Service Manual Manual

ManualsBrandsJLG ManualsSpecial machinery800A_AJ

Service and Maintenance Manual

Models

800A

800AJ

P/N - 3120858

December 12, 2012

Summary of content (466 pages)

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Service and Maintenance Manual Models 800A 800AJ P/N - 3120858 December 12, 2012
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised A-2 - August, 1998 - September 15, 1999 - August 29, 2001 - January 14, 2003 - October 19, 2004 - July 11, 2005 - June 12, 2007 - May 23, 2008 - December 12, 2012 – JLG Lift – 3120858
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 2.3 2.4 2.5 2.6 TITLE PAGE NO. Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Changing Hydraulic Oil . . . . .
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TABLE OF CONTENTS SECTION NO. 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 3120858 TITLE PAGE NO. Drive Motor (S/N 83332 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.24 3.25 3.26 3.27 3.28 3.29 3.30 iv TITLE PAGE NO. EFI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92 Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92 EFI Diagnostics (Prior to S/N 0300065534) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.31 3.32 TITLE PAGE NO. GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-136 Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136 Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136 Propane Fuel Filter Replacement . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 vi TITLE PAGE NO. Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Upper Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 4.20 TITLE PAGE NO. UMS Troubleshooting and Fault Messages - ADE Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67 Backward Stability Concern Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67 Forward Stability Concern Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67 Auto Detection Input Low Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 CANbus Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 2-1. 2-2. 2-3. 2-4. 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. 3120858 TITLE PAGE NO. Lubrication and Operator Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 3-44. 3-45. 3-46. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 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. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. x TITLE PAGE NO. Swing Brake (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-34. 5-35. 5-36. 6-1. 6-2. 3120858 TITLE PAGE NO. Transportation Switch Installation. (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 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. 7-40. 7-41. 7-42. 7-43. 7-44. xii TITLE PAGE NO. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 7-45. 7-46. 7-47. 7-48. 7-49. 7-50. 7-51. 7-52. 7-53. 7-54. 7-55. 7-56. 7-57. 7-58. 7-59. 7-60. 7-61. 7-62. 7-63. 7-64. 7-65. 7-66. 7-67. 7-68. 7-69. 7-70. 3120858 TITLE PAGE NO. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford Prior to S/N 99884 - Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22 1-23 1-24 1-25 1-26 1-27 1-28 1-29 1-30 1-31 1-32 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 4-1 4-2 4-3 5-1 5-2 5-3 5-4 5-5 xiv TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 5-6 5-7 5-8 5-9 5-10 5-11 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 3120858 TITLE PAGE NO. Actuator Response Is Sluggish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44 Low Pump Output Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally.
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Capacities Table 1-1. Operating Specifications Table 1-2. Capacities Travel Speed 2WD 4WD 3.0 MPH (4.83 Km/hr.) 3.0 MPH (4.83 Km/hr.) Gradeability 2WD 4WD 30% 45% Turning Radius (Outside) 2WS 4WS 22 ft.- 6 in. (6.86 m) 14 ft.- 6 in. (4.42 m) Turning Radius (Inside) 2WS 4WS 12 ft.- 0 in. (3.66 m) 11 ft.- 0 in. (2.13 m) Overall Width Machine Height Stowed Machine Length (Stowed) 800A 800AJ Wheel base 8 ft.-0 in.
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SECTION 1 - SPECIFICATIONS Table 1-4. Deutz F4M2011F Specifications Table 1-6. Caterpillar 3044C Type Liquid Cooled (Oil) Fuel Diesel Oil Capacity Cooling System Crankcase Total Capacity 5 Quarts (4.5 L) 11 Quarts (10.5 L) w/Filter 16 Quarts (15 L) 1000 Low RPM 1800 High RPM 2800 Alternator 55 Amp, belt drive Battery 1.90 GPH (7.19 lph) 2.50 GPH (9.46 lph) 1000 Cold Cranking Amps, 210 minutes Reserve Capacity, 12 VDC Horsepower Cylinders 4 in-line 65 @ 2800 RPM, full load 3.
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SECTION 1 - SPECIFICATIONS Tires Hydraulic Drive Pump Table 1-9. Tire Specifications Table 1-12. Hydraulic Drive Pump Specifications Pump Output 35.5 GPM (134 lpm) @ 2800 RPM Size Type Ply Rating Load Range IN 385/65D 19.5 pneumatic 16 H 95PSI (6.5 Bar) IN 445/55D 19.5 pneumatic 16 H 85 PSI (6.0 Bar) 15 X 19.5 pneumatic 16 H 95PSI (6.5 Bar) 18 X 19.5 pneumatic 16 H 85 PSI (6.0 Bar) IN 385/65D 19.5 foam-filled 16 H N/A IN 445/55D 19.5 foam-filled 16 H N/A Type 15 X 19.
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SECTION 1 - SPECIFICATIONS Hydraulic Filter - In-line Test Notes Table 1-16. Hydraulic FIlter Specifications Return Filter 10 Microns Absolute Charge Filter 10 Microns Absolute Hydraulic Strainers (In Tank) 1.3 1. Stop watch should be started with the function, not with the controller or switch. 2. Drive test results reflect 15x19.5 or 18x19.5 tires, pneumatic or foam filled. 30 Microns 3. All speed tests are run from the platform. These speeds do not reflect the ground control operation.
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SECTION 1 - SPECIFICATIONS 1.4 TORQUE REQUIREMENTS 1.5 Hydraulic Oil Table 1-18. Torque Requirements Description Torque Value (Dry) LUBRICATION Table 1-19. Hydraulic Oil Interval Hours Hydraulic System Operating Temperature Range Wheel Bolts 300 ft. lbs. (407 Nm) 150 Support to Rotator Bolts 50 ft. lbs. (68 Nm) 150 Rotator Center Bolt 480 ft.lbs. (651 Nm) 150 Swing Bearing Bolts 190 ft. lbs. (260 Nm) 50/600* Starter or Aux Pump Solenoid Contacts Coil 95 in. lbs. (10.5 Nm) 40 in. lbs.
