Service Manual Instruction Manual

ManualsBrandsJLG ManualsSpecial machinery660AJ

Table Of Contents

Service and Maintenance Manual

Model

600A

660AJ

S/N 0300176000

to Present

P/N - 3121616

January 8, 2014

Summary of content (334 pages)

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Service and Maintenance Manual Model 600A 660AJ S/N 0300176000 to Present P/N - 3121616 January 8, 2014
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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 the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue A-2 - January 8, 2014 – JLG Lift – 3121616
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TABLE OF CONTENTS SECTION NO. SECTION A B C SECTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 SECTION 2.1 2.2 2.3 2.4 2.5 2.6 3121616 TITLE PAGE NO. A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. SECTION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 ii TITLE PAGE NO. 3 - CHASSIS & TURNTABLE Tires And Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tire Damage . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3121616 TITLE PAGE NO. Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.21 SECTION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 SECTION 5.1 5.2 iv TITLE PAGE NO. Check/Drain Oil Build-Up In 2-Stage Vaporizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Air Fuel Mixer/Throttle Control Device Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Exhaust System And Catalytic Converter Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 5.3 5.4 5.5 5.6 5.7 3121616 TITLE PAGE NO. Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder. . . . . . . . . . . . . . . . . . Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 5.8 5.9 SECTION 6.1 6.2 6.3 6.4 SECTION 7.1 7.2 7.3 7.4 7.5 vi TITLE PAGE NO. Shaft Seal and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Charge 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. 2-1. 2-2. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41. 3-42. 3-43. 3-44. 3-45. 3-46. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3121616 TITLE PAGE NO. Operator Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 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. 3-97. 3-98. 3-99. 3-100. 3-101. 3-102. 3-103. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 5-1. 5-2. viii TITLE PAGE NO. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 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. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 5-43. 5-44. 5-45. 5-46. 5-47. 5-48. 5-49. 5-50. 5-51. 5-52. 5-53. 5-54. 5-55. 5-56. 5-57. 5-58. 5-59. 5-60. 5-61. 5-62. 5-63. 5-64. 5-65. 3121616 TITLE PAGE NO. Telescope and Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-66. 5-67. 5-68. 5-69. 5-70. 5-71. 5-72. 5-73. 5-74. 5-75. 5-76. 5-77. 5-78. 5-79. 5-80. 5-81. 5-82. 5-83. 5-84. 5-85. 5-86. 5-87. 5-88. 5-89. 5-90. 5-91. 5-92. 5-93. 5-94. 5-95. 5-96. 5-97. 5-98. 5-99. 5-100. 5-101. 5-102. 5-103. 5-104. 5-105. 5-106. 5-107. 5-108. 5-109. 5-110. 5-111. 5-112. 5-113. 5-114. 5-115. 5-116. 5-117. 5-118. 5-119. 5-120. 5-121. 5-122. 5-123. 5-124. 5-125. 5-126. 5-127. 5-128. x TITLE PAGE NO. Rod Seal Installation . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 5-129. 5-130. 5-131. 5-132. 5-133. 5-134. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 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. 7-34. 7-35. 7-36. 7-37. 7-38. 7-39. 3121616 TITLE PAGE NO. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 4-1 5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 xii TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-2. Dimensional Data Table 1-1.
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SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES 1.5 ENGINE DATA Table 1-3. Capacities Table 1-5. Deutz TD 2.9 Specifications Fuel Tank 30 gal (113.6 L) Hydraulic Oil Tank Ultra Low Sulfur Diesel (15 ppm) Output 67 hp (50 kW) 40 gal (121 L) Torque 173 ft.lbs. (234 Nm) @ 1800rpm Hydraulic System (Including Tank) Torque Hub, Drive* 20 oz (0.6 L) Engine Crankcase Deutz D2011L04 Deutz 2.9 L 04 GM 3.0 Fuel 30.6 gal (115.8 L) 11 qt (10.5 L) 2.4 gal (8.9 L) w/Filter 4.5 qt (4.
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SECTION 1 - SPECIFICATIONS Platform Rotate: Platform level and completely rotated one direction. Rotate opposite direction, record time. Rotate other direction, record time. 1.6 FUNCTION SPEEDS Table 1-8.
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SECTION 1 - SPECIFICATIONS 1.8 HYDRAULIC OIL Table 1-12. Mobile DTE 10 Excel 32 Table 1-10. 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) 10W-20, 10W30 +50° to + 210° F (+10° to +99° C 20W-20 NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types. They may not contain required additives or be of comparable viscosities.
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SECTION 1 - SPECIFICATIONS Table 1-14. Mobil EAL 224 Type Synthetic Biodegradable ISO Viscosity Grade 46 Specific Gravity .922 Pour Point -25°F (-32°C) Flash Point 428°F (220°C) Operating Temp. 0 to 180°F (-17 to 162°C) Weight 7.64 lb. per gal. (0.9 kg per liter) Viscosity at 40° C 37 cSt at 100° C 8.4 cSt Viscosity Index 213 1.
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SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance and Lubrication 1. Swing Bearing 1.10 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 1-1., Operator Maintenance and Lubrication. Table 1-18. Lubrication Specifications. KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
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SECTION 1 - SPECIFICATIONS 5. Wheel Drive Hub 2. Wheel Bearings (If equipped) Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation 3. Swing Drive Hub 6. Hydraulic Return Filter 4. Lube Point(s) - Level/Fill Plug Capacity - 43 oz. (1.
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SECTION 1 - SPECIFICATIONS 7. Hydraulic Charge Filter 9. Oil Change w/Filter - Deutz 2011 Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter, or as shown by Condition Indicator. 8. Hydraulic Tank Lube Point(s) - Fill Cap Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual.
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SECTION 1 - SPECIFICATIONS 10. Oil Change w/Filter - Deutz D2.9 11. Air Filter - Deutz D2.9 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 8.45 Qt (8 L) Crankcase and Filter Interval - Every Year or 600 hours of operation Comments - Check level daily/Change in accordance with engine manual.
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SECTION 1 - SPECIFICATIONS 1. Oil Change w/Filter - GM 5. Air Filter 2. Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 6. Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 7. 2-Stage Vaporizer (LP only) 3.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Size TPI Bolt Dia Torque (Dry) Tensile Clamp Load Stress Area Torque Lubricated TM Loctite® 242 Vibra-TITE 4 6 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 NOTES: TM or 271 TM 111 or 140 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
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SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
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SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121616
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE Annual Machine Inspection General This section provides information needed by personnel responsible to place machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure all necessary inspections and maintenance have been completed before placing machine in service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or at each Operator change. User or Operator User or Operator Operation and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL 2. Component Disassembly and Reassembly Complete procedural 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 is 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 Lubrication Specifications Hydraulic System 1. 2. 3. 4. The primary enemy of a hydraulic system is contamination. Contaminants can enter the system by using inadequate hydraulic oil; allowing moisture, grease, filings, or other contaminants to enter during maintenance; or allowing the pump to cavitate due to insufficient system warm-up or leaks in pump supply (suction) lines.
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SECTION 2 - GENERAL 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES 2.6 NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external structure, or component, Filament wound bearings. 1. Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment: a. Excessive sloppiness in joints. • Disconnect battery. b. Noise originating from joint during operation. 2.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL
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SECTION 2 - GENERAL ! " ! ! # " ! # ! $ & ! & % ! ! " " $ " " " $ ! ! ! $
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS 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. Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure all tires are inflated to pressure recommended by JLG.
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SECTION 3 - CHASSIS & TURNTABLE 3. Torque to specifications shown in Table 3-1 below. LEAK TEST The purpose of a leak test is to make sure unit is air tight. You can tell if your unit has a leak if pressure gauge test reading starts to fall once you have pressurized the unit. Table 3-1. Wheel Torque Chart TORQUE SEQUENCE 4. 1st Stage 2nd Stage 3rd Stage 40 ft-lb (55 Nm) 100 ft-lb (130 Nm) 170 ft-lb (255 Nm) Torque wheel nuts after first 50 hours of operation and after each wheel removal.
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SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Seal 1C. Bearing 1D. Housing 1E. Ring Gear 1F. Bearing Nut 1G. Setscrew 1H. Wheel Stud 1K. Retaining Ring 1L. Spring 1M. Thrustwasher 2. Thrustwasher 3A. Carrier 3B. Thrustwasher 3C. Needle Bearing 3E. Planet Shaft 3F. Planet Gear 4B. Thrustwasher 4C. Needle Bearing 4D.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: Carefully pressurize unit with air to pop cover off. Main Disassembly 1. Perform Roll Check, Leak Check, and Brake Check if applicable before disassembly. 2. Drain oil from unit. Note condition and volume of oil. 3. Remove Retaining Ring (6G) by prying open end of Retaining Ring out of groove in Ring Gear (1E) with a screwdriver. Grasp loose end with pliers and pull out Retaining Ring. 4. Remove Cover Subassembly (6). 5. Remove Input Carrier Subassembly (3).
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SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 11. Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet Shaft (4E) until it bottoms against Spindle (1A). 12. Grasp Roll Pin (4G) with needle nosed pliers or a hooked tool and pull Planet Shaft (4E) out of Spindle (1A). 13. Drive Roll Pin (4G) out of Planet Shaft (4E). Discard roll pin. 14. Slide Planet Gear Subassembly (4) out of Spindle (1A). Do not drop Needle Bearings (4C). 15.
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SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Disassembly 5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable. 1. Place unit on bench with Spindle (1A) end down. 6. 2. Remove 2 Set Screws (1G) and Bearing Nut (1F) using T206569. If necessary, press nine Studs (1H) out of Hub (1D). Locate Hub (1D) on Seal (1B) end. 7. Remove Seal (1B) from Hub (1D). Discard seal. 8. Remove “B” position Bearing Cone (1C) from Bearing Cup (1C) in Hub (1D). 9.
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SECTION 3 - CHASSIS & TURNTABLE (8B). Remove Flat Head Cap Screws (22) and Pressure Plate (8B) from brake cavity in Spindle (1A). Spindle-Brake Disassembly NOTE: Units with integral Input Brake (8) only. COMPRESSED SPRINGS CAN FLY OUT AND CAUSE SEVERE EYE DAMAGE OR OTHER INJURIES. WEAR EYE PROTECTION WHEN PERFORMING THESE PROCEDURES. 1. Install two 1/4"-20 x 5/8" Flat Head Cap Screws (22) through Pressure Plate (8B) into Piston (8A).
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SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Cover Assembly 1. Remove O-Ring (17) from groove in Cover (6A). 2. Remove Thrust Washer (2) from Cover (6A) pockets. 3. Unscrew two Hex Head Bolts (6C) and remove Disengage Cap (6B) from Cover (6A). 4. Pull Disengage Rod (6D) out from Cover (6A). 5. Use appropriate tool to remove O-ring (6E) from internal groove in Cover (6A). 6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A). 1.
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SECTION 3 - CHASSIS & TURNTABLE Input Carrier Sub-Assembly 1. Apply a liberal coat of grease to bore of one Input Planet Gear (3F). 2. Line inside of Planet Gear (3F) with 14 Needle Rollers (3C). NOTE: The last roller installed must be installed end wise. That is, the end of the last roller must be placed in between ends of the two rollers which form the space, and then slid, parallel to the other rollers, into place. 4. Repeat Step 2 to put in second roll of Needle Rollers (4C). 5.
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SECTION 3 - CHASSIS & TURNTABLE 13. Hub-Spindle Sub-Assembly NOTE: Spray a light film of oil on all component parts during assembly. Spray a generous amount of oil on bearings during installation. Insert Planet Shaft (4E) through first set of Thrust Washers (4B), Planet gear, then second set of Washers (4B). Use an alignment punch or similar tool to align roll pin holes on Spindle (1A) and Planet Shaft (4E). NOTE: Do not hit Planet Gears (4F) when driving in Roll Pins (4G). 1.
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SECTION 3 - CHASSIS & TURNTABLE 9. Place Input Carrier Sub-Assembly (3A) on Output Sun Gear (11) splines. Drop Input Sun (10) in mesh with planet gears for specific ratios, if required. (No timing required). 10. Grease O-Ring (17) and insert in groove in Cover SubAssembly (6). 11. Install Cover Sub-Assembly (6) in Ring Gear (1E) counterbore and install Retaining Ring (6G) in groove in Ring Gear (1E). 12. Attach ID Tag (15) on unit using Drive Screws (16). 13.
PAGE 56
SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Lip Seal 1C. Tapered Bearing 1D. Housing 1E. Ring Gear 1F. Bearing Nut 1G. Setscrew 1H. Stud 1K. Retaining Ring 1L. Spring 1M. Thrust Washer 1Q. Seal Boot 2. Thrust Spacer 3A. Carrier 3B. Thrust Washer 3C. Needle Bearing 3E. Planet Shaft 3F. Planet Gear 4B. Thrust Washer 4C. Needle Bearing 4D. Thrust Spacer 4E. Planet Shaft 4F. Planet Gear 4G. Roll Pin 4H. Thrust Washer 5. Retaining Ring 6A. Cover 6B. Disengage Cap 6C. Bolt 6D. Dowel Pin 6E. O-Ring 6F.
PAGE 57
SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Bearing Cup Pressing Tool Figure 3-12.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Bearing Cup Pressing Tool Figure 3-14.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 FREE WHEELING OPTION 3.4 DRIVE MOTOR Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel) Description 1. Chock wheels securely if not on flat level surface. 2. Disconnect both drive hubs by inverting disconnect caps in center of hubs. 3. If equipped, move steer/tow selector valve to float (tow) position by pulling valve knob out. Engage Drive Motors and Brakes (Normal Operation) 1.
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SECTION 3 - CHASSIS & TURNTABLE INSPECTION Shaft Seal Replacement Inspect new seal, motor housing seal bore, and sealing area on shaft for rust, wear, and contamination. Polish shaft and clean housing if necessary. REMOVAL 1. Remove snap ring (1) retaining shaft seal, and support washer. INSTALLATION 1 2 3 1. 2. 3. 1. Cover shaft splines with an installation sleeve to protect shaft seal during installation. 2. Install new shaft seal with cupped side facing motor.
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SECTION 3 - CHASSIS & TURNTABLE INSPECTION Loop Flushing Valve Inspect new O-rings and the sealing area for rust, wear, or contamination. Check springs and poppet for wear. REMOVAL 1. Remove plug (1) and (2) using an 11/16 in internal hex wrench. INSTALLATION 1. Install orifice poppet (13). 2. Install shift spool (12). 3. Install spring retaining washers on springs (10 and 11). 4. Carefully install centering springs (7, 8, and 9). 5. Install new O-rings (6, 4, and 5). 6.
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SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-2. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil supply to motor. Insufficient hydraulic fluid could lead to cavitation that would cause system noise. Fill reservoir to proper level. Ensure oil supply to motor is adequate and lines are unobstructed. Check for air in system. Air trapped in system lines or motor could result in cavitation that would cause system noise.
PAGE 63
SECTION 3 - CHASSIS & TURNTABLE Disassembly 17 NOTE: Removal of endcap voids warranty. 19 Coat all moving parts with a film of clean hydraulic oil during assembly. This ensures parts will be lubricated during start-up. 15 Replace all O-Rings and gaskets. It is recommended to replace all O-rings. Lightly lubricate O-rings with clean petroleum jelly before assembly. 14 6 9 11 5 7 21 2 13 3 18 12 10 8 4 16 16 1 20 14. 15. 16. 17. 1. 2. 3. 4. Plug Plug Plug O-ring 5. 6. 7. 8.
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SECTION 3 - CHASSIS & TURNTABLE 25 22 27 30 29 23 26 24 28 22. Screw 23. End Cap 24. O-ring 25. 26. 27. 28. 29. 30. Figure 3-21. End Cap 13. Using an 8 mm internal hex wrench, remove endcap screws (22). 14. Remove endcap (23). Remove O-ring (24) from housing or endcap. When endcap screws are removed, pressure from servo spring will cause endcap to bind on shaft. Press down on portion of endcap covering servo piston and hold endcap level while removing.
PAGE 65
SECTION 3 - CHASSIS & TURNTABLE 36 35 37 31 38 31. Cylinder Kit Assembly 35. 36. 37. 38. Figure 3-23. Cylinder Kit 19. Turn housing on its side and remove cylinder kit assembly (31). Set assembly aside. Do not to scratch running surface. NOTE: Grooves on surface of cylinder kit identify its displacement: Table 3-5. Displacement Identifiers # of Grooves Frame L Frame K 1 25 38 2 30 45 3 35 -- Inner Snap Ring Snap Ring Bearing Shaft Figure 3-25. Shaft & Front Bearing 21.
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SECTION 3 - CHASSIS & TURNTABLE 28. 44 45 Turn block over. Using a press, apply pressure on block spring washer (50) to compress the block spring. Compress spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining ring (51). Carefully release pressure and remove outer block spring washer (50), block spring (52), and inner block spring washer (53) from cylinder block.
PAGE 67
SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements. Table 3-7.
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SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate bearings while feeling for uneven movement. Bearings should spin smoothly and freely. Replace bearings that appear worn or do not rotate smoothly. 1. Install new O-ring (1) and piston seal (2) to servo piston (3). Install piston seal over O-ring. Installing piston seal stretches it, making it difficult to install servo piston in its bore.
PAGE 69
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) in cylinder block groove. 6. Install journal bearings (13) in housing seats. Use assembly grease to keep bearings seated during assembly. Ensure locating nubs drop into seat cavities. If reusing bearings, install in original location and orientation.
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SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) on shaft (16). Press bearing on 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) on shaft. Install with slippers facing swashplate. Rock the 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) in 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. 3 mm [0.12 in] Install endcap (25) on housing with endcap screws (26). Ensure endcap will properly seat to housing without interference. Improper assembly of internal components may prevent endcap from seating properly. Ensure O-rings seat properly when installing endcap.
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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 in housing until it bottoms out. Press evenly to avoid binding and damaging seal. Install seal support washer (28) and snap ring (29). 20. Install orifice poppet (30). 37 36 33 39 34 27 ft.lbs. (37 Nm) 40 29 41 11/16 in 30 5/8 in 20 ft.lbs. (27 Nm) 28 32 35 38 27 31 42 11/16 in 27 ft.lbs. (37 Nm) 30. 31. 32. 33. 27. Shaft Seal 28.
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SECTION 3 - CHASSIS & TURNTABLE 4. To ensure pump and motor stay filled with oil, install case drain lines in upper most case drain ports. 5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pressure gauge port of pump to monitor system pressure during start up. 6. While watching pressure gauge, run engine at lowest possible speed until system pressure builds to normal levels (minimum 160 psi [11 bar]). Once system pressure is established, increase to full operating speed.
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SECTION 3 - CHASSIS & TURNTABLE 15. Oscillating Axle Lockout Test LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels before starting lockout cylinder test. 1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left front wheel.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING DRIVE 20 12 2 6 1I 1H 5A 1E 4 13 5 1G 11 1J 3 1C 11 44 8 1A 1A. Output Shaft 1B. Lip Seal 1C. Bearing 1E. Bearing 1G. Housing 1H. Thrust Washer 1I. Retaining Ring 1J. Pipe Plug 2. Internal Gear 3. Carrier Assembly 4. Ring Gear 5. O-Ring 5A. O-Ring 6. Brake Housing 8. Sun Gear 11. Thrust Washer 12. Bolt 13. Dowel Pin 20. Pipe Plug 44. Internal Retaining Ring Figure 3-41.
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SECTION 3 - CHASSIS & TURNTABLE 101 102 104 105 103 106 104 107 104 108 104 8K 109 110 8K 104 8K 112 29 28 23 32 113 115 114 116 125 117 8K 118 8K 29 6 28 22 21 30 35 6. Brake Housing 8A. Piston 8D. O-Ring 8E.Back-Up Ring 8F. O-Ring 8H. Back-up Ring 8J. Rotor Disc 8K. Stator Disc 8L. Spring 21. Bolt 22. Lockwasher 23. Pipe Plug 26. O-Ring 28. Lifting Lug 29. Bolt 30. Elbow 35. Tube 101. Bolt 102. End Cover 103. Commutator Seal 104. Ring Seal 105. Commutator and Ring Assy 106. Ring 107.
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SECTION 3 - CHASSIS & TURNTABLE Gear Backlash Set backlash to .010 - .015 in (0.254 to 0.381mm). 1. Insert shim (JLG P/N 4071009) between pinion and bearing on the bearing high spot. The bearing high spot should be stamped with an "X" on the surface below the teeth and marked with yellow paint in the tooth space. 5. Loosen jam nut. 6. Tighten jack bolt until pinion is snug against shim and bearing, then loosen jack bolt. 7. Apply JLG Thread locking compound P/N 0100019 to jack bolt threads.
PAGE 78
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly Motor and Brake Disassembly 1. Place unit on bench with motor end up. 2. Remove Drain Plug (1P) and drain oil from gearbox. 3. Remove Hydraulic Tubing Assembly (35). 4. Loosen jam nuts on Elbow Fittings (30). Remove fittings from Brake (6) and Motor Control Valve (32). 5. Remove O-ring Plugs (23) from Motor Control Valve (32). 6. Remove four bolts (21), washers (22), and Motor Control Valve (32) from Motor (31). 7.
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SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Hub-Shaft Disassembly 1. Remove Sun Gear (8) with Retaining Ring (44) inside. 2. With unit resting on Output Shaft (Pinion) (1A), remove Bolts (12) from Brake Housing (6). 3. Remove Brake Housing (6) from main assembly. 11. 4. Remove O-ring (5A) from Brake Housing (6) and Ring Gear (4). Using retaining ring pliers, remove and discard Retaining Ring (11) from groove in Output Shaft (1A). 12. Remove Thrust Washer (1H). 13.
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SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 1. Using a 3/16" punch drive Roll Pin (3G) holding Planet Shaft (3E) in Carrier (3A) in Planet Shaft (3E) until it bottoms. 3B 3F 3G 3C 3D 3C 3B MAKE SURE ROLL PIN HAS BOTTOMED OR CARRIER MAY BE DAMAGED WHEN PLANET SHAFT IS REMOVED. 2. Remove Planet Shaft (3E) from Carrier (3A). Use a small punch to remove Roll Pin (3G) from Planet Shaft (3E). 3. Slide Planet Gear (3F) and two Thrust Washers (3B) out of Carrier (3A). 3E 4.
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SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Subassembly 1. Press Bearing Cup (1C) in Housing (1G). Make sure cup starts square with bore of Hub (1G). 2. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing (1G). 3. Apply grease to rubber portion of Seal (1B). Press or tap Seal (1B) with smooth face up, in counterbore of Housing (1G) until it is flush with Housing (1G) face bore. 4. Invert Hub (1G) and press Bearing Cup (1E) in counterbore of Housing (1G). 5.
PAGE 82
SECTION 3 - CHASSIS & TURNTABLE Carrier Subassembly 1. Apply a liberal coat of grease to bore of Cluster Gear (3F). This holds Needle Rollers (3C) in place during assembly. 2. Install first row of Needle Rollers (3C) in bore of Cluster Gear (3F). 3. Insert Spacer (3D) in bore of Cluster Gear (3F) on top of Needle Rollers (3C). 4. Place second row of Needle Rollers (3C) in bore of Cluster Gear (3F) against Spacer(3D). 5. Place Carrier (3A) with one roll pin hole straight up. 6.
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SECTION 3 - CHASSIS & TURNTABLE Main Assembly 1. With Hub Shaft Subassembly resting on Shaft (1A) install Internal Gear (2). The spline of Internal Gear (2) bore will mesh with spline of Output Shaft (1A). This will be a tight fit. 2. Inspect location of Internal Gear (2) on Output Shaft (1A). A portion of Output Shaft (1A) should protrude through Internal Gear (2) bore. 3. Install 4 Dowel Pins (13) into counter bore holes in Hub (1G). 4.
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SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly 1. Insert Stator (8K) (O.D. lobes) in bore of Brake Housing (6). Alternate Rotors (8J) (I.D. splines) and Stators, ending with a Stator (8K). 2. Grease O-rings (8F) & (8D) and Back-up rings (8H) & (8E). Place them in their respective grooves in Brake Housing (6) and Piston (8A). Make sure Back-up rings are correctly positioned. 3. 1. NOTE: Align holes in control valve with motor ports.
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SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING BEARING Wear Tolerance Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after first 50 hours of machine operation and every 600 hours of machine operation thereafter.
PAGE 86
3-42 – JLG Lift – Measuring Point b. Main boom fully elevated. Figure 3-59. Swing Bearing Tolerance Measurement Location & Boom Placement Measuring Point a. Tower boom fully elevated and main boom level.
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SECTION 3 - CHASSIS & TURNTABLE INSTALLATION Swing Bearing Replacement 1. REMOVAL 1. Operate boom from Ground Control station to provide access to frame opening or rotary coupling. NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING. 2. Attach an adequate support sling to boom and draw all slack from sling. Prop or block boom if feasible. 3.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-60. Swing Bearing Torque Sequence a. Carefully lower turntable onto swing bearing. Ensure scribed line of inner bearing race aligns with scribed line on turntable. If a new swing bearing is used, ensure filler plug fitting is 90° fore and aft center line of turntable. Swing Bearing Torque Values b.
PAGE 89
SECTION 3 - CHASSIS & TURNTABLE 3.9 SWING BRAKE - MICO Assembly Disassembly NOTE: Lubricate all seals and O-rings with clean hydraulic oil prior to assembly. 1. With shaft protrusion downward, remove end cover (13) by removing capscrews (12). END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE.
PAGE 90
SECTION 3 - CHASSIS & TURNTABLE 3.10 ROTARY COUPLING Use the following procedure to install the seal kit. NOTE: Step 1 applies to machines S/N 75606 to Present. 1. If not already removed, remove axle oscillation valve from cylinder barrel. The valve spool protrudes into the barrel and will damage spool and seals if left in place. 2. Remove snap ring (12) from end. 3. Remove thrust ring (13) from same end. 4. Remove center body (10) from housing (11). 5. Cut off old seals (14,15,17,18). 6.
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SECTION 3 - CHASSIS & TURNTABLE 12 13 10 15 16 2 3 1 17 18 4 5 17 18 11 6 16 9 15 7 14 8 13 DETAIL A 12 1. 2. 3. 4. 5. O-ring Plug Check Valve Screw Plug 6. Spring 7. Valve Block Plunger 8. Valve Block 9. O-ring 10. Body 11. Housing 12. Retaining Ring 13. Ring 14. Oil Seal 15. O-ring 16. Bearing 17. Cap Seal 18. O-ring Figure 3-62.
PAGE 92
SECTION 3 - CHASSIS & TURNTABLE 7 5 1,5 2 5 6 6 2 1 7 2,7 3 4 4 7 3 3 1 2 2 2 4 1 3 3 4 5 6 7 7 7 7 Figure 3-63.
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SECTION 3 - CHASSIS & TURNTABLE 7 5 1,5,9 2,8 5 6 6 1 7 2,7 3 4 4 9 8 2 7 3 8 3 1 2 2 2 1 3 3 4 4 5 6 7 7 7 8 7 8 9 Figure 3-64.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Coupling Port Information Table - 2WS 3.11 GENERATOR Port No.
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SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER. Refer to Figure 3-69., Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings. The circuit breaker protects generator windings from overload. Generator output stops if circuit breaker opens.
PAGE 96
SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings 2 3 Acceptable Unacceptable Brushes must ride completely on slip rings 1 1/4 in (6 mm) Or Less - Replace 2 7/16 in - 1/2 in (11 - 12 mm) New 3 1. 2. 3. Brush Holder Assembly Brushes Slip Rings Figure 3-69.
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SECTION 3 - CHASSIS & TURNTABLE 3.12 DEUTZ D2.9 L4 ENGINE 1 13 7 2 8 6 4 14 5 3 10, 11 12 15 17 36 38 37 16 35 34 33 32 18 31 19 30 29 20 28 25 24 21 23 27 26 1. 2. 3. 4. 5. 6. 7. 8. Fan Adapter Drive Belt Water Pump Fuel Injector Thermostat Oil Fill Cap Temperature Sender 22 9. 10. 11. 12. 13. 14. 15. 16. Turbocharger Exhaust Pipe Spark Arrester Pressure Sensor Front Engine Mount Motor Mount Shuttle Valve Catalytic Converter/Muffler 17. 18. 19. 20. 21. 22. 23. 24.
PAGE 98
SECTION 3 - CHASSIS & TURNTABLE Vent 1 Return Supply 5 2 4 3 15 7 6 To Engine 9 14 10 8 12 13 1. 2. 3. Coolant Recovery Tank Radiator Assembly Air Filter Service Indicator 11 4. 5. 6. Coolant Overflow Hose Coolant Level Sensor Fuel Pump 7. 8. 9. Fuel Pre-Filter Battery Power Module Relay 10. Relay 11. Lanyard 12. Hitch Pin 13. Engine Tray 14. Air Filter Assembly 15. Engine Control Unit (ECU) Figure 3-71. Deutz D2.
PAGE 99
SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions. Change Engine Oil Check Oil Level 1. Allow engine to warm up. Engine oil should reach approximately 176° F (80° C). 1. Make sure machine and engine are level and switch engine OFF before checking oil level. 2. Make sure machine and engine are level and switch off engine. 2. Remove oil dipstick and wipe with clean cloth. 3. Place oil tray under engine. 3.
PAGE 100
SECTION 3 - CHASSIS & TURNTABLE Change Oil Filter Change Fuel Filters 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. 3. Catch any escaping oil. 4. Clean any dirt from filter carrier sealing surface. 5. Lightly coat new oil filter rubber gasket with clean oil 6. Screw in new filter by hand until gasket is flush. 7. Hand-tighten filter another half-turn. 8. Check oil level. 9.
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SECTION 3 - CHASSIS & TURNTABLE 3.13 DEUTZ D2011 ENGINE 1 5 6 24 7 3 2 9 8 4 10 23 11 22 21 12 19 20 OR 13 18 14 15 16 17 1. 2. 3. 4. 5. 6. Radiator Mounting Plate Fan Dipstick Oil Filler Cap Control Module Fuel Injector 7. 8. 9. 10. 11. 12. Oil Cooler Hose Exhaust Pipe Extension Air Cleaner Right Rear Engine Mounting Plate Exhaust Pipe Coupling 13. 14. 15. 16. 17. 18. Pump Adapter Plate Piston Pump Gear Pump Left Rear Engine Mounting Plate Engine Mount Left Front Engine Support 19.
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SECTION 3 - CHASSIS & TURNTABLE 5 9 1 10 2 16 6 8 7 3 14 4 13 15 11 12 18 1. 2. 3. 4. Battery Battery Hold-Down J-Bolt Battery Hold-Down Plate 5. 6. 7. 8. Temperature Sensor Oil Filter Fuel Filter Oil Pressure Sensor 9. 10. 11. 12. Throttle Actuator Temperature Sensor Starter Oil Lube Pump 17 13. Oil Filler Cap 14. Fuel Supply Pump 15. Relay 16. Speed Sensor 17. Hitch Pin 18. Engine Tray Figure 3-75.
PAGE 103
SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions. Changing Engine Oil Checking Oil Level 1. Allow engine to warm up. Engine oil should reach approximately 176° F (80° C). 1. Make sure machine and engine are level and switch engine OFF before checking oil level. 2. Make sure machine and engine are level and switch off engine. 2. Remove oil dipstick and wipe with clean cloth. 3. Place oil tray under engine. 3.
PAGE 104
SECTION 3 - CHASSIS & TURNTABLE 10. Changing Oil Filter Check oil filter cartridge for leaks. Replace 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. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM. 3. Catch any escaping oil. 4.
PAGE 105
SECTION 3 - CHASSIS & TURNTABLE 3.14 SPARK ARRESTER CLEANING INSTRUCTIONS 3.15 GLOW PLUGS 1. Remove cleanout plug in bottom of spark arrester (muffler). 2. Without causing deformation (or any type of damage to spark arrester) repeatedly tap on arrester near cleanout plug. This may be enough to begin spark trap drainage. 3. An industrial vacuum cleaner can do a complete job at this point. a. Or, IN A SAFE AREA, start engine. Alternate between low idle and high idle for two to three minutes. b.
PAGE 106
SECTION 3 - CHASSIS & TURNTABLE 106. Gear Pump 112. Piston Pump 218. Fan 220. Oil Cooler Hose 224. Engine Mount 230. Radiator 245. Air Cleaner 254. Radiator Mounting Plate 248. Right Rear Engine Mounting Plate 249. Left Rear Engine Mounting Plate 255. Exhaust Pipe 301.Coupling 302. Pump Adapter Plate 401. Dipstick 402. Oil Filler Cap 405. Fuel Injector 411. Alternator 412. Starter 421.
PAGE 107
SECTION 3 - CHASSIS & TURNTABLE 3. 26. 27. 28. Battery Battery Hold-Down J-Bolt Battery Hold-Down Plate 105. Hitch Pin 231. Relay 251. Engine Tray 402. Filler Cap 403. Oil Lube Pump 404. Oil Filter 406. Fuel Filter 407. Fuel Supply Pump 414. Temperature Sensor 415. Oil Pressure Sensor 416. Speed Sensor 417. Throttle Actuator 420. Temperature Sensor Figure 3-79.
PAGE 108
SECTION 3 - CHASSIS & TURNTABLE 3.16 DEUTZ EMR 2 The EMR2 consists of sensors, control unit, and actuator. Engine-side controls and the JLG Control System are connected by separate cable harnesses to the EMR control unit. Sensors attached to the engine provide control unit electronics with all relevant physical parameters In accordance with information of the current engine conditions and preconditions (throttle position etc.
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Figure 3-81.
PAGE 110
Figure 3-82.
PAGE 111
Figure 3-83.
PAGE 112
Figure 3-84.
PAGE 113
SECTION 3 - CHASSIS & TURNTABLE Figure 3-85.
PAGE 114
SECTION 3 - CHASSIS & TURNTABLE Figure 3-86.
PAGE 115
Figure 3-87.
PAGE 116
Figure 3-88.
PAGE 117
Figure 3-89.
PAGE 118
Figure 3-90.
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Figure 3-91.
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SECTION 3 - CHASSIS & TURNTABLE 3.17 BIO FUEL IN DEUTZ ENGINES APPROVED ENGINES General 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513 series are approved for bio-diesel from year of manufacture 1993 under compliance with basic conditions specified below. Use of bio fuels is permitted for the compact engines made by DEUTZ. BASIC CONDITIONS TO BE OBSERVED • A power loss of 5-9% in relation to diesel fuel in accordance with EN 590 is possible due to the lower heating value.
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SECTION 3 - CHASSIS & TURNTABLE PREVENTIVE MEASURES Biological Contamination In Fuels • Keep storage tank clean. Perform regular cleaning of the tank by specialist companies SYMPTOMS The following symptoms may indicate a fuel tank is contaminated by micro-organisms: • Installation of fuel pre-filters with water traps, especially in countries with frequently fluctuating fuel qualities and high percentage of water.
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SECTION 3 - CHASSIS & TURNTABLE • Check ground and platform control stations to ensure all warning indicator lights are functioning. 3.18 GM ENGINE GENERAL MAINTENANCE 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.
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SECTION 3 - CHASSIS & TURNTABLE Changing Engine Oil 1. Loosen worm gear clamp on coolant line running to EPR as shown below. Remove hose from EPR. Place a rag under hose to prevent coolant from running onto engine/machine. 2. Remove radiator cap. Fill radiator with coolant until coolant starts to appear from previously removed hose at the EPR. Reinstall hose back on EPR and continue to fill radiator with coolant. 3.
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SECTION 3 - CHASSIS & TURNTABLE 3.19 GM ENGINE DUAL FUEL SYSTEM WITH ENGINE RUNNING OR WHEN SHUTTING OFF ENGINE, SOME HEATED COOLANT MAY SPILL OUT DUE TO AIR "BURPING" OUT OF THE SYSTEM WITH RADIATOR CAP OFF. 5. Verify the two coolant hoses on the EPR are warm. If they are not warm repeat step 3 and 4, otherwise continue to step 6. A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIATOR HOSE AND A WARM EPR HOSE.
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SECTION 3 - CHASSIS & TURNTABLE 1. 1 inch Split Loom 2. 90° Fitting 3. 90° Fitting 4. 90° Fitting 5. Clamp 6. Adapter Fitting 7. Hose 8. Hose 10. Clamp 11. Nipple 12. Lock-Off Valve 15. Clamp 16. Regulator 17. 45° Fitting 18. Bolt 19. Bolt 20. Nut 101. Plug 102. Electronic Pressure Regulator 103. Adapter 104. Mixer 105. Bolt 106. Stud 107. Nut 108. Spacer (600A Only) 201. Throttle Body 202. Gasket 203. O-Ring 204. Adapter 205. Spacer 206. Bolt 207. Washer 208. Bolt 402. T-MAP Sensor 403. Bolt 404.
PAGE 126
SECTION 3 - CHASSIS & TURNTABLE Direct Electronic Pressure Regulator (DEPR) Air Fuel Mixer THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOULD ONLY BE SERVICED BY QUALIFIED TECHNICIANS. THE AIR/FUEL MIXER IS AN EMISSION CONTROL DEVICE. COMPONENTS INSIDE THE MIXER ARE SPECIFICALLY CALIBRATED TO MEET THE ENGINE’S EMISSIONS REQUIREMENTS AND SHOULD NEVER BE DISASSEMBLED OR REBUILT. IF THE MIXER FAILS TO FUNCTION CORRECTLY, REPLACE WITH AN OEM REPLACEMENT PART.
PAGE 127
SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control (ETC) Engine Control Module (ECM) The Electronic Throttle Control device or "Throttle Body Assembly" is connected to the intake manifold of the engine. The electronic throttle control device utilizes an electric motor connected to the throttle shaft. When the engine is running, electrical signals are sent from equipment controls to the engine ECM.
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SECTION 3 - CHASSIS & TURNTABLE Heated Exhaust Gas Oxygen Sensor Gasoline Fuel Pump There are two Heated Exhaust Gas Oxygen Sensors (HEGO). The first HEGO is mounted in the exhaust system downstream of the engine. It is used to measure the amount of oxygen present in the exhaust stream and communicate that to the ECM via an electrical signal. The amount of oxygen present in the exhaust stream indicates whether the fuel/air ratio is too rich or too lean.
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SECTION 3 - CHASSIS & TURNTABLE Fuel Filter 3.20 GM ENGINE FUEL SYSTEM REPAIR After fuel is drawn into the fuel pump, the fuel flows through the gasoline fuel filter. The fuel filter traps small particles as fuel passes through the filter to remove debris and prevents fuel pressure and temperature manifold and fuel injectors from becoming damaged. Fuel filter maintenance is required as shown in Section 1.
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SECTION 3 - CHASSIS & TURNTABLE INSTALLATION Propane Fuel Filter Replacement REINSTALL FILTER MAGNET IN HOUSING BEFORE INSTALLING NEW SEAL. 1. 2. 3. 4. 5. 6. Electric Lock Off Solenoid Mounting Plate Housing Seal Filter Magnet Filter Housing Seal 7. 8. 9. 10. 11. 12. Electrical Connector Fuel Outlet O-ring Filter Fuel Inlet Retaining Bolt 1. Install mounting plate to lock off O-ring seal. 2. Install retaining bolt seal. 3. Install housing seal. 4. Drop magnet in bottom of filter housing. 5.
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SECTION 3 - CHASSIS & TURNTABLE 13. Check/Drain Oil Build-Up In 2-Stage Vaporizer Slowly open manual service valve. NOTE: Refer to Figure 3-93. GM 3.0 Dual Fuel System Components. During normal operation for LPG engines oil or “heavy ends” may build inside the Vaporizer secondary chamber. These oil and heavy ends may be a result of poor fuel quality, fuel contamination, or regional variation of the fuel make up. A significant build up of oil can affect performance of the secondary diaphragm response.
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SECTION 3 - CHASSIS & TURNTABLE Exhaust System And Catalytic Converter Inspection And Maintenance Throttle Body (ETC) Replacement NOTE: Refer to Figure 3-93. GM 3.0 Dual Fuel System Components. REMOVAL EXHAUST SYSTEM ON THIS EMISSION CERTIFIED ENGINE CONTAINS A HEATED EXHAUST GAS OXYGEN SENSOR (HEGO) WHICH PROVIDES FEEDBACK TO THE ECM ON AMOUNT OF OXYGEN PRESENT IN THE EXHAUST STREAM AFTER COMBUSTION. OXYGEN IN THE EXHAUST STREAM IS MEASURED IN VOLTAGE AND SENT TO THE ECM.
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SECTION 3 - CHASSIS & TURNTABLE Electronic Pressure Regulator (EPR) Replacement REMOVAL Coolant Hose Replacement REMOVAL NOTE: Refer to Figure 3-93. GM 3.0 Dual Fuel System Components. 1. Unplug EPR (102) electrical connector. 2. Remove hoses from EPR. 3. Remove four flange nuts (107) and EPR from Mixer (104). 4. If new EPR is being installed, remove and retain hose adapter (103) and four bolts (105). Install EPR (102) on Mixer (104). Secure with four flange nuts (107). 3. Reattach all hoses.
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SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL REMOVAL 1. Disconnect Negative battery cable. 1. Disconnect negative (-) battery cable. 2. Remove controller from mounting bracket. 2. Disconnect O2 sensor electrical connector. 3. Push connector lock back to unlock connector. 3. Using an O2 Sensor socket, remove and discard Sensor. 4. Unplug and remove controller.
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SECTION 3 - CHASSIS & TURNTABLE 3.21 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on LPG. If vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Fuel System Description NOTE: Before proceeding with this procedure, verify vehicle has a sufficient quantity of fuel and that liquid fuel is being delivered to the LPR.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-10. LP Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2 2 Perform the On Board Diagnostic (OBD) System Check.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-10. LP Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 15 1. Turn the ignition OFF. 2. Close the manual shut-off valve on the LPG tank. CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Perform this step in a well ventilated area. 3. Loosen the fuel inlet hose fitting at the inlet of the LPL. Was fuel present when the fitting was loosened? -- Go to Step 23 Go to Step 17 16 1. Turn OFF the ignition. 2.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. 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.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp (MIL) The following components can cause intermittent MIL and no DTC(s): ² 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 The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Exhaust System Checks Action ² Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. ² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis Hard Start DEFINITION: The engine cranks OK, but does not start for a long time.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Additional Checks Action ² Cuts Out, Misses DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks ² Refer to Important Preliminary Checks.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Action Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. ² Check for the proper ignition voltage output with J 26792 or the equivalent.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Action Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. ² Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. ² Check for proper installation of the mixer module assembly. ² Check all air inlet ducts for condition and proper installation. ² Check for fuel leaks between the LPR and the mixer.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Additional Check Action ² Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual. ² Check for dragging brakes. Rough, Unstable, or Incorrect Idle, Stalling DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Symptom Diagnosis Checks Action Fuel System Checks ² Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. ² Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis. ² Verify proper fuel control solenoid operation. ² Verify that the LPG manual shut-off valve is fully open.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12.
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SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-104 – JLG Lift – 3121616
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 MAIN BOOM MAINTENANCE Remove Platform Level (Slave) Cylinder UNSECURED COMPONENTS CAN MOVE OR FALL AND CAUSE DEATH, SERIOUS INJURY, OR DAMAGE TO PROPERTY AND EQUIPMENT. PROPERLY SECURE OR SUPPORT ALL COMPONENTS. Refer to Figure 4-1., Rotator, Platform Level Cylinder, and Jib Lift Cylinder Installation. 600A 1. Support platform or rotator if not removed. 2. Tag and disconnect hydraulic lines to platform level cylinder (3).
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SECTION 4 - BOOM & PLATFORM Figure 4-1. Rotator, Platform Level Cylinder, and Jib Lift Cylinder Installation 8. Remove Main Boom Powertrack 1. Disconnect wiring harness connectors in tower upright. 2. Tag and disconnect hydraulic lines from connectors at boom assembly. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports. 3. Disconnect dual capacity indicator limit switch from side of boom section. 4.
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SECTION 4 - BOOM & PLATFORM INSPECTION Remove Main Boom 1. Support boom assembly weight along entire length using suitable lifting equipment. NOTE: Replace worn or damage components as needed. 1. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. 2. Inspect telescope cylinder attach point for scoring, tapering and ovality. 3. Tag and disconnect hydraulic lines from telescope cylinder. Use suitable container to retain any residual hydraulic fluid.
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SECTION 4 - BOOM & PLATFORM INSTALLATION 1. 4.2 TOWER BOOM Use a suitable lifting device to position boom assembly on turntable. Align pivot holes in boom and turntable. 2. Install boom pivot pin. Ensure location of hole in pin is aligned with attach point on turntable. 3. Gently tap pin in position with soft headed mallet. Install pin mounting hardware. 4. Connect all wiring connectors. 5. Connect all hydraulic lines running along side of boom assembly. 6.
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SECTION 4 - BOOM & PLATFORM DISASSEMBLY Remove Tower Boom 1. 1. Remove brackets securing hoses and wiring harnesses to push tubes and top of tower boom assembly. 2. Mark all hoses and wiring harnesses at bracket on aft end of tower base boom section for future assembly. Remove hoses and wiring harness from tower boom powertrack. 3. Remove mounting hardware which secures the push tubes to the tower fly boom section. 4. Remove mounting hardware which secures push tubes to the powertrack.
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SECTION 4 - BOOM & PLATFORM INSPECTION 7. Install wear pads in forward position of tower base boom section. Shim boom, if necessary, for a total of 2/ 10 inch (0.20) clearance. 8. Align cylinder with slots at aft end of tower base boom section. Secure cylinder with mounting hardware. 9. Install powertrack to attach point on the tower base boom section, then secure with mounting hardware. 10. Attach push tubes to the powertrack and attach point on the tower fly boom section; with mounting hardware.
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SECTION 4 - BOOM & PLATFORM 4.3 BOOM CLEANLINESS GUIDELINES 4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest exiting point from the boom. Make sure that all debris is removed before operating the machine. 5. If pressurized air cannot dislodge debris, apply water and mild solvents with a pressure washer. Wash debris toward nearest exit point from the boom.
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SECTION 4 - BOOM & PLATFORM 4.4 ROTARY ACTUATOR Required Tools Theory of Operation 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. Each actuator is composed of a housing with integrated gear teeth (1) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (2), and the annular piston sleeve (3).
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SECTION 4 - BOOM & PLATFORM 600A 14 2 5 6 11 12 7 3 8 600AJ 7 8 1 5 16 13 15 9 10 4 14 1. 2. 3. 4. Housing Shaft Piston End Cap 5. 6. 7. 8. O-Ring Shaft Bearing Thrustwasher Bearing Packing 9. 10. 11. 12. Cap Seal Back-Up Ring Rod Seal Piston Seal 13. 14. 15. 16. Cap Bearing Capscrew Bolt Valve Block Figure 4-6.
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SECTION 4 - BOOM & PLATFORM Disassembly 1. Remove end cap (4) using tools provided with Helac seal kit. 5. Using a metal bar or similar tool, unscrew end cap (4) by turning it counter clockwise. 6. Remove end cap (4) and set aside for later inspection. Remove capscrews (113) over end cap lock pins (109). 2. Using a 1/8” (3.18mm) drill bit, drill a hole in center of each lock pin approximately 3/16" (4.76mm) deep. 3. Remove lock pins using an ”Easy Out” (Size #2 shown.
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SECTION 4 - BOOM & PLATFORM 7. Remove stop tube if installed. 8. Actuator has timing marks for proper engagement. 3121616 – JLG Lift – 9. Before removing shaft, (2), use a felt marker to clearly indicate timing marks between shaft and piston. This simplifies timing during assembly. 10. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet.
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SECTION 4 - BOOM & PLATFORM 11. Before removing piston (3), mark housing (1) ring gear in relation to piston O.D. gear. There should be timing marks on housing (1) ring gear, piston (3), and shaft (2). 13. At the point when piston gear teeth come out of engagement with housing gear teeth, mark piston and housing with a marker as shown. 12. To remove piston (3), use a rubber mallet and plastic mandrel so piston is not damaged. 14.
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SECTION 4 - BOOM & PLATFORM 15. Remove wear guides (302) from end cap (4) and shaft (2). 17. Remove thrust washers (304) from end cap (4) and shaft (2). 16. To remove main pressure seals (205), cut them with a sharp razor blade. Do not to damage seal groove. 18. Remove wiper seal (304.1) from end cap (4) and shaft (2). 19. Remove piston O.D. seal (202).
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SECTION 4 - BOOM & PLATFORM 20. Remove piston I.D. seal (200). 2. Inspect thrust washers (304) for rough or worn edges and surfaces. Measure thickness is within specifications (Not less than 0.092” or 2.34 mm). 3. Inspect wear guide condition and measure thickness (not less than 0.123” or 3.12 mm). Inspection 1. 4-14 Clean all parts in a solvent tank and dry with compressed air before inspecting.
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SECTION 4 - BOOM & PLATFORM Assembly 1. Gather all components and tools to one location. Use cut away drawing to reference seal orientations. 2. Install thrust washer (304) on shaft (2) and end cap (4). 3121616 – JLG Lift – 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 a seal tool install main pressure seal (205) on shaft (2) and end cap (4). Use seal tool in a circular motion. 5.
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SECTION 4 - BOOM & PLATFORM 6. 7. Install inner T-seal (200) in piston (3) using a circular motion. Install outer T-seal (202) by stretching it around the groove in a circular motion. Each T-seal has two back-up rings (see drawing for orientation). Beginning with inner seal (200) insert one end of b/u ring in lower groove and feed the rest in using a circular motion. Make sure wedged ends overlap correctly. 8.
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SECTION 4 - BOOM & PLATFORM 10. Looking from opposite end of housing (1) when timing marks line up, tap piston (3) in until gear teeth mesh together. Tap piston in housing until it bottoms out. 13. Install 2 bolts in threaded holes in flange. Using a bar, rotate shaft clockwise until wear guides are seated in housing bore. 11. Install shaft (2) in piston (3). Do not damage seals. Do not engage piston gear teeth. 14. Install stop tube on shaft end.
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SECTION 4 - BOOM & PLATFORM 16. Install 0-ring (204) and back-up ring (207) in inner seal groove on end cap (4). 17. Thread end cap (4) on shaft (2) end. Ensure wear guide stays in place on end cap as it is threaded in housing (1). 18. 4-18 19. 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. Insert set screws (113) over lock pins. Tighten to 25 in-lb (2.825 Nm). Tighten end cap (4).
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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 shanks of the three bolts at time of installation. 4. Torque 1/4-inch bolts 110-120 in-lb (12.4-13.5 Nm). Do not torque over 125 in-lb (14.1 Nm). Torque 5/16-inch bolts to 140 in-lb (15.8 Nm). Do not torque over 145 in-lb (16.3 Nm). Refer to Figure 4-7., Rotator Counterbalance Valve. 1.
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SECTION 4 - BOOM & PLATFORM Testing Actuator 1. If equipment is available, test actuator on a hydraulic test bench. Breakaway pressure — the pressure at which the shaft begins to rotate — should be approximately 400 psi (28 bar). Cycle actuator at least 25 times at 3000 psi (210 bar) pressure. After 25 rotations, increase pressure to 4500 psi (315 bar). Check for leaks and cracks. Perform test again at end of rotation in the opposite direction.
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SECTION 4 - BOOM & PLATFORM Table 4-1. Troubleshooting Troubleshooting Problem 1. Shaft rotates slowly or not at all Cause Solution a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator. b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for restrictions and leaks. c. Control or counterbalance valve has internal leak c.
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SECTION 4 - BOOM & PLATFORM 4.5 FOOT SWITCH ADJUSTMENT 4.6 PLATFORM Adjust foot switch to operate functions when pedal is at center of travel. Adjust if switch operates within last 1/2 in. (6.35 mm) of top or bottom travel. Platform Support Torque Settings NOTE: If any rotator bolts are replaced, re-torque all rotator bolts. ELECTRIC SHOCK OR UNCONTROLLED MACHINE MOVEMENT CAN CAUSE DEATH OR SERIOUS INJURY. DISCONNECT INPUT POWER BEFORE PERFORMING INSTALLATION OR MAINTENANCE.
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SECTION 4 - BOOM & PLATFORM 2. 4.7 POWERTRACK MAINTENANCE Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. Remove Link NOTE: Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different. 1. Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a T20 Torx bit, remove 8-32 x 0.500 screw from one side.
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SECTION 4 - BOOM & PLATFORM 5. REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 3. To remove a link, rivets holding links together must be removed. Use a right-angle pneumatic die grinder with a ¼” ball double cut bur attachment. 4. insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed. 4-24 After grinding it may be necessary to use a center punch with a hammer to remove rivet.
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SECTION 4 - BOOM & PLATFORM 6. Insert flat head screwdriver between links. Twist and pull links apart. 3121616 – JLG Lift – 7. Remove link from other section of powertrack using screwdriver.
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SECTION 4 - BOOM & PLATFORM Install New Link 1. 4-26 2. Spread half-shear (female) end of new link and slide cutout end of track section into it. Use screwdriver if necessary. 3. Round half-shears will not fit properly in cut-outs after new link is installed. Squeeze cut-out end of new link into half-shear (female) end of track section.
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SECTION 4 - BOOM & PLATFORM 4. 5. Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will rotate into cut-outs. 6. Push pin through center hole. Slide washer on pin. 7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed. Parts shown below connect new link to powertrack.
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SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed properly. Correct 1. 4-28 2. Pull up on other end of round bar. Slide new poly roller on bar. Incorrect Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar. Torque to 18-20 inlb (2-2.25 Nm).
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SECTION 4 - BOOM & PLATFORM 3. Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in-lb (2-2.25 Nm). Replace Fixed End Brackets REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove rivets as shown in link removal instructions. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head.
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SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. 3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. Replace Moving End Brackets REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-20. Repeat on other bracket if replaced.
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SECTION 4 - BOOM & PLATFORM 2. NOTE: Ensure snap rings are seated in pin groove and closed properly. Install center pin with snap ring in new bracket. Correct 3. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced. 3121616 – JLG Lift – 1. Incorrect Make sure both brackets rotate correctly.
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SECTION 4 - BOOM & PLATFORM NOTES: 4-32 – JLG Lift – 3121616
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SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 O-RING LUBRICATION 2. Hold fitting over hydraulic oil container and brush an even film of oil around entire O-ring in fitting. Make sure O-ring is completely saturated. 3. Turn fitting over and repeat previous step to O-ring on other side of fitting. Make sure entire O-ring is coated with hydraulic oil. When assembling connectors, all fittings with O-rings must be lubricated with hydraulic oil before assembly.
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SECTION 5 - HYDRAULICS Dip Spray NOTE: This method works best with Face Seal O-rings, but will work for all O-ring fitting types. This method requires a pump or trigger spray bottle. Tools needed: • Small leak proof container 1. Fill spray bottle with hydraulic oil. 2. Hold fitting over suitable catch can. 3. Spray entire O-ring surface with medium coat of oil. • Sponge cut to fit inside container • Small amount of hydraulic oil to saturate sponge. 1.
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SECTION 5 - HYDRAULICS 5.2 CYLINDERS - THEORY OF OPERATION Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder Systems With Double Acting Cylinders Systems with double acting cylinders are the Slave Level, Master Level, Lift, Telescope, Articulating Jib Boom Lift, Axle Lockout, and Steer. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions.
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SECTION 5 - HYDRAULICS Cylinders With Single Counterbalance Valve Cylinders With Dual Counterbalance Valves (Upper Lift Cylinder) (Articulating Jib Boom Lift, and Slave), Slave Level, Lower Lift, Upright level, Main Telescope and Tower Telescope) OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system. IMPROPERLY SUPPORTED BOOM CAN FALL AND CAUSE DEATH, SERIOUS INJURY, OR DAMAGE TO PROPERTY AND EQUIPMENT.
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SECTION 5 - HYDRAULICS 5.4 CYLINDER REMOVAL AND INSTALLATION Cylinder Locations 7 8 4 5 3 6 7 2 1 10 10 9 Item 1 2 3 4 5 Cylinder Tower Boom Lift Upright Level Master Main Boom Lift Main Boom Telescope Item 6 7 8 9 10 Cylinder Tower Boom Telescope Platform Level Slave Jib Lift Steer Axle Lockout Figure 5-2.
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SECTION 5 - HYDRAULICS Main Boom Telescope Cylinder Removal Main Boom Telescope Cylinder Installation 1. Place machine on flat and level surface with main boom horizontal. Extend telescope for access to cylinder rod pin (1). 2. Shut down engine. Support main boom basket end with a prop (2). See Figure 5-1., Boom Positioning and Support, Cylinder Repair. CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING LINES TO PREVENT SYSTEM CONTAMINATION. 1.
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SECTION 5 - HYDRAULICS Main Boom Lift Cylinder Removal 1. Main Boom Lift Cylinder Installation Place machine on flat and level surface. Start engine and place main boom horizontal. Shut down engine and prop boom. (See Figure 5-1., Boom Positioning and Support, Cylinder Repair. 2. Remove bolt and keeper pin from cylinder rod pin (7). Drive out pin using a suitable brass drift. 3. Fully retract lift cylinder rod using auxiliary power, 4.
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SECTION 5 - HYDRAULICS Upright Level Cylinder Removal 1. With aid of an assistant, manually override Plunger Valve with a pry bar. From Ground Control, use auxiliary power and extend tower telescope to access leveling cylinder rod end pin (3). Pry Bar 5. Drive barrel end attach pin (1) through mounting holes in upright and leveling cylinder using a suitable drift. 6. Remove mounting hardware from upright to tower boom assembly pivot pin (2). 7.
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SECTION 5 - HYDRAULICS Tower Boom Lift Cylinder Removal Refer to Figure 5-6., Boom Positioning and Support, Cylinder Repair. 4. Remove mounting hardware securing cylinder rod pin to tower boom. Drive out cylinder rod attach pin using a suitable brass drift. 5. Place machine on a flat and level surface. Place main boom in a horizontal position with telescope cylinder fully retracted. Place tower boom in a fully elevated and fully retracted position.
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SECTION 5 - HYDRAULICS Tower Lift Cylinder Installation Tower Telescope Cylinder Installation 1. With boom positioned as in Figure 5-3., Telescope and Lift Cylinder Installation, slide telescope cylinder into boom, aligning cylinder port block end with slotted holes in Base Boom. Secure telescope cylinder with mounting hardware. 2. Remove caps and plugs from hydraulic lines and ports. Connect hydraulic lines to cylinder as tagged during Removal. Reinstall cover plate.
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SECTION 5 - HYDRAULICS 5. 5.5 HYDRAULIC CYLINDER REPAIR Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). Tower Boom Lift Cylinder DISASSEMBLY Refer to Figure 5-11. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
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SECTION 5 - HYDRAULICS 23 7 1A 1 24 8 5 13 14 3 14 16 13 15 6 17 18 19 4 20 9 21 26 10 11 12 2 *Torque to 30 ft-lb (40.6 Nm) 2A 1683288M 1. 1a. 2. 2a. 3. 4. Barrel Composite Bushing Rod Composite Bushing Piston Head 5. 6. 7. 8. 9. 10. Tapered Bushing Spacer Cartridge Valve O-Ring Plug Ring Washer Capscrew 11. 12. 13. 14. 15. 16. Lock king Compound Locking Primer Seal Lock Ring O-Ring Back-Up Ring 17. 18. 19. 20. 21. 22. Wear Ring O-Ring Back-Up Ring Rod Seal Wiper Not Used 23. 24.
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SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
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SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL CYLINDER HEAD Figure 5-16. Wiper Seal Installation 3. Place new O-ring (1) and back-up seal (2) in applicable outside diameter groove of cylinder head (3).
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SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring Seal Back-Up Rings 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
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SECTION 5 - HYDRAULICS 5. Upright Level Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). DISASSEMBLY Refer to Figure 5-24. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
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SECTION 5 - HYDRAULICS 1A 7 8 10 25 1 5 11 12 4 12 11 14 13 6 15 17 16 3 18 19 26 22 9 20 21 2 *Torque to 30 ft-lb (40.6 Nm) 2A 1684498D 1. 1a. 2. 2a. 3. 4. Barrel Composite Bushing Rod Composite Bushing Head Piston 5. 6. 7. 8. 9. 10. Tapered Bushing Spacer Cartridge Valve Cartridge Valve Socket Head Bolt O-Ring Plug 11. 12. 13. 14. 15. 16. Lock Ring Hydrolock Seal O-Ring Back-Up Ring Wear Ring O-Ring 17. 18. 19. 20. 21. 22.
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SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 199
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL CYLINDER HEAD Figure 5-29. Wiper Seal Installation 3. Place new O-ring (1) and back-up seal (2) in applicable outside diameter groove of cylinder head (3).
PAGE 200
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring Seal Back-Up Rings 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 201
SECTION 5 - HYDRAULICS 5. Master Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). DISASSEMBLY Refer to Figure 5-37. Master Cylinder. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 202
SECTION 5 - HYDRAULICS 1A 1A 24 1 5 11 21** 12 3 12 11 13 6 16 14 17 15 4 18 19 8 7 9 10 2A 2 *9 ft-lb (12 Nm) 2A 1683266 (A) 1683263 (AJ) 1. 1a. 2. 2a. 3. Barrel Composite Bushing Rod Composite Bushing Piston 4. 5. 6. 7. 8. Head Tapered Bushing Spacer Capscrew Ring Washer 9. 10. 11. 12. 13. Locking Compound Locking Primer Seal Lock Ring O-Ring 14. 15. 16. 17. 18. Back-Up Ring Wear Ring O-Ring Back-Up Ring Rod Seal 19. Wiper 20. Not Used 21. Capscrew Figure 5-37.
PAGE 203
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 204
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL Figure 5-42. Wiper Seal Installation CYLINDER HEAD 3. Place new O-ring (1) and back-up seal (2) in applicable outside diameter groove of cylinder head (3).
PAGE 205
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. Seal Back-Up Rings INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 206
SECTION 5 - HYDRAULICS 5. Main Boom Lift Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). DISASSEMBLY Refer to Figure 5-50. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 207
SECTION 5 - HYDRAULICS 11 8 1A 7 1 6 19 20 4 20 19 17 18 5 16 15 14 3 13 10 12 9 21 22 2 *Torque to 9 ft-lb (12 Nm) 2A 1683294I 1. 1a. 2. 2a. 3. Barrel Composite Bushing Rod Composite Bushing Head 4. 5. 6. 7. 8. Piston Spacer Tapered Bushing Cartridge Valve Cartridge Valve 9. 10. 11. 12. 13. Capscrew Ring Washer O-Ring Plug Wiper Rod Seal 14. 15. 16. 17. 18. O-Ring Back-Up Ring Wear Ring O-Ring Back-Up Ring 19. 20. 21. 22. 23. 24.
PAGE 208
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 209
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL CYLINDER HEAD Figure 5-55. Wiper Seal Installation 3. Place new O-ring (1) and back-up seal (2) in applicable outside diameter groove of cylinder head (3).
PAGE 210
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. Seal Back-Up Rings INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 211
SECTION 5 - HYDRAULICS 5. Main Boom Telescope Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). Refer to Figure 5-63. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 212
SECTION 5 - HYDRAULICS 11 8 1 28* 9 9 6 12 13 12 3 14 21 21 24 5 15 16 17 25 18 26 4 7 19 20 24 10 22 23 2 *Torque to 9 ft-lb (12 Nm) 1683307G 1. 2. 3. 4. 5. 6. Barrel Rod Piston Head Spacer Taper Bushing 7. 8. 9. 10. 11. 12. Wear Pad Mounting PLate Valve Block Assembly O-Ring Plug Capscrew Capscrew Wear Ring 13. 14. 15. 16. 17. 18. Seal O-Ring O-Ring Wear Ring O-Ring Back-Up Ring 19. 20. 21. 22. 23. 24. Rod Seal Wiper Back-Up Ring Locking Primer Locking Compound Wear Pad 25. 26.
PAGE 213
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 214
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL Figure 5-68. Wiper Seal Installation CYLINDER HEAD 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head.
PAGE 215
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. Seal Back-Up Rings INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 216
SECTION 5 - HYDRAULICS 5. Tower Boom Telescope Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). Refer to Figure 5-76. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 217
SECTION 5 - HYDRAULICS 7 24 8 23* 9 6 1 11 12 11 3 13 14 14 15 18 17 4 16 19 5 10 20 21 2 *Torque to 9 ft-lb (12 Nm) 1683312H 1. 2. 3. 4. 5. Barrel Rod Piston Head Ring Washer 6. 7. 8. 9. 10. Tapered Bushing Cartridge Valve Cartridge Valve O-Ring Plug Capscrew 11. 12. 13. 14. 15. Wear Ring T-Seal O-Ring Back-Up Ringl Wear Ring 16. 17. 18. 19. 20. Rod Seal O-Ring Back-Up Ring Back-Up Ring Locking Primer 21. 22. 23. 24. Locking Compound Not Used Bolt Cartridge Valve Figure 5-76.
PAGE 218
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 219
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL CYLINDER HEAD Figure 5-81. Wiper Seal Installation 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head.
PAGE 220
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring Seal Back-Up Rings 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 221
SECTION 5 - HYDRAULICS 5. Platform Level (Slave) Cylinder Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). Refer to Figure 5-89., Platform Level (Slave) Cylinder Assembly. DISASSEMBLY CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
PAGE 222
SECTION 5 - HYDRAULICS 7** 1A 23** 8 25 24 1 5* 14 13 3 13 14 15 16 6 17 19 18 4 20 10 21 9* 11 12 2 *5 ft-lb (9 Nm) **50-55 ft-lb (68-75 Nm) 2A 1683415 (A) 1683418 (AJ) 1. 1a. 2. 2a. 3. 4. Barrel Composite Bushing Rod Composite Bushing Piston Head 5. 6. 7. 8. 9. 10. Tapered Bushing Spacer Cartridge Valve O-Ring Plug Capscrew Ring Washer 11. 12. 13. 14. 15. 16. Locking Compound Locking Primer Seal Ring Lock O-Ring Back-Up Ring 17. 18. 19. 20. 21.
PAGE 223
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 224
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL Figure 5-94. Wiper Seal Installation CYLINDER HEAD 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head.
PAGE 225
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring Seal Back-Up Rings 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 226
SECTION 5 - HYDRAULICS 5. Jib Lift Cylinder (AJ Only) Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head cap screws (4). Refer to DISASSEMBLY CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
PAGE 227
SECTION 5 - HYDRAULICS 6* 1A 8 8 8 1 6* 26** 8 11 16 17 10 17 16 9 20 14 15 12 19 22 18 15 14 2 3 21 5 4 23 24 *50-55 ft-lb (68-75 Nm) **5 ft-lb (9 Nm) 5A 1683609 G 1. 1a. 2. 3. 4. Barrel Bushing Head Ring Washer Capscrew 5. 5a. 6. 7. 8. Rod Bushing Cartridge Valve Not Used O-Ring Plug 9. 10. 11. 12. 13. O-Ring Plug Piston Tapered Bushing Spacer Not Used 14. 15. 16. 17. 18. Seal Lock Ring O-Ring Back-Up Ring Rod Seal 19. 20. 21. 22. 23.
PAGE 228
SECTION 5 - HYDRAULICS 8. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to piston as possible. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 9. Loosen and remove nut attaching piston to rod. Remove piston. 8. Inspect seal and O-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary. 10. Loosen and remove cap screw(s), if applicable, attaching tapered bushing to piston. 9. 11.
PAGE 229
SECTION 5 - HYDRAULICS Assembly NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylinder head gland groove. 1 SEAL TOOL 1" #7004275 1 1/2" #7004276 2" #7002826 ROD SEAL CYLINDER HEAD Figure 5-107. Wiper Seal Installation 3. Place new O-ring and back-up seal in applicable outside diameter groove of cylinder head.
PAGE 230
SECTION 5 - HYDRAULICS 6. If applicable, place new O-ring and back-up rings in inner piston diameter groove. Guide Lock Ring 11. Remove cylinder rod from holding fixture. 12. Place new guide locks and seals in applicable outside diameter grooves of cylinder piston. 13. Position cylinder barrel in a suitable holding fixture. Seal Back-Up Rings INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON. O-Ring 14.
PAGE 231
SECTION 5 - HYDRAULICS 5. Steer Cylinder Unscrew Spanner Nut (13) with hook spanner. DISASSEMBLY Refer to Figure 5-115. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate hydraulic power source and extend cylinder.
PAGE 232
SECTION 5 - HYDRAULICS 14 5 14 3 2 2 4 1* 11 7 4 12 8 9 13** 10 *150-180 ft-lb (203-244 Nm) **57-63 ft-lb (77-85 Nm) 14 6 14 1001097242 C 1. 2. 3. 4. Piston Seal O-Ring Setscrew 5. 6. 7. 8. Barrel Rod Head O-Ring 9. Back-Up Ring 10. Seal 11. O-Ring 12. Wiper 13. Spanner Nut 14. Composite Bushing Figure 5-115.
PAGE 233
SECTION 5 - HYDRAULICS 7. Remove two Seals (2) and O-Ring (3) from Piston (1). 8. Loosen two Setscrews (4) in Piston (1). Unscrew and remove Piston (1) from Rod (6) with strap wrench. Cleaning and Inspection 1. Clean all parts in an approved cleaning solvent. 2. Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite™ or equivalent. Replace rod if necessary. 3.
PAGE 234
SECTION 5 - HYDRAULICS 5. Assembly NOTE: Install O-Ring (3) and two seals (2) in piston groove. Apply a light film of hydraulic oil to all components before assembly. 1. 3 Position cylinder barrel in a suitable holding fixture. 2 2 IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER CYLINDER OPERATION. 4 1 2. Install Spanner Nut (13) on Rod (6). 3. Install Rod Seal (10) and Wiper (12) in Cylinder Head (7). 4. Install Backup Ring (9), O-Ring (8), and O-Ring (11). 4 Figure 5-120.
PAGE 235
SECTION 5 - HYDRAULICS ASSEMBLY Axle Lockout Cylinder NOTE: Refer to Figure 5-122., Axle Lockout Cylinder. DISASSEMBLY 8. Install two new wear rings (5) and rod seal (7) in piston bore grooves. Make sure they are not twisted. 9. Install new wiper (6) in housing. 10. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. INSERTING PISTON OFF-CENTER CAN DAMAGE PISTON AND PISTON BORE SURFACES. USE EXTREME CARE WHEN INSTALLING PISTON.
PAGE 236
SECTION 5 - HYDRAULICS 3 4 FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE. CYLINDER ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED. 9* 4 3 8 9 1 5 7 5 5 6 7 5 6 2 2 *Torque to 25 - 27 ft-lb (33 - 36 Nm) 1684465 F 1. 2. 3. Barrel Rod Plug 4. 5. 6. Pilot Piston Wear Ring Wiper 7. 8. 9. Rod Seal Bleeder Cartridge Valve Figure 5-122.
PAGE 237
SECTION 5 - HYDRAULICS 5.6 HYDRAULIC PUMP (GEAR) 7. Remove pump from vise and place on clean work bench. Remove four hex head bolts and spacers if applicable. 8. Lift and remove end cover. 9. Carefully remove gear housing and place on work bench. Make sure rear bearing block remains on drive and idler shafts. Disassembly NOTE: The following general instructions also apply to multiple section gear pumps.
PAGE 238
SECTION 5 - HYDRAULICS 10. Remove rear bearing block from drive and idler shafts. 13. Remove front bearing block. 11. Remove idler shaft from bearing block. 14. Turn mounting flange over, with shaft seal up. Remove retaining ring with snap ring pliers. 12. Remove drive shaft from mounting flange. 15. Remove oil seal from mounting flange. Do not mar or scratch seal bore. 16. Remove dowel pins from gear housing. Do not lose pins. NOTE: Shaft seal will be replaced. 17.
PAGE 239
SECTION 5 - HYDRAULICS Inspect Parts For Wear 1. 2. 3. 4. Inspect gear face for scoring or excessive wear. If face edge of gear teeth are sharp, they will mill into the bearing blocks. If wear has occurred, parts are unusable. 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 inside surface of intake side is normal.
PAGE 240
SECTION 5 - HYDRAULICS General Information 2. Install retaining ring in groove in seal bore of mounting flange. 3. Place front and back bearing blocks on a clean surface with E-seal grooves facing up. Apply a light coating of petroleum jelly in the grooves. Coat E-seal and backup with petroleum jelly. This helps keep seals in place during reassembly 4. Place E-seals, flat side out, into grooves in both bearing blocks.
PAGE 241
SECTION 5 - HYDRAULICS 5. Place mounting flange, with shaft seal side down, on a clean flat surface. 6. 7. 10. Place rear bearing block over drive and idler gear shafts with seal side up and open end of E-seal facing intake side of pump. Apply a light coating of petroleum jelly to exposed face of front bearing block. 11. Install two dowel pins in mounting flange holes or two long dowel pins through gear housing if pump is a multiple section pump.
PAGE 242
SECTION 5 - HYDRAULICS 13. Gently slide gear housing over rear bearing block assembly. Slide housing down until it engages dowel pins. Press firmly in place with hands, do not force or use any tool. Check intake port in housing is on same side as open end of E-seal, and marked lines on mounting flange and gear housing are aligned. 15. Install four spacers (if applicable) and hex head bolts through bolt holes in end cover. Hand tighten. 16.
PAGE 243
SECTION 5 - HYDRAULICS Placing Pump Back Into Service 1. 5.7 VARIABLE PUMP If shop test stand is available, use the following procedure for testing rebuilt pumps: a. Mount pump on test stand. Make sure proper level of clean oil is available in reservoir. Check suction line for leaks and obstructions. b. Start pump and run for three minutes at zero pressure. Ports and Pressure Gauges Proper servicing of pumps and motors requires pressure measured and monitored at various hydraulic circuit points.
PAGE 244
SECTION 5 - HYDRAULICS SHIM ADJUSTABLE STYLE Remove and Install FNR and NFPE Modules 1. Clean pump and module housings. 2. Remove four screws retaining module to pump housing (4 mm Int. Hex). Remove module from housing. 3. Remove O-rings from the control ports. Examine ports for cleanliness. 4. Clean sealing surfaces. 5. Replace locator pin. 6. Install new O-rings. 7. Replace screws. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).
PAGE 245
SECTION 5 - HYDRAULICS 1. System Pressure Gauge Port M2 7. Case Drain Port L2 2. System Pressure Port B 8. Servo Pressure Gauge Port L4 3. System Pressure Port A 9. Case Drain Port L1 4. System Pressure Gauge Port M1 10. Case Drain Port L1 (non-feedback) 5. Servo Pressure Gauge Port M5 11. Charge Pressure Gauge 6. Case Drain Port L2 (non-feedback) 12. Charge Pump Inlet Port S Figure 5-124.
PAGE 246
SECTION 5 - HYDRAULICS Torque # Plug/ Fitting lb. ft.
PAGE 247
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 5-127. Shaft Seal Components Figure 5-126. Screw Adjustable Charge Relief Valve Components A lip type shaft seal is used in Series 42 pumps.
PAGE 248
SECTION 5 - HYDRAULICS 1. Position pump with shaft facing up. NOTE: If unit is positioned horizontally when shaft is removed, cylinder block could move out of place, making shaft installation difficult. 2. Remove retaining ring from housing. 3. Pull out seal carrier assembly. 4. Remove O-ring from seal carrier. To install a new shaft only, go to step 8. 5. Place seal carrier in an arbor press with shaft bearing side down and press out old seal.
PAGE 249
SECTION 5 - HYDRAULICS Charge Pump NOTE: Disassemble charge pump to inspect and clean, or change auxiliary shaft drive coupling. 1. Remove auxiliary pump if necessary. 2. Remove screws retaining charge pump cover to pump housing (Torx T). Seven screws are used with “no pad” or SAE “A” auxiliary mounting pad charge pump cover, and six screws are used with SAE “B” auxiliary mounting pad charge pump cover. Remove charge pump cover, gasket, and cover locating pins. 3.
PAGE 250
SECTION 5 - HYDRAULICS NOTE: Oil used to fill component housing must be clean. Store fill container properly to prevent contamination. 5.8 HYDRAULIC COMPONENT START-UP The goal at hydrostatic system start up is to preserve the designed life span of the system. Use the following start-up procedure when a new pump or motor is installed or a system is restarted after a pump or motor has been removed and reinstalled.
PAGE 251
SECTION 5 - HYDRAULICS 5.9 PRESSURE SETTING PROCEDURES Articulating Jib Boom (If Equipped) COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS. JLG INDUSTRIES, INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES PRIOR TO CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALIBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF SPECIFIED PRESSURES. Main Relief, Steer, Swing, and Lift Down 1.
PAGE 252
SECTION 5 - HYDRAULICS " # $%&'( # ) ! ! "# Figure 5-132.
PAGE 253
SECTION 5 - HYDRAULICS " # $ %&'()*' +' $,' - ! ! "# Figure 5-133.
PAGE 254
SECTION 5 - HYDRAULICS ! " ! # $ % ! &" ' ( % $ % ! ) *+ , ! 1.
PAGE 255
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM speed, and max.-speed for all boom, drive, and steering functions. 6.1 INTRODUCTION WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS. AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/ ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
PAGE 256
SECTION 6 - JLG CONTROL SYSTEM & " ( ) * # ! " # ! " $ - ./0 $ # %& # ' + , Figure 6-2.
PAGE 257
SECTION 6 - JLG CONTROL SYSTEM Connect JLG Control System Analyzer 1. Using Analyzer Connect four pin end of cable supplied with hand-held or wireless analyzer to controller module on platform box or at controller module inside ground control box. Connect other end of cable to analyzer. NOTE: Cable has a keyed four pin connector at each end. It cannot be connected backwards. 1. Power up Control System by turning lower key to platform or ground position and pulling both emergency stop buttons out.
PAGE 258
SECTION 6 - JLG CONTROL SYSTEM If ENTER is selected at the HELP: PRESS ENTER display, and a fault is present, the analyzer display scrolls the fault across the screen. If no fault is detected, the display shows: HELP: EVERYTHING OK. If powered up at the ground station, the display shows: GROUND OK. If ENTER Pressing ENTER with any of the above displayed menus, displays additional sub-menus within the selected menu.
PAGE 259
SECTION 6 - JLG CONTROL SYSTEM Adjust Parameters Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN digit of the password, 3. Once you have gained access to level 1, and a personality item arrow keys, enter first is selected, press the UP adjust its value, for example: or DOWN arrow keys to Then using the RIGHT arrow key, position cursor right one space to enter the second digit of the password. Use the UP or DOWN arrow key to enter the second digit of the password which is 33271.
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SECTION 6 - JLG CONTROL SYSTEM There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: Machine Setup When a machine digit item is selected, press UP DOWN ELEVATION CUTBACK or arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFORMANCE OF YOUR MACHINE. AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION ABBREVIATION MEANING MEANING ACCELERATE GND ACTIVE GRN GREEN A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE AMB.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION S/C MEANING SHORT CIRCUIT SEL SELECTOR SN SERIAL NUMBER SPD STOW STOWD SW SPEED STOWED STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ.
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SECTION 6 - JLG CONTROL SYSTEM MENU: HELP:PRESS ENTER HELP: (001) EVERYTHING OK LOG:(xxx) x:xxxxxxxxxxx MENU: DIAGNOSTICS TO MENU: SYSTEM TEST DIAGNOSTICS: DRIVE/STEER DIAGNOSTICS: BOOM FUNCTIONS JOYSTICK DRIVE: FORWARD XXX% JOYSTICK LIFT: MAIN UP XXX% JOYSTICK STEER: LEFT XXX% LIFT OUTPUT: MAIN UP XXX% DRIVE OUTPUT: FORWARD XXX% LIFT UP COMMANDED:XXXXMA TO DIAGNOSTICS: ENGINE DRIVE FORWARD: COMMANDED:XXXXMA BRAKES STATUS: LOCKED LIFT DOWN COMMANDED:XXXXMA DRIVE REVERSE: COMMANDED:XXXXMA C
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SECTION 6 - JLG CONTROL SYSTEM From DIAGNOSTICS: BOOM FUNCTIONS DIAGNOSTICS: ENGINE DIAGNOSTICS: SYSTEM DIAGNOSTICS: UMS START SEQUENCE: NOT ACTIVE GROUND MODULE: BATTERY: XX.XV CHASSIS TILT ANGLE: XX.X BATTERY VOLTAGE: XX.XV PLATFORM MODULE: BATTERY: XX.XV UMS TO TURNTABLE ANGLE: XX.X COOLANT TEMPERATURE:XXXF AMBIENT TEMPERATURE:XXXF UMS INCLINATION ANGLE: XX.X ELECTRIC FAN OUTPUT: OFF PLATFORM SELECT KEYSWITCH: OPEN CHASSIS TILT X-AXIS: XX.
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SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: UMS DIAGNOSTICS: LOAD DIAGNOSTICS: CAN STATISTICS DIAGNOSTICS: 1 CALIBRATION DATA DIAGNOSTICS: DATALOG DIAGNOSTICS: VERSIONS CAPACITY LENGTH SWITCH: CLOSED CAN STATISTICS RX/SEC: X CALIBRATION DATA 1 LOAD ZERO: DATALOG: ON: XXXh XXm GROUND MODULE SOFTWARE: XX.XX CAPACITY ANGLE SWITCH: CLOSED CAN STATISTICS TX/SEC: X CALIBRATION DATA 1 LOAD 500LB: DATALOG: ENGINE: XXXh XXm GROUND MODULE COST. DATA:XX.
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SECTION 6 - JLG CONTROL SYSTEM FROM MENU: DIAGNOSTICS MENU: SYSTEM TEST SYSTEM TEST: ACTIVATE? MENU: ACCESS LEVEL ACCESS LEVEL: CODE XXXXXX MENU: PERSONALITIES PERSONALITIES: DRIVE PERSONALITIES: STEER PERSONALITIES: LEFT TRACK PERSONALITIES: RIGHT TRACK DRIVE: ACCEL X.XS STEER: MAX SPEED XXX% LEFT TRACK: ACCEL X.XS RIGHT TRACK: ACCEL X.XS DRIVE: DECEL X.XS LEFT TRACK: DECEL X.XS RIGHT TRACK: DECEL X.
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SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES: RIGHT TRACK PERSONALITIES: MAIN LIFT PERSONALITIES: SWING PERSONALITIES: TOWER LIFT PERSONALITIES: MAIN TELESCOPE PERSONALITIES: TOWER TELESCOPE MAIN LIFT: ACCEL X.XS SWING: ACCEL X.XS TOWER LIFT: ACCEL X.XS MAIN TELESCOPE: ACCEL X.XS TOWER TELESCOPE: ACCEL X.XS MAIN LIFT: DECEL X.XS SWING: DECEL X.XS TOWER LIFT: DECEL X.XS MAIN TELESCOPE: DECEL X.XS TOWER TELESCOPE: DECEL X.
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SECTION 6 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MACHINE SETUP MENU: CALIBRATIONS 1 MODEL NUMBER: 600S MARKET: CE ENGINE: PERKINS ECM FLYWHEEL TEETH: 133 TEETH GLOW PLUG: IN-CYLINDER STARTER LOCKOUT: DISABLED ENGINE SHUTDOWN: ENABLED TILT: 5 DEGREES JIB: NO 4 WHEEL STEER: NO STOUCH/SKYGUARD: NO GEN SET/WELDER: NO GEN SET CUTOUT: MOTION ENABLED H & T LIGHTS: NO CABLE SWITCH: NO LOAD SYSTEM: NO LOAD SENSOR: 4 UNDER PLATFORM FUNCTION CUTOUT: NO GROUND ALARM: MOTION DRIVE: 4
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the adjustment range for optimum machine performance. 6.2 MACHINE PERSONALITY SETTINGS Table 6-2. Personality Ranges/Defaults FUNCTION DRIVE PERSONALITY RANGE DEFAULTS - 600S ACCELeration 0.1s to 5.0s 2.0 DECELeration 0.1s to 3.0s 2.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION SWING PERSONALITY RANGE DEFAULTS - 600S ACCELeration 0.1 to 5.0s 2.0 DECELeration 0.1 to 3.0s 1.8 MINimum LEFT speed 0 to 50% 30 MAXimum LEFT speed 0 to 100% 65 CREEP maximum LEFT speed 0 to 65% 45 MINimum RIGHT speed 0 to 50% 30 MAXimum RIGHT speed 0 to 100% 65 CREEP maximum RIGHT speed 0 to 65% 45 800 to 2900 1400 ACCELeration 0.1 to 5.0 3.5 DECELeration 0.1 to 3.0 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION BASKET ROTATE PERSONALITY RANGE DEFAULTS - 600S ACCELeration 0.1 to 5.0 1.8 DECELeration 0.1 to 3.0 0.7 MlNimum LEFT speed 0 to 65% 46 MAXimum LEFT speed 0 to 100% 50 MINimum RIGHT speed 0 to 65% 46 MAXimum RIGHT speed 0 to 100% 50 800 to 2900 1500 ACCELeration 0.1 to 5.0 5.0 DECELeration 0.1 to 3.0 1.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Code Communicated (Displayed on Analyzer) Fault None 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 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Code Communicated (Displayed on Analyzer) Fault Description D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to battery has occurred. Inductive joysticks: The trigger points for these faults are dependent on the centertap voltage reading.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Code Communicated (Displayed on Analyzer) Fault Description l/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt range around these values where the fault may be indicated. Inductive joysticks: These faults occur when center tap voltage is not between 2.18 volts and 2.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Code Communicated (Displayed on Analyzer) Fault Description Priority LIFT UP DUMP SHORT TO BATTERY LIFT DOWN HOLDING SHORT TO GROUND LIFT DOWN HOLDING OPEN CIRCUIT LIFT DOWN SHORT TO BATTERY HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation. It may be reported during self test. FORD ECM POWER OPEN CIRCUIT This fault cannot be detected during normal operation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Code Communicated (Displayed on Analyzer) Fault FUEL SENSOR SHORT TO GROUND 4/4 Description Indicates fuel sensor is reading below 0.2 volts. Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second power-up. BATTERY LOW Battery voltage is below 11V for more than 5 seconds. This fault is not detected during crank. This is a warning – controller does not shut down.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Configuration Digit Number Description Default Number NOTE: Machine configuration must be completed before any personality settings can be changed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Configuration Digit TILT: 8 Number Description 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep. 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above elevation; also reduces drive speed to creep.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Configuration Digit Number Description Default Number H & T LIGHTS: 14 0 1 NO: No head and tail lights installed. YES: Head and tail lights installed. 0 CABLE SWITCH: 15* 0 1 NO: No broken cable switch installed. YES: Broken cable switch installed. 0 * Certain market selections will alter default setting. LOAD SYSTEM: 16* 0 NO: No load sensor installed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Configuration Digit FUNCTION CUTOUT: 18* Number 0 1 2 3 Description NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive cutout above elevation. DRIVE CUT E&T: Drive cutout above elevation and tilted. Default Number 0 * Only visible under certain market selections. * Certain market selections will limit function cutout options or alter default setting.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Configuration Digit Number Description Default Number CLEARSKY: 25 0 1 NO: ClearSky Telematics system not installed. YES: ClearSky Telematics system installed. 0 CRIBBING OPTION: 26 0 1 NO: Cribbing Option is disabled. YES: Cribbing Option is enabled. 0 FUEL TANK SIZE: 27 0 1 31 Gallon tank. 52 Gallon tank. 0 ALARM/HORN: 28 0 1 SEPERATE: Separate alarm and horn. COMBINED: combination alarm/horn.
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SECTION 6 - JLG CONTROL SYSTEM Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc;) Test Notes 1. Personality settings can be adjusted anywhere within the adjustment range for optimum machine performance. 2. Stop watch should start when function is activated - not controller or switch. 3. Unless noted, measure function speeds from platform. 4. Platform speed knob must be at full speed (fully clockwise). 5.
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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 6-6.
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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 6-6.
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
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SECTION 6 - JLG CONTROL SYSTEM Figure 6-11.
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SECTION 6 - JLG CONTROL SYSTEM " $ 2 7 " $ ) * + , . / " $ ) * + , . "/ " "" "$ ") "* "+ ", "".
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SECTION 6 - JLG CONTROL SYSTEM & & ' ( , / 1 2 3 & ' ( , / 1 2 &3 & && &' &( &, &/ & &1 &2 '3 ' '& '' '( ', ! # %$! ! " ) $# *" + -, . $ "$ " ) $# + *" + $ $$ ! # %$! # %$! "$ 0 % $ *" + 4 $ *" + $ +"#+ # %$! ! * *" + -, .
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SECTION 6 - JLG CONTROL SYSTEM ) # ( ) * . / 0 + # ( ) * . / 0 #+ # ## #( #) #* #.
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SECTION 6 - JLG CONTROL SYSTEM " " # % & ( ) + , . " # % & ( ) + , ". " "" "# "% "& "( ") "+ ", #. # #" ## #% #& /! 1 - ! - ! $1$ ' - $ * *!$$ $ ! !/ ! - * $1$ ' $ $$ ! $ ! / 6 !/ ! ! ' - ! ! &.. / ! ! 1 ! ...
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SECTION 6 - JLG CONTROL SYSTEM . $ & &%( / $ %& '( # $ %& '( * + . / # 4 ) " -) " 0 ) - ! " ! " )" ! ) " )" ! ) " ! " 4 ) " -) " 0 * + .
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SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-54 – JLG Lift – 3121616
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL Polarity This section contains basic electrical information and schematics for locating and correcting most electrical problems. If a problem develops which is not presented in this section or corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any additional maintenance.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS • To prevent oxidation at mechanical joint between male and female pins. Current Measurement • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with external seals. 1.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Dielectric Grease Application AMP Seal Before following these instructions, refer to excluded connector types (See Exclusions below). 1. Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors. 2. Apply dielectric grease to the female contact (fill it approximately ½ full; see example below) 3. Leave a thin layer of dielectric grease on connector face. 4.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON/PHOENIX CONTACT M12 AMP Mate-N-Lok This connector uses gold contact material to resist corrosion and an O-ring seal for moisture integrity. Low-force contacts cannot displace dielectric grease to achieve electrical contact. Once contaminated, replacement of female contacts is required. The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 connector system.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Connector Assembly Plug and header assembly colors are mechanically keyed to mate only with identical colors. 1. Check wedge lock is in the open, or as-shipped, position. Figure 7-13. AMP Connector Figure 7-15. AMP Connector Assembly Contact Assembly 1.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 4. After all contacts are inserted, close wedge lock to its locked position. Release locking latches by squeezing them inward. NOTE: Wedge lock should never be removed from housing for insertion or removal of contacts. Figure 7-17. Close Wedge Lock 5. Slide wedge lock in housing until flush with housing. Figure 7-19.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly 1. Grasp crimped contact (1) about 25mm behind contact barrel. 2. Hold connector with rear grommet (2) facing you. 3. Push contact straight into connector grommet (3) until a click is felt. A slight tug confirms it is locked in place. 1. Remove wedgelock (1) using needle-nose pliers or a hook shaped wire to pull wedge straight out. 2.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly 1. Grasp contact (1) about 25mm behind contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool (1) over wire of contact to be removed. 2. Hold connector with rear grommet (2) facing you. 2. Push tool in the insert cavity (2) until it engages contact and resistance is felt. 1 2 1 Figure 7-22. HD/HDP Contact Installation 3.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FOOTSWITCH PLATFORM FLOODLIGHTS 7500W GENERATOR PLATFORM BOX PLATFORM WORK LIGHTS J2 J5 J6 J1 J7 GENERATOR SWITCH J8 MAIN BOOM ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH (600A ANSI, ANSI EXPORT, BRAZILIAN & JAPANESE SPECS) BOOM LENGTH LIMIT SWITCH PLATFORM CONTROL BOX J2 J1 J12 J7 J8 J3 J4 HEADLIGHTS GROUND CONTROL BOX DIAGNOSTIC ANALYZER TAILLIGHTS Figure 7-26.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS OR OR 2500W GENERATOR RELAY 2500W GENERATOR CONTROL BOX 2500W GENERATOR 7500W GENERATOR CONTROL BOX ENGINE TO FUEL WATER IN CONTROL (DEUTZ TD2.9L4) PUMP FUEL IND. 7500W GENERATOR RELAYS ENGINE CONTROL (DEUTZ D2011) ECU MODULE GM OR FUEL REGULATOR (GM HARNESS) DEUTZ TD2.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001151752A - Sheet 1 Figure 7-28.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001151752A - Sheet 1 Figure 7-29.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Note: Zones refer to Figure 7-28 and 7-29. Figure 7-30.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Note: Zones refer to Figure 7-28 and 7-29. Figure 7-31.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Note: Zones refer to Figure 7-28 and 7-29. Figure 7-32.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Note: Zones refer to Figure 7-28 and 7-29. Figure 7-33.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 6 Figure 7-34.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 6 Figure 7-35.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 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 NOTES: 7-24 – JLG Lift – 3121616
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3121616 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65813058 JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG Latino Americana Ltda. Rua Eng.