Screw Power Plate Protective Plug Washer Bolt Gasket Figure 2-31.
SECTION 2 - PROCEDURES Assembly 8. For replacement of the seal; a. Use a shop press to install the bearing (4) into the housing. Press on the outer surface of the bearing only. Install the retaining ring (5) into the groove. THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES. CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY. IN THE CASE OF SPRINGS, SPACE THE SPRINGS AS SHOWN IN THE FIGURE. b. Press the seal (6) into the housing (1) until it is flush with the face of the housing.
SECTION 2 - PROCEDURES Functional Check 2.21 BOOM LIMIT SWITCHES There are no adjustments to be made to the two boom limit switches which bolt in place on the uprights. 2.22 LIFT UP AND PLATFORM LEVEL DOWN DISABLE SWITCH DISABLE SWITCH FUNCTIONAL CHECK MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 1. Tape a small piece of metal to the end of the limit switch (e.g. a coin).
SECTION 2 - PROCEDURES Quick-start Installations If you are experienced in installing and adjusting Electric Governor, follow these steps. Otherwise, refer to the more detailed instructions starting with MOUNTING-ACTUATOR. The following sketch indicates the proper linkage geometry for most installations. 70 degrees 1. Mount Actuator rigidly to engine location which will permit a short, straight linkage to the carburetor or fuel valve. Avoid very hot areas. Spring-loaded to idle Engine at idle 2.
SECTION 2 - PROCEDURES The needed travel of the carburetor determines how far out on the Actuator arm the rod is to be attached. In most cases, the carburetor should be moved from closed to above 10 degrees from full open as the Actuator is moved min. to max. THEN ALTER THE LENGTH OF THE ROD SLIGHTLY (PERHAPS 0.030"), SO THAT THE ACTUATOR IS JUST OFF ITS INTERNAL STOP, AND IS PULLING THE BUTTERFLY AGAINST ITS STOP.
SECTION 2 - PROCEDURES Single-Turn Adjustment (Gain, Factory Adjust) This pot is 3/8" square and has a 1/8" plastic screw in its center. Be gentle! This pot turns 270 degrees, and overturning will break the internal stops, making adjustment impossible. Turning this pot CW increase Governor sensitivity. On most applications, best operation is achieved with the pot set as shown in diagram below. NOTE: These settings are factory set, Start Lockout, Factory Adjust and Overspeed.
SECTION 2 - PROCEDURES 9. The overspeed adjustment is factory set. If necessary, it may be readjusted to shut off ignition power at a different engine speed by means of the overspeed adjustment pot. The overspeed is simply to shut down an over revving engine. 2. Incorrect Linkage - Re-check linkage as discussed on page 40 and 41. Freedom of movement and lack of play are important. 3.
SECTION 2 - PROCEDURES 3120749 – JLG Lift – 2-53
SECTION 2 - PROCEDURES d. By carefully varying engine speed, you should be able to cause the Governor arm to pause momentarily near the middle of its travel. This engine speed is the speed for which the Governor is adjusted. If grossly incorrect, reset High Engine Pot. Governor is unstable at light-load or no-load. See Linkage for carbureted engines.c. Governor experiences sudden, momentary spikes toward max. at random intervals, then recovers. a. Look for loose wiring or momentary shorts in wiring. e.
SECTION 2 - PROCEDURES 2.24 FORD EFI ENGINE (MACHINES AFTER S/N 46089) Performing Diagnostics 1. Verify the complaint and determine if it is a deviation from normal operation. 2. Once the complaint has been verified, preliminary checks can be done. Conduct a thorough visual inspection, be alert for unusual sounds or odors, and gather diagnostic trouble code information. 3. Perform a system check that will verify the proper operation of the system in question and check for recent information updates.
SECTION 2 - PROCEDURES When reading Diagnostic Trouble Codes thru the MIL, the following conditions apply: • The flashing MIL is on for 0.4 second and off for 0.4 second. • The MIL is off for 1.2 seconds between digits of two digit DTCs. • The MIL is off for 2.4 seconds between DTCs. • Each DTC repeats 3 times before the next stored DTC begins flashing. • Up to 6 DTCs can be stored. • Once all stored DTCs are flashed, the process repeats with the first stored DTC.
SECTION 2 - PROCEDURES Table 2-4.
SECTION 2 - PROCEDURES ENGINE COOLANT TEMPERATURE (ECT) SENSOR HEATED OXYGEN SENSOR The engine coolant temperature (ECT) sensor is a g 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.
Figure 2-35.
SECTION 2 - PROCEDURES INTAKE AIR TEMPERATURE (IAT) SENSOR The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the 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 5-volt signal to the sensor through a resistor in the ECM and monitors the signal voltage.
SECTION 2 - PROCEDURES The ECM is designed to maintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency. The ECM monitors numerous engine functions via electronic sensors such as the throttle position (TP) sensor and the heated oxygen sensor (HO2S). • When measuring voltages, use only a digital voltmeter with an input impedance of at least 10 megohms. • Do not jump start with more than 12 volts.
SECTION 2 - PROCEDURES ELECTROSTATIC DISCHARGE DAMAGE Electronic components used in the ECM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, It takes as much as 4000 volts for a person to feel the spark of a static discharge. There are several ways for a person to become statically charged.
SECTION 2 - PROCEDURES HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 2-36. Typical Fuel System FUEL METERING SYSTEM PURPOSE The basic function of the air/fuel metering system is to control the 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. The ECM monitors signals from several sensors in order to determine the fuel needs of the engine.
SECTION 2 - PROCEDURES FUEL PRESSURE REGULATOR The fuel pressure regulator is a relief valve mounted in the fuel filter. It provides a constant fuel pressure of 441 kPa (64 psi). ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2.5L EFI industrial engine, throttle control is achieved by using an electronic governor which is controlled by the engine control module (ECM). If the pressure is too low, poor performance and a DTC 32 will set. If the pressure is too high, excessive odor and/or a DTC 42 will result.
SECTION 2 - PROCEDURES OPEN LOOP AND CLOSED LOOP OPERATION CRANKSHAFT POSITION (CKP) SENSOR The ECM will operate in the following two modes: The crankshaft position (CKP) sensor provides a signal used by the engine control module (ECM) to calculate the ignition sequence. The sensor initiates the reference pulses which the ECM uses to calculate RPM and crankshaft position. • Open loop • Closed loop When the engine is first started, the system is in "open loop" operation.
SECTION 2 - PROCEDURES IGNITION COIL The electronic ignition system uses a coil pack with one ignition coil for each two cylinders in the engine. Each cylinder is paired with its opposing cylinder in the firing order, so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust. The spark that occurs in the cylinder on the exhaust stroke is referred to as a "waste spark.
SECTION 2 - PROCEDURES Both outputs are linear between the Threshold setting and their respective setting. The controller is in the Hi Range mode when 12 volts is applied to the (R) terminal. As a fail safe, when system voltage is removed from the (R) terminal, the Lo Range feature is active. I.R.S (Integrated Ramp System) This controller is calibrated to provide a maximum ramp time of 2 seconds.
SECTION 2 - PROCEDURES 2.26 LIFT AND SWING CONTROLLER 2.27 FUNCTION CONTROL Adjustment Rotary Selector Controller Theory & Definitions This Rotary Selector Controller is specifically designed and manufactured to provide a proportional output to a HYDRAFORCE flow control electro-hydraulic valve. The Rotary Selector Controller you are about to calibrate has the following features: Figure 2-38. Lift and Swing Adjustment NOTE: The following procedures are for a preliminary adjustment.
SECTION 2 - PROCEDURES Dual Range This Rotary Selector Controller is capable of providing two, independently adjustable, maximum output ranges with the same amount of handle travel. The Hi Range would normally be adjusted for full flow (maximum function speed) of the valve at full handle travel. The LO Range would provide some portion of the Hi Range setting, providing reduced oil flow to the valve, with the handle at full travel.
SECTION 2 - PROCEDURES 1. Power the ignition switch at the ground control panel. Set the mid rpm. 2.28 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ ENGINE 2. Supply 12 volts of power to the white wire on the controller. Set the high engine rpm. General The throttle control system on the Deutz engine includes the positional controller and the actuator. NOTE: Actuator rod travel must stop slightly before lever makes contact with throttle lever stop. Failure to do so will burn out actuator.
SECTION 2 - PROCEDURES or Clutch engaged actuator retracting then Controller fault - clutch disengaged and no actuator movement Action: Failure Modes 1. Inspect and clean wiring connections. Immediate Red Light 2. Examine throttle linkage for any damage or bent components and correct. 3. With linkage disconnected, check each potentiometer for operation. 4. Reconnect linkage and reset each potentiometer for correct operation. 5. If failure continues to occur, replace unit.
SECTION 2 - PROCEDURES 2.29 AUTOMATIC CHOKE ADJUSTMENT FORD ENGINE 2.30 COLD WEATHER STARTING DIFFICULTY 1. At 70°F the choke plate should be open 1/32" (not touching the choke bore). 2. If the ambient temperature is not 70°F, an additional adjustment is required. a. Loosen the three cover plate screws. b. Adjust the cover to open the choke plate 1/32". Machines equipped with carbureted Ford LRG-425 engines in weather conditions of 15 to 20° F (-9.5 to -6.
SECTION 2 - PROCEDURES Checking the Carburetor 3. Check the choke pull-off (butterfly stop) screw for proper adjustment as follows: After cranking the engine for a period of time there may be white smoke noticed coming out of the exhaust tube. This is an indication the engine is receiving fuel and is in a “flooded” condition. NOTE: Make sure the choke is adjusted using the asterisk (*). There is also a zero (0) stamped on the choke.
SECTION 2 - PROCEDURES a. Ignition module series: AA, AB and FA prior to date code-1889 may need replaced. (refer to: Ford Technical Bulletin # FF-91-99) b. Check the vacuum advance tube attached to the ignition module for secure connection. Try to start the engine. 2.32 TILT ALARM SWITCH PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH. Manual Adjustment 2.
SECTION 2 - PROCEDURES Figure 2-42.
SECTION 2 - PROCEDURES Figure 2-43.
SECTION 2 - PROCEDURES FR O N T REAR FLOW DIVIDER HIGH SPEED VALVE BYPASS VALVE FRONT FLOW DIVIDER TWO WHEEL/FOUR WHEEL VALVE Figure 2-44.
SECTION 2 - PROCEDURES Bang-Bang Sequence Valve Platform Level Retract 1. Install the pressure gauge at port G2 on the Main Valve. 1. Remove the hose from port B1 on the Main Valve and cap it. 2. Energize the main dump valve by applying 12 volts to pin 14 at the ground control box. The gauge should read between 230 and 325 psi (16 and 22.5 bar). This valve is non-adjustable. 2. Install a pressure gauge into port B1. 3. Activate the level down function and hold. 4.
SECTION 2 - PROCEDURES oil, a vacuum reading should be taken at the inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher than it is capable of. 2.34 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS 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.
SECTION 2 - PROCEDURES sure is inadequate, shut down and determine the cause for improper pressure. INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR’ S ABILITY TO CONTROL THE MACHINE. Shut down the engine and connect the external control input signal. Also reconnect the machine function(s), if disconnected earlier. Start the engine, checking to be certain the pump remains in neutral. With the engine at normal operating RPM, slowly check for forward and reverse machine operation.
SECTION 2 - PROCEDURES Assuming Normal Wear It is normal for the bushing to wear down to the bolt and for the link hole to wear oblong till it is ready to break out the end. To adjust the slack measurement, move the bolts from the first hole to the second to create less slack, or from the second to the first to create more slack. Adjustment IMPROPER SLACK ADJUSTMENT COULD CAUSE TRACK PARTS TO BREAK. Place a straight edge long enough to reach from the idler to the drive wheel on the tracks.
SECTION 2 - PROCEDURES 2.36 HOSE AND CABLE INSTALLATION AND ROUTING When installing replacment hoses or cable, it is important that the new hoses and cables are routed as shown to ensure maximum service life. Figure 2-45.
SECTION 2 - PROCEDURES Figure 2-46.
SECTION 2 - PROCEDURES Figure 2-47.
SECTION 2 - PROCEDURES Figure 2-48.
SECTION 2 - PROCEDURES Figure 2-49.
SECTION 2 - PROCEDURES The inspection and maintenance code numbers are as follows: 2.37 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 1. Check for proper and secure installation. The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the "AREA" to be inspected, and the "INTERVAL" at which the inspection is to take place.
SECTION 2 - PROCEDURES Table 2-7.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY BOOM 1. Platform 1,4 2. Platform Gate 1,4 3. Platform Rotator 4. Footswitch 5. Controllers 1,11 6. Switches 1,11 7 Lift Up/Platform Down Disable Switch* 7. Placards and Decals 1,2 8. Control Tags 1,2 9. Valves 1,11 5,6 10. Carrier (Hoses and Cables) 1 4,8 11. Lockout Cylinders (If equipped) 1 5 12. Pins 8 13.
SECTION 2 - PROCEDURES Table 2-7.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY MONTHLY WEEKLY 3 MONTH 6 MONTH YEARLY TURNTABLE 1. Engine Oil (see mfg. manual) 3 5 2. Battery 3 5 3. Radiator 3 5 4. Air Cleaner 1 14 5. Exhaust System 1 1,5 6. Spark Arrester 1 1,5 7. Engine Mount 8. Ground Controls 1,2,11 9. Main Hydraulic Pump 1 5 10. Auxiliary Power Pump 1 5 11. Valves 1,11 5 12. Hydraulic Filters 14 5 13. Hydraulic Hoses 1 5 14.
SECTION 2 - PROCEDURES Table 2-7.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY MONTHLY WEEKLY 3 MONTH 6 MONTH YEARLY CHASSIS 1. Wheel and Tire Assembly 2. Drive Motors 1,5,6 3. Drive Torque Hubs** 1,5,6 4. Drive Brakes 1,5,6 5. Steer Cylinders 1 1,5,6,13 6. Steer Components 1 4,6 8 7. Lockout Cylinders (if equipped)* 1 5,13 8 8. Hydraulic Hoses 1 9. Placards and Decals 1,2 10. Wheel Bearings 11.
SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 3.2 TROUBLESHOOTING.
SECTION 3 - TROUBLESHOOTING . Table 3-1.Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Automatic leveling inoperative. Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on slave cylinder or main lift cylinder. Clean, repair, or replace line or fitting. Worn seal(s) in slave level or main lift cylinder. Replace seal(s).
SECTION 3 - TROUBLESHOOTING . Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature buildup. Flush system and change oil using recommended viscosity Moisture in oil. Flush system and change oil using recommended viscosity Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting. Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Control valve not functioning properly. Repair or replace valve. Lift cylinder not functioning properly. Repair or replace cylinder Lift function not activated within 7 seconds after footswitch was depressed. Recycle footswitch. Load capacity exceeded (personnel or equipment on platform). Reduce load.(Refer to capacity placard.) Hydraulic system oil low. Replenish oil as necessary.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function Speed, Drive Speed and High Engine does not operate below horizontal. Damaged wiring on level limit switch. Repair or replace wiring. Solenoid failure. Replace solenoid. Tripped circuit breaker. Reset circuit breaker. Damaged level limit switch. Replace switch, repair or replace holder. Defective relay, main terminal box. Replace relay. Defective platform switch. Replace switch.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom extends and retracts erratically. Hydraulic system oil low. Replenish oil as necessary. Wear pads worn. Replace pads as required. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Control valve not functioning properly. Repair or replace valve. Worn seals in telescope cylinder. Replace seals. Cylinder not functioning properly.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction. 3120749 Hydraulic system oil low. Replenish oil as necessary. Lack of lubricant on swing gear or speed reducer pinion. Lubricate as required. (See Lubrication Chart.) Swing motor not functioning properly. Repair or replace swing control switch. Worn or broken teeth on swing gear or swing motor pinion. Replace gear(s) as required.
SECTION 3 - TROUBLESHOOTING . Table 3-3.Turntable Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVE. Valve Spool Sticking. Dirt in oil causing excessive temperature builtup. Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting.Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary. Return spring weak or broken.
SECTION 3 - TROUBLESHOOTING . Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY POWER PLANT. Engine will not start. Station power selector switch not in required position. Actuate switch as required. Circuit breaker open. Determine and correct cause; reset circuit breaker. Defective starter motor. Replace starter motor. Damaged wiring in ignition circuit (broken wire on starter). Repair, replace wiring. Ignition switch not functioning properly. Replace switch.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Engine worn badly. Rebuild engine. Engine improperly timed. Time engine. Engine overheating. Determine cause of overheating and remedy. Dirty fuel filter. Replace filter. Fuel line pinched. Replace fuel line. Throttle governor not working properly. Repair or replace governor. Governor not adjusted properly. Correctly adjust governor. Fuel tank overfilled.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Drive wheel tire treads worn smooth. Replace tires as necessary and inflate to specified pressure. Drive brakes "dragging". Re-adjust pressure. System pressure too low. Re-adjust pressure. Drive hub(s) defective. Repair or replace hub. Engine RPM’s not set. Correctly set engine RPM. Drive motors worn. Repair or replace drive motors. Counterbalance valve defective.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Motor turns slowly in the direction of the last command. Valve not returning to neutral. Check neutral springs. Function speed switch malfunction. Replace function switch. Sticking spool due to contamination. Remove end cap and check spool freedom. Repair as necessary. Valve spool is not traveling far enough due to: Repair or replace drive motor(s). Worn, leaking drive motor(s).
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY If equipped, swivel coupling leaking internally. (Seals defective.) Repair or replace coupling. Steer control valve not functioning properly. Repair or replace valve. Steer cylinder not functioning properly. Repair or replace cylinder. Hydraulic system oil low. Replenish oil as necessary. Restricted hydraulic line or fitting. Clean, repair or replace line or fitting.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine wanders; steering not firm. 3-14 Crossover relief valve set too low or not functioning properly. Reset, repair or replace valve as required. Steer linkages loose. Tighten linkage. Steer wheel toe-in not set properly. Adjust toe-in for 1/4 inch overall. Spindle bushings badly worn. Replace bushings.
SECTION 3 - TROUBLESHOOTING . Table 3-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEMS - GENERAL. Hydraulic pump noisy. Air entering system through broken line or fitting. (Suction Side.) Repair or replace line or fitting. Suction screen dirty. Clean suction screen. Air bubbles in oil. (Reservoir oil too low. Replenish oil as required. Suction hose squeezed shut. Determine cause and repair. Oil filter dirty. Replace hydraulic filter.
SECTION 3 - TROUBLESHOOTING Table 3-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pump not delivering oil. Restricted suction line. Clean, repair, or replace line. Air entering system through broken line or fitting. Repair or replace line or fitting. Broken pump drive shaft/pump coupling. Repair or replace pump/pump coupling. Note: Any time pump or pump drive coupling is removed coat pump and drive coupling splines with Lithium Soap Base Grease (TEXACO CODE 1912 OR EQUIVALENT).
SECTION 3 - TROUBLESHOOTING Table 3-5.Hydraulic System - Troubleshooting TROUBLE 3120749 PROBABLE CAUSE REMEDY Damaged wiring on control switch or auxiliary pump. See proper wiring diagram. Control switch not functioning properly. Replace switch. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Pump motor solenoid not functioning properly. Replace solenoid. Pump motor not functioning properly. Repair or replace motor.
SECTION 3 - TROUBLESHOOTING . Table 3-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS. No power to platform controls. 15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary. Contact block in footswitch malfunctioning. Repair, replace or adjust contact block as required. Faulty power circuit wiring. Check wiring continuity.
SECTION 3 - TROUBLESHOOTING Table 3-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY INSTRUMENTS AND INDICATORS. Travel warning horn inoperative. Circuit breaker open. Determine and correct cause; reset circuit breaker. Damaged wiring in horn circuit. Repair or replace wiring. Damaged horn. Replace horn. Damaged wiring in hourmeter circuit. Repair or replace wiring. Defective pressure switch. Replace pressure switch. Inoperative hourmeter. Replace hourmeter.
SECTION 3 - TROUBLESHOOTING Figure 3-1.
SECTION 3 - TROUBLESHOOTING Figure 3-2.
SECTION 3 - TROUBLESHOOTING Figure 3-3.
SECTION 3 - TROUBLESHOOTING 1870101A Figure 3-4.
SECTION 3 - TROUBLESHOOTING Figure 3-5.
SECTION 3 - TROUBLESHOOTING 1870101A Figure 3-6.
SECTION 3 - TROUBLESHOOTING Figure 3-7.
SECTION 3 - TROUBLESHOOTING 1870099B Figure 3-8.
SECTION 3 - TROUBLESHOOTING Figure 3-9.
SECTION 3 - TROUBLESHOOTING 1870085C Figure 3-10.
SECTION 3 - TROUBLESHOOTING Figure 3-11.
SECTION 3 - TROUBLESHOOTING 1870085C Figure 3-12.
SECTION 3 - TROUBLESHOOTING Figure 3-13.
SECTION 3 - TROUBLESHOOTING 1870098A Figure 3-14.
SECTION 3 - TROUBLESHOOTING Figure 3-15.
SECTION 3 - TROUBLESHOOTING 1870098A Figure 3-16.
SECTION 3 - TROUBLESHOOTING Figure 3-17.
SECTION 3 - TROUBLESHOOTING 2792372D Figure 3-14.
SECTION 3 - TROUBLESHOOTING Figure 3-14.
SECTION 3 - TROUBLESHOOTING 2792372D Figure 3-14.
SECTION 3 - TROUBLESHOOTING Figure 3-14.
SECTION 3 - TROUBLESHOOTING 2792372D Figure 3-14.
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Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