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SECTION 1 - SPECIFICATIONS Table 1-21. Mobil DTE 13M Specs ISO Viscosity Grade #32 Specific Gravity 0.877 Pour Point, Max -40°F (-40°C) Flash Point, Min. 330°F (166°C) Table 1-24. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity Viscosity at 40° C 33cSt at 100° C 6.6 cSt at 100° F 169 SUS at 210° F 48 SUS cp at -20° F 6,200 Viscosity Index 140 at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index 376 NOTE: 1.
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SECTION 1 - SPECIFICATIONS 1.7 CYLINDER SPECIFICATIONS Table 1-26. Cylinder Specifications - 800A DESCRIPTION BORE STROKE ROD DIA. Lower Left 8.00 (203.2) 49.38 (1254.1) 3.00 (76.2) Tower Telescope 4.00 (101.6) 79.50 (2019.3) 2.50 (63.5) Upright Level 8.00 (203.6) 42.00 (1066.8) 3.50 (88.9) Upper Lift 8.00 (203.2 28.75 (730.3) 3.50 (88.9) Upper Telescope 3.50 (88.9) 244.0 (6197.6) 2.75 (69.9) Steer 3.00 (76.2) 10.75 (273.1) 1.50 (38.1) Lockout 4.00 (101.6) 3.88 (98.4) 1.
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SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS Table 1-29. Major Component Weights - 800AJ MAJOR COMPONENTS Table 1-28. Major Component Weights - 800A MAJOR COMPONENTS Platform & Control Console LBS. KG.
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SECTION 1 - SPECIFICATIONS Critical Stability Weights Table 1-31. Critical Stability Weights - 800AJ COMPONENTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY. Table 1-30. Critical Stability Weights - 800A Engine Counterweight Wheel Hubs Platform 3120858 Engine KG. 365/65D19.5 565 255 445/55D19.5 675 305 15 X 19.
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SECTION 1 - SPECIFICATIONS Figure 1-1. Lubrication and Operator Maintenance Diagram 1.9 LUBRICATION AND OPERATOR MAINTENANCE NOTE: It is recommended as a good practice to replace all filters at the same time. NOTE: The following numbers correspond to those in Figure 1-1., Lubrication and Operator Maintenance Diagram. 1. Swing Bearing - Internal Ball Bearing Table 1-32. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
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SECTION 1 - SPECIFICATIONS 2. Wheel Bearings 4. Hydraulic Return Filter Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 5. Hydraulic Charge Filter 3. Wheel Drive Hub Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.
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SECTION 1 - SPECIFICATIONS 7. Suction Strainers 9. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts(10.5 L) Crankcase Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual. Refer to Figure 1-2., Deutz Engine Dipstick. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 8.
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SECTION 1 - SPECIFICATIONS 14. Fuel Filter - Deutz 10. Oil Change w/Filter - Isuzu Lube Point(s) - Fill Cap/Spin-on Element Capacity - 8.5 qt. (8.0L) engine; 5.3 qt. (5.L) cooler Lube - EO Interval - Change oil after first 50 and every 200 hrs. there after. Change oil filter after 50hrs. and every 400 hrs. there after. Comments - Check level daily/Change in accordance with engine manual. 11. Oil Change w/Filter - Caterpillar Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10.
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SECTION 1 - SPECIFICATIONS 2. Start the engine and bring to operating temperature. 19. Electronic Pressure Regulator (LP only) 3. With the engine running, close the manual tank valve and run the engine out of fuel. 4. Push in the Emergency Switch once the engine stops. 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. Interval - 3 Months or 150 hours of operation Comments - Drain oil build up.
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SECTION 1 - SPECIFICATIONS Propane Fuel Filter Replacement 1 1 7 8 7 8 2 13 9 3 9 3 10 10 4 4 OR 5 5 11 6 11 12 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 Figure 1-3. Filter Lock Assembly REMOVAL INSTALLATION 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2.
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SECTION 1 - SPECIFICATIONS Propane Fuel System Pressure Relief THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS. To relieve propane fuel system pressure: 1. Close the manual shut-off valve on the propane fuel tank. 2. Start and run the vehicle until the engine stalls. 3. Turn the ignition switch OFF.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) 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: 1-24 – JLG Lift – 3120858
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
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SECTION 2 - GENERAL Section 1. Always examine filters for evidence of metal particles. 2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed. 3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion.
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SECTION 2 - GENERAL ature and temperature stabilized. 2.6 The cylinder must have the normal load, which is the normal platform load applied. NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external structure, or component, If the cylinder passes this test, it is acceptable. NOTE: This information is based on 6 drops per minute cylinder leakage. 2.5 Do the Following When Welding on JLG Equipment • Disconnect the battery.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120° F(49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F(43° C) 100° F(38° C) 90° F(32° C) 80° F(27° C) SUMMER GRADE FUEL ENGINE SPECIFICATIONS 70° F(21° C) 60° F(16° C) 50° F(10° C) 40° F(4° C) 30° F(-1° C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL 4150548 E Figure 2-2.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE SPECIFICATIONS 60 F(16 C) 50 F(10 C) 40 F(4 C) 30 F(-1 C) 20 F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL 4150548 E Figure 2-4.
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS ment tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.
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SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. 3. Using a Phillips screwdriver, remove screw from connection on the brake valve and remove connector as shown. Table 3-1. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 70 ft. lbs. (95 Nm) 170 ft. lbs. (225 Nm) 300 ft. lbs. (405 Nm) 4.
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SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test. 3.
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SECTION 3 - CHASSIS & TURNTABLE 3.4 TORQUE HUB, DRIVE 4. Inspect all geared components for chipped or broken teeth and for excessive or uneven wear patterns. Disassembly 5. Inspect carrier for damage, especially in anti-roll pin and planet shaft hole areas. 1. Position hub over suitable container and remove drain plugs (10) from unit. Allow oil to completely drain, then replace drain plugs. 6. Inspect all planet shafts for scoring or other damage. 2.
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SECTION 3 - CHASSIS & TURNTABLE 2. Carrier Assembly. a. Drive anti-roll pin (19) into planet shaft (17) using a suitable punch. b. Using a suitable press, press planet shaft from carrier (13). After planet shaft is removed, drive anti-roll pin from shaft. c. Remove cluster gear (18) and thrust washers (14) from carriers. d. Remove sixteen needle rollers (15) from cluster gear bore. e. Remove spacer (16) from cluster gear bore and remove second set of sixteen needle rollers (15). f.
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SECTION 3 - CHASSIS & TURNTABLE o. Drive anti-roll pin flush into carrier hole, locking planet shaft into place. p. repeat steps (h) through (o) for remaining two cluster gears. 3. Input Shaft Assembly. Install retaining ring into input shaft groove to secure spacers and spring to shaft. Assembly 1. Using a suitable press, press new bearing cups (3, 5), with large inside diameters facing out, into hub (7) counter bores. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION a.
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SECTION 3 - CHASSIS & TURNTABLE 6. Place bearing shim (8) over end of spindle and against bearing cone. 3. Press new seal (2) into hub counter bore with flat metal side facing in. Use a flat object to ensure that seal is pressed evenly and is flush with hub face. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. 7. Install new retaining ring (9) completely into spindle groove and against bearing shim. Ensure retaining ring is entirely in groove. 4.
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SECTION 3 - CHASSIS & TURNTABLE 8. Place internal gear (12) onto end of spindle. 9. Install thrust washers and thrust bearing (39, 40) on the portion of the spindle which extends into the internal gear. 10. Install retaining ring (34) into input shaft retaining ring groove. 11. Place input shaft assembly (35) into spindle bore with unsplined end facing out. 3-8 12. Place thrust spacer (36) over input shaft (35) with counter bore side facing spindle. 13.
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SECTION 3 - CHASSIS & TURNTABLE 15. Place carrier assembly on a flat surface with large gears up and positioned as shown. Find punch marked tooth on each large gear and locate at 12 o’clock (straight up) from each planet pin. Marked tooth will be located just under carrier on upper two gears 18. Install input gear (37) into carrier, meshing with large diameter cluster gears (18). Counter bore in bore of input gear must be to outside of carrier assembly. 19.
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SECTION 3 - CHASSIS & TURNTABLE 21. Place o-ring (22) into cover assembly counter bore. Use petroleum jelly or grease to hold o-ring in place. 24. Install bolts (41) in remaining holes. Torque bolts to 47 ft. lbs. (64 Nm). 25. Place coupling (1) into spindle and onto input shaft. 22. Place cover assembly over ring gear with oil level check plug in cover located approximately 90 degrees from oil fill plug in hub. 23.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
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SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE BRAKE - AUSCO (PRIOR TO S/N 56875) Disassembly 1. With shaft protrusion downward, disassemble the parts in the following order; bolts (24 alternately, washers (23), power plate (21), and gasket. 2. Remove the following parts; stationary discs (14), rotating discs (12), primary disc (11), torque pins (3), springs (8&9), and the spring retainer (7). Assembly NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Housing Gasket Torque Pin Ball Bearing Retaining Ring Seal Spring Retainer 8. 9. 10. 11. 12. 13. Small Compression Ring Large Compression Ring Shaft Primary Disc Rotating Disc Not Used 14. 15. 16. 17. 18. 19. Stationary Disc Piston Backup Ring O-ring Backup Ring O-ring 20. 21. 22. 23. 24. 25. Bleeder Screw Power Plate Protective Plug Washer Bolt Gasket Figure 3-4.
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SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE BRAKE - MICO (S/N 56875 TO 83332) 3. Press bearing (18) into position until it bottoms out on borestep. NOTE: Cover plate (16) must be supported as indicated in Figure 1. Disassembly 1. Remove pressure plate (3) from cover plate (16) by removing cap screws (1) and washers (2). 4. Install retaining ring (20) in cover plate (16). 5. Press shaft (10) into bearing (18) until it bottoms on shoulder.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Capscrew Washer Pressure Plate Case Seal O-ring Backup Ring Piston 8. 9. 10. 11. 12. 13. 14. O-ring Backup Ring Shaft Stator Disc Rotor Disc Return Plate Springs 15. 16. 17. 18. 19. 20. Dowel Pin Cover Plate Oil Seal Bearing Retaining Ring Retaining Ring Figure 3-5.
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SECTION 3 - CHASSIS & TURNTABLE Bleeding top port. Pressure should not exceed 6.9 bar (100 psi) during bleeding. 1. Install brake in system and connect pressure lines. 3. Apply sufficient pressure to release brake and check for proper operation in system. 2. Bleed pressure release section of brake by pressurizing side inlet port and allowing air to escape from Table 3-2.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE BRAKE (S/N 83332 TO PRESENT) Assembly 1. Lightly lubricate rotary shaft seal (12) and assemble to housing (2) taking care not to damage seal lip. Disassembly 2. Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing (2) bearing recess adjacent to shoulder. 1.
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SECTION 3 - CHASSIS & TURNTABLE 13 14 20 5 8 7 17 18 9 15 16 1 6 3 21 6 3 4 19 22 23 2 12 10 1. 2. 3. 4. 5. Shaft Housing Friction Plate Pressure Plate Gasket 6. 7. 8. 9. 10. Outer Plate Gasket Cylinder Piston Ball Bearing 11. 12. 13. 14. 15. Retaining Ring Shaft Seal Capscrew Lockwasher O-ring 16. 17. 18. 19. 20. Backup Ring O-ring Backup Ring Dowel Pin Plug 11 21. Plug 22. Spring (Natural) 23. Spring (Blue) Figure 3-6.
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SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE MOTOR (PRIOR TO S/N 83332) Rotary group complete 9 pistons, cylinder sub-assembly, valve plate (cw or ccw corresponding to the order) retaining plate and retaining ball. Spare Parts Kits Sealing kit, existing spare parts: shaft sealing ring, 6 different O-rings and a circlip (sealing mat.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-7. 600S Drive Motor Cutaway 2. Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring. Replacing the Drive Shaft Seal 1.
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SECTION 3 - CHASSIS & TURNTABLE 3. Be careful while you seal the drive shaft, use an adhesive tape to protect the splines. Disassembly and Assembly 1. Disassemble the pilot valve. 4. Assemble the sealing ring. The fitting tool will hold the sealing ring in the correct position in the pump housing. 2. Mark the position of the port plate and remove the socket screw from the port plate. 5. Assemble the snap ring. 3.
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SECTION 3 - CHASSIS & TURNTABLE 8. Loosen the retaining nut of the stopper max flow and remove it. 4. Remove the O-ring. 5. Disassemble the taper roller bearing. 9. Turn in the stopper max flow to get swivel angle zero. 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper - max. flow.
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SECTION 3 - CHASSIS & TURNTABLE 12. Remove the threaded pin (stopper - max.flow) 16. Disassembly of the swash plate. 13. Disassemble the plug. 17. Remove the spring. 14. Disassemble the control piston while moving the swash plate. 18. Remove both bearing shells. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disassemble the piston rod.
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SECTION 3 - CHASSIS & TURNTABLE 23. Remove the O-ring. Lifting of the valve plate isn’t shown. 20. Remove the snap ring. 21. Disassemble the sealing ring. 24. A usual commercial bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care not to damage the surface of the port plate. 22. The external front bearing ring is pulled out of the pump housing. 25.
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SECTION 3 - CHASSIS & TURNTABLE Assembly Notes 4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees de-centered in ccw position. 1. Measurement of the taper roller bearing pretension. 2. Note that there is a correct connection of the piston rod and the swash plate. 5. Assembly of the port plate and the pump housing: Note the correct position of the drilling that connects high pressure to the control valve.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin each rotation is appr. 3,1 cm3. Figure 3-8.
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SECTION 3 - CHASSIS & TURNTABLE Testing and Setup DR: When pressure line is closed adjust the pressure of the controller (if it’s DFR design then open the adjustable orifice and increase force of the spring - FR -). Mechanical flow limiter: While screwing in the threaded pin you will be able to reduce the flow from Vg max to 50% of Vg max. 3.9 FR: If swivel angle is in the mid position adjust differential pressure 14 bar adjustable orifice is partly closed).
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SECTION 3 - CHASSIS & TURNTABLE 3.10 DRIVE MOTOR (S/N 83332 TO PRESENT) Shaft Seal Replacement REMOVAL Description 1. Remove the snap ring (1) retaining the shaft seal and support washer. The drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston. They are designed for operation in both open and closed circuit applications. The standard control is a direct acting single line hydraulic control. The integral servo piston controls motor displacement.
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SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT THE COMPONENTS Inspect new O-rings and the sealing area for rust, wear, or contamination. Also check springs and poppet for wear. REMOVAL 1. Using a 11/16 in internal hex wrench remove plug (1) and (2). 6 1. Install orifice poppet (13). 2. Install shift spool (12). 9 11 INSTALLATION 2 11/16 in 3. Install spring retaining washers onto springs (10 and 11). 27 ft.lbs. (37 Nm) 4. Carefully install centering springs (7, 8, and 9). 5.
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SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil supply to the motor. Insufficient hydraulic fluid could lead to cavitation that would cause system noise. Fill the reservoir to the proper level and ensure that oil supply to the motor is adequate and the lines are unobstructed. Check for air in the system.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly 17 NOTE: Removal of the endcap voids warranty. 19 During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. 15 Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. 14 6 21 9 11 5 7 2 13 18 3 12 10 8 4 16 16 1 20 14. 15. 16. 17. 1. 2. 3. 4.
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SECTION 3 - CHASSIS & TURNTABLE 25 22 27 30 29 23 26 24 29 28 22. Screw 23. End Cap 24. O-ring 25. 26. 27. 28. 29. 30. Figure 3-15. End Cap 13. Using an 8 mm internal hex wrench, remove the endcap screws (22). Figure 3-16. Valve Plate & Rear Shaft Bearing 14. Remove the endcap (23). Remove O-ring (24) from the housing or endcap. When the endcap screws are removed, pressure from the servo spring will cause the endcap to bind on the shaft.
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SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring (30) from the housing. To avoid damaging the shaft during seal removal. Install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal. 36 31 35 37 38 31. Cylinder Kit Assembly Figure 3-17. Cylinder Kit 19. Turn the housing on its side and remove the cylinder kit assembly (31).
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SECTION 3 - CHASSIS & TURNTABLE Lift here 44 39 45 47 40 48 43 42 49 41 46 53 52 39. 40. 41. 42. 43. Swashplate Servo Piston Piston Seal O-ring Journal Bearings 50 51 Figure 3-20. Swash Plate & Servo Piston 44. 45. 46. 47. 48. 23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever. 24. Remove the servo piston (40). Remove the piston seal (41) and O-ring (42) from the servo piston. Discard the seal and O-ring. 25.
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SECTION 3 - CHASSIS & TURNTABLE SLIPPERS 28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining ring (51). Carefully release the pressure and remove the outer block spring washer (50), block spring (52), and inner block spring washer (53) from the cylinder block. Inspect the running surface of the slippers.
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SECTION 3 - CHASSIS & TURNTABLE BALL GUIDE AND SLIPPER RETAINER Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat. Do not reuse. Replace swashplate if the difference in thickness from one side to the other exceeds specification. 0.0025 mm [0.0001 in] Slipper retainer 25.8 mm LV [1.015 in] mm KV 24.6 [0.969 in] Ball guide Thickness equality side to side: 0.05 mm [0.
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SECTION 3 - CHASSIS & TURNTABLE SERVO PISTON AND MINIMUM ANGLE STOP Assembly Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace if necessary. 1. Install new O-ring (1) and piston seal (2) to the servo piston (3). Install the piston seal over the O-ring. Installing the piston seal stretches it, making it difficult to install the servo piston in its bore. Allow 30 minutes for the seal to relax after installation.
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SECTION 3 - CHASSIS & TURNTABLE RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. 3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder block.
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SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) onto shaft. 10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the slippers facing the swashplate. Rock the shaft to align the block splines and slide the cylinder kit into place.
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SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the endcap. Install the bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface. 22 2 mm [0.08 in] 23 3 mm [0.12 in] 15. Install the endcap (25) onto the housing with the endcap screws (26). Check to ensure the endcap will properly seat onto the housing without interference. Improper assembly of the internal components may prevent the endcap from seating properly.
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SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with the cup side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. Install seal support washer (28) and snap ring (29). 19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation torques. 5/16 in 63 ft.lbs. (85 Nm) 1/4 in 33 ft.lbs.
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SECTION 3 - CHASSIS & TURNTABLE Initial Start-up Procedures 20. Install orifice poppet (30). Follow this procedure when starting-up a new motor or when installing a motor that has been removed. 37 36 33 39 41 34 11/16 in 30 27 ft.lbs. (37 Nm) 40 5/8 in 20 ft.lbs. (27 Nm) 32 35 38 Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid. 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.11 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not penetrate under the bolt head to the bolt shank. Turntable Bearing Mounting Bolt Condition Check d. Swing the turntable 90 degrees, and check some selected bolts at the new position. NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-33. Swing Bearing Tolerance Boom Placement.
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Figure 3-34. Swing Bearing Tolerance Boom Placement.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-36. Swing Bearing Tolerance Measuring Point Figure 3-35. Swing Bolt Feeler Gauge Check Swing Bearing Replacement Wear Tolerance 1. Removal. 1. From the underside of the machine, at rear center, with the upper boom fully elevated and fully retracted, and tower boom stowed, as shown in Figure 3-33., Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2), using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable.
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SECTION 3 - CHASSIS & TURNTABLE Machines built prior to S/N 0300068040 NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Machines built S/N 0300068040 to Present Figure 3-37.
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SECTION 3 - CHASSIS & TURNTABLE h. Carefully place the turntable on a suitably supported trestle. ensure that the filler plug fitting is at 90 degrees from the fore and aft center line of the turntable. i. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Swing Torque Hub Adjustment 3.12 SWING HUB INSTALLATION 1. Ensure mounting plate and mounting location of the base plate are clean and painted with a uniform coating of minimum thickness. (no runs, drips, etc.) 2. Assemble mounting plate, hub, brake, and motor. 3. Torque Items #1 to 120 ft. lbs.(17kgm)(w/#242 Loctite) 6. With bearing free to slide, shim between pinion gear and the bearing teeth to +0.008" / +0.012" (+0.20mm/+0.30mm)backlash. 7.
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SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING HUB (PRIOR TO S/N 0300068040) Assembly 1. With the Hub Shaft Sub-assembly resting on the Shaft (1A) install Internal Gear (2). The Spline of the Internal Gear (2) bore will mesh with the Spline of the Output Shaft (1A). Disassembly 1. Loosen all 12 Cover Bolts (12) 8 (13) and drain the oil from the unit. 2. Remove the 12 Cover Bolts (12) 8 (13) and lift off the Cover (6). Remove and discard the o-ring (5) from the counterbore of the Cover (6). 3.
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SECTION 3 - CHASSIS & TURNTABLE Also at this time locate and mark the 4 counter beamed holes in the face of the Hub (1G). This is for identification later in the assembly. 6. With shoulder side of Ring Gear (4) facing down, place Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation. The side of the Ring Gear with an X stamped on it should be up. 4. Thrust Spacer (9) is installed into the bore of the Output Shaft (1A).
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SECTION 3 - CHASSIS & TURNTABLE 8. Input Gear (8) is installed, meshing with the teeth of the large diameter Cluster Gear (3F). The counterbore on the Input Gear (8) locates on the shoulder of the Thrust Spacer (9). This is to be a slip fit and operate freely. 11. Place o-ring (5) into Cover (6) counterbore. Use petroleum jelly to hold o-ring in place. BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O-RING. 9.
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SECTION 3 - CHASSIS & TURNTABLE 13. Install regular Grade 8 Bolts (12) into remaining holes. Hub Shaft Sub-Assembly 14. Pipe Plugs (20) are to be installed into Cover (6) using a lubricant seal of some sort. 15. Torque Shoulder Bolts (13) to 23-27 ft.-lbs. and regular Grade 8 Bolts (12) to 23-27 ft.– lbs. 1. Press Bearing Cone (1D) onto Shaft (1A). 2. Press Bearing Cup (1C) into Hub (1G) taking care to insure cup start square with the bore of Hub (1G). 3.
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SECTION 3 - CHASSIS & TURNTABLE 4. Returning the Hub (1G) to locate on the large diameter end, the Output Shaft (1A) is carefully installed into the Hub (1G). 5. The Shaft Seal (1B) is installed over the Output Shaft (1A) and into the counterbore of the Hub (1G). Care should be taken to insure the Seal (1B) is being correctly installed (smooth face UP and located just flush with the counterbore face). 3-54 – JLG Lift – 6. The Bearing Cone (1F) is an interference fit and has to be pressed or tapped on.
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SECTION 3 - CHASSIS & TURNTABLE 8. Bearing Spacer (1H) is installed around the Output Shaft (1A) and locates on Bearing Cone (1F). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 10. A soft metal punch should be used to insure that this Retaining Ring (11) is completely seated in the groove of the Output Shaft (1A). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 9. Retaining ring (11) installed into the groove provided in the Output Shaft (1A).
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SECTION 3 - CHASSIS & TURNTABLE Carrier Sub-Assembly 4. Place second set of sixteen Needle Rollers into Cluster Gear. 1. Apply a coat of grease or petroleum jelly to Cluster Gear bore. 5. Apply grease or petroleum jelly to the tang side of two Thrust Washers. Place Thrust Washers against bosses in Carrier with washer tang fitting into slot in Carrier outside diameter. 2. Place sixteen Needle Rollers into Cluster Gear bore.
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SECTION 3 - CHASSIS & TURNTABLE 6. While keeping Thrust Washers in place, slide Cluster Gear into Carrier with the larger gear on the side with the small pin hole. 7. Line up Cluster Gear and thrust Washers with hole in Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pin hole in Carrier. 3120858 – JLG Lift – 8. Drive Anti-Roll Pin flush into Carrier hole, thereby locking Planet Shaft into place. 9.
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Figure 3-39.
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SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BRAKE - AUSCO (PRIOR TO S/N 0300068040) Disassembly 1. With the shaft protrusion downward, Disassemble the parts in the following order; bolts (24) alternately, washers (23), power plate (21), and gasket. 2. Remove the following parts; stationary discs (14), rotating discs (12), primary disc (11), torque pins (3), springs (8&9), and the spring retainer (7). Assembly NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-40.
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SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING MOTOR (EATON) (PRIOR TO S/N 0300068040) Cleanliness is extremely important when repairing hydraulic motors. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the motor. Before disassembly, drain oil from the motor. Then plug the ports and thoroughly clean the exterior of the motor. Check the output shaft, remove any burrs, nicks, or sharp edges. Disassembly 1.
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SECTION 3 - CHASSIS & TURNTABLE housing. Apply just enough heat to remove screw, do not over heat the motor housing or mounting flange. Reassembly Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage.
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SECTION 3 - CHASSIS & TURNTABLE 3. Lightly stretch, lubricate and install the second of the three larger diameter seals in the groove in the Geroler. Standard Timing: Align any star point with threaded hole noted for the location of the timing dot. Reverse Timing: Align any star valley with the threaded hole noted for the location of the timing dot. 4. Rotate the geroler to align the screw holes and install driver spacer if applicable. 5.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Capscrew Exclusion Seal Mounting Flange Backup Ring Pressure Seal Seal Bearing Race Needle Thrust Bearing Key Output Shaft 11. 12. 13. 14. 15. 16. 17. 18. 19. Housing Seal Drive Spacer Plate Seal Geroler Seal End Cap Capscrew Figure 3-42.
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SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING HUB (S/N 0300068040 TO PRESENT) 12. The cluster gear (3F) can now be removed from the carrier (3A). THe thrust washers (3B) will be removed with the cluster gear (3F). Disassembly 13. The needle rollers (3C) and spacer (3D) are now removed from the cluster gear (3F). 1. Loosen all 12 cover bolts (12)&(13) and drain the oil from the unit. 2. Remove the 12 cover bolts (12)& (13) and lift off the cover (6).
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SECTION 3 - CHASSIS & TURNTABLE 3. Place O-ring (5) into hub counterbore. Use petroleum jelly to hold O-ring in place. Also at this time locate and mark the 4 counter beamed holes in the face of the hub (1G). This is for identification later in the assembly. 6. With shoulder side of ring gear (4) facing down, place ring gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during ring gear installation. The side of the ring gear with an x stamped on it should be up.
PAGE 123
SECTION 3 - CHASSIS & TURNTABLE 8. Input gear (8) is installed, meshing with teeth of the large diameter cluster gear (3F). The counterbore on the input gear (8) locates on the shoulder of the thrust spacer (9). This is to be a slip fit and operate freely. 9. Thrust washer (10) is installed onto the input gear (8) and should locate on the gear teeth shoulder. BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O-RING. 12. The cover (6) is now installed on this assembly.
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SECTION 3 - CHASSIS & TURNTABLE 14. Pipe plugs (20) are to be installed into cover (6) using a lubricant of some sort. 2. Press bearing cup (1C) into hub (1G) taking care to insure cup start square with the bore of the hub. 15. Torque shoulder bolts (13) to 23-27 ft./lbs. and regular grade 8 bolts (12) to 23-27 ft./lbs, 3. Invert hub (1G) and press bearing cup (1E) into inter counterbore of hub (1G). This completes the assembly.
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SECTION 3 - CHASSIS & TURNTABLE 5. The shaft seal (1B) is installed over the output shaft (1A) and into the counterbore of the hub (1G). Care should be taken to insure the seal (1B) is being correctly installed (smooth face up and located just flush with the counterbore face). 8. Bearing spacer (1H) is installed around the output shaft (1A) and locates on bearing cone (1F). 9. Retaining ring (1I) installed into groove provided in the output shaft (1A).
PAGE 126
SECTION 3 - CHASSIS & TURNTABLE 10. A soft metal punch should be used to insure that this retaining ring (1I) is completely seated in the groove of the output shaft (1A). Carrier Sub-Assembly 1. Apply a coat of grease or petroleum jelly to cluster gear bore. EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 2. Place sixteen needle rollers into cluster gear bore. 11. Upon completion of step 10, rap the internal end of the output shaft (1A) twice with a piece of soft metal rod.
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SECTION 3 - CHASSIS & TURNTABLE 4. Place second set of sixteen needle rollers into cluster gear. 5. Apply grease or petroleum jelly to the tang side of two thrust washers. Place thrust washers against bosses in carrier with washer tang fitting into slot in carrier outside diameter. NOTE: Some old style carriers will not have slots and tangs should be located inside boss relief. 7. Line up cluster gear and thrust washer with hole in carrier and slide planet shaft through.
PAGE 128
Figure 3-43.
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SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING BRAKE (S/N 0300068040 TO PRESENT) 7. Insert dowel pins (15), spring retainer (14) and springs (13) in cover (16). Disassembly 1. Remove pressure plate (2) from cover (16) by removing washer head cap screws (1). PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 907 KGF (2000 LBS.) THE TWO WASHER HEAD CAP SCREWS MUST BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 1361 KGF (3000 LBS.
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SECTION 3 - CHASSIS & TURNTABLE * Items Included in Repair Kit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Capscrew Pressure Plate Case Seal O-ring Backup Rings Piston O-rings Backup Rings Shaft Stator Disc 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Rotor Disc Return Plate Springs Spring Retainer Dowel Pin Cover Oil Seal Bearing Retaining Ring Retaining Ring Figure 3-44.
PAGE 131
SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING MOTOR (S/N 0300068040 TO PRESENT) 4. Remove seal from end cap. Disassembly Cleanliness is extremely important when repairing these motors. Work in a clean area. Before disconnecting lines, clean port area of motor. Remove key when used. Check shaft and key slot. Remove burrs, nicks and sharp edges. Before disassembly, drain oil from motor. Then plug ports and thoroughly clean exterior of motor.
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SECTION 3 - CHASSIS & TURNTABLE 13. Reposition motor in vise. Clamp across ports as shown above. Do not clamp side of housing. Excessive clamping pressure on side of housing causes distortion. 14. Remove cap screws from mounting flange. These screws are assembled with Loctite to hold them in place. The screws will require 35-45 Nm (300 - 400 in/lbs) of torque to break loose and 11 Nm (100 in/lbs) torque to remove. Do not use impact wrench on screws that have been secured with Loctite.
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SECTION 3 - CHASSIS & TURNTABLE stone (such as an Arkansas stone). Do not file or grind motor parts. NOTE: Lubricate all seals with petroleum jelly. Use new seals when reassembling motor. DO NOT STRETCH SEALS BEFORE INSTALLING THEM. Cleanliness is extremely important in the successful application of Loctite. Before Loctite can be applied, the parts should be cleaned as follow: NOTE: Fully cured Loctite resists most solvents, oils, gasoline and kerosene and is not affected by cleaning operations.
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SECTION 3 - CHASSIS & TURNTABLE 4. Install exclusion seal in flange. Carefully press exclusion seal into place. 5. Visually check seal seat in mounting flange for scratches or other marks that might damage the pressure seal. Check for cracks in flange that could cause leakage. 6. Lubricate I.D. of seal tube and O.D. of shaft pressure seal with light film of petroleum jelly. Align small I.D. end of seal tube with seal seat in mounting flange.
PAGE 135
SECTION 3 - CHASSIS & TURNTABLE TO AID INSTALLATION OF SEALS, APPLY LIGHT COAT OF CLEAN PETROLEUM JELLY TO SEALS. DO NOT STRETCH SEALS BEFORE INSTALLING THEM IN GROOVE. 2. Pour approximately 35 cc of clean hydraulic oil in output shaft cavity. 3. Install 73 mm (2.875 in.) I.D. seal in housing seal groove. Avoid twisting seal. Timing Procedure a. Install drive. Use felt tip marker to mark or drive tooth. Align this tooth with timing dot on shaft.
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SECTION 3 - CHASSIS & TURNTABLE Reverse rotation align any star valley with marked tooth (see figure below). 1. Rotate gerotor to line up with bolt holes. Be careful not to disengage star from drive or disturb gerotor seal. 4. Install cap screws and seal washers (if applicable) in end cap. Pre-tighten screws to 7.4 Nm (40 in/lbs). Make sure seal washers are properly seated. Then torque screws to 27 - 28 Nm (235 - 250 in/lbs) in sequence, as shown above. 2. Install drive spacer if applicable. 3.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Capscrew Exclusion Seal Mounting Flange Backup Ring (-008, -009 Motors) Pressure Seal Seal Bearing Race Needle Bearing Thrust Output Shaft Seal Washer (When Applicable) Capscrew Plug/O-ring S/A End Cap Seal 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
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SECTION 3 - CHASSIS & TURNTABLE 3.19 ROTARY COUPLING 4. Remove center body (1) from housing (3). 5. Cut off old seals (2,4,5). Use the following procedure to install the seal kit. 6. Assemble lip seals (2) in direction shown in Figure 346., Rotary Coupling Seal Installation. NOTE: Step 1 is applicable for machines S/N 83332 to Present. 1. If not already removed, remove the axle oscillation valve from the cylinder barrel.
PAGE 139
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. Center Body Seal Housing O-ring 5. 6. 7. 8. Seal Thrust Ring Snap Ring Valve Block (Axle Oscillation) Figure 3-47.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-48.
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SECTION 3 - CHASSIS & TURNTABLE 9 17 10 7 8 11 18 12 13 14 16 15 14 20 13 19 12 2 3 11 8 8 4 8 5 1 6 1. 2. 3. 4. 5. Loctite #242 Bolt Bolt Bolt Bracket 6. 7. 8. 9. 10. Rotary Coupling Spool Retaining Ring Plug Torque Lug 11. 12. 13. 14. 15. Ring Seal O-ring Bearing Cap Seal 16. 17. 18. 19. 20. O-ring Valve Check Valve Case Plunger Valve Figure 3-49.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Coupling Port Information Table Port Outlets Port Size No. Description Operating Pressure PSI (Bar) Proof Pressure PSI (Bar) 1 2 -6 Brake 450 (31) 675 (46.5) 2 2 -6 2 Speed 4500 (310) 6750 (465) 3 1 -6 Steer 2500 (138) 3750 (258.5) 4 1 -6 Steer 2500 (172) 3750 (258.5) 5 3 2-16, 1-6 Drive Reverse 4500 (310) 6750 (465) 6 1 -16 Drive Forward 4500 (310) 6750 (465) 7 2 -12 Drain 250 (17) 375 (26) 3.
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SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally.
PAGE 144
SECTION 3 - CHASSIS & TURNTABLE A D B D B C Figure 3-51.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. DC Motor Coupling Half Washer Lockwasher Screw Bushing Spider Mounting Gasket Shaft Seal Stator Washer Screw Gasket Kit 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Drive Shaft Key Retaining Ring Gear Gear Housing Beta Plug Screw Dowel Bushing Valve Block Screw Needle Bearing Pin Idler Shaft 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Ball Spring Spring Gasket Adjustment Screw Hex Cap O-ring Logic Valve I.D.
PAGE 146
SECTION 3 - CHASSIS & TURNTABLE 3.22 GENERATOR stops. If the circuit breaker continues to open, check for faulty equipment connected to the platform receptacles. Every 250 hours Every 250 hours of operation, check the drive belt for proper tension. CIRCUIT BREAKER 1/2 in. (13 mm) Every 500 hours Every 500 hours of operation, service the generator brushes and slip rings. Hostile environments may require more frequent service.
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SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings 2 3 Acceptable Unacceptable Brushes must ride completely on slip rings 1 1/4 in (6 mm) Or Less - Replace 2 7/16 in - 1/2 in (11 - 12 mm) New 3 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-53.
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SECTION 3 - CHASSIS & TURNTABLE 3.23 DUAL FUEL SYSTEM tarily re-installed to verify that it was indeed the source of the problem. IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. Changing from Gasoline to LP Gas 1. Start the engine from the ground control station. 2. Open the hand valve on the LP gas supply tank by turning counterclockwise.
PAGE 149
SECTION 3 - CHASSIS & TURNTABLE EFI Diagnostics (Prior to S/N 0300065534) The EFI diagnostics are designed to assist in locating a faulty circuit or component. When a malfunction is detected by the Engine Control Module (ECM), a diagnostic trouble code (DTC) is set and the Malfunction Indicator Lamp (MIL) will be illuminated. MIL DTC RETRIEVAL Diagnostic trouble codes (DTCs) can be retrieved by pushing and holding the test button on the side of the ground control box.
PAGE 150
SECTION 3 - CHASSIS & TURNTABLE Table 3-10.
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SECTION 3 - CHASSIS & TURNTABLE HEATED OXYGEN SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor is a g thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5-volt signal to the ECT sensor through resistors in the ECM and measures the voltage.
PAGE 152
Figure 3-55.
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SECTION 3 - CHASSIS & TURNTABLE INTAKE AIR TEMPERATURE (IAT) SENSOR The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5-volt signal to the sensor through a resistor in the ECM and monitors the signal voltage.
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SECTION 3 - CHASSIS & TURNTABLE The ECM is designed to maintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency. The ECM monitors numerous engine functions via electronic sensors such as the throttle position (TP) sensor and the heated oxygen sensor (HO2S). ECM SERVICE PRECAUTIONS The ECM is designed to withstand normal current draws associated with engine operation.
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SECTION 3 - CHASSIS & TURNTABLE may set DTC 22. If either DTC 12 or DTC 22 are set, the throttle will be forced to a 6% (idle) position. • Before removing the part from the package, ground the package to a known good ground on the equipment. • If the part has been handled while sliding across a seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part.
PAGE 156
SECTION 3 - CHASSIS & TURNTABLE HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-56. Typical Fuel System assembly keeps fuel available to the fuel injectors at a constant pressure. A return line delivers unused fuel back to the tank. FUEL METERING SYSTEM PURPOSE The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve.
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SECTION 3 - CHASSIS & TURNTABLE regulate pressure and could cause engine problems or component damage. ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2.5L EFI industrial engine, throttle control is achieved by using an electronic governor which is controlled by the engine control module (ECM). FUEL PUMP ELECTRICAL CIRCUIT When the key is first turned "ON," the ECM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly.
PAGE 158
SECTION 3 - CHASSIS & TURNTABLE grammed routine to calculate the air/fuel ratio based on inputs from the TP, ECT, and MAP sensors. pulses which the ECM uses to calculate RPM and crankshaft position. The system remains in open loop until the following conditions are met: • The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature). • The ECT has reached 160°F (71°C). • Seven minutes has elapsed since starting the engine.
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SECTION 3 - CHASSIS & TURNTABLE "Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals from the ECM. 3.25 FORD LPG SYSTEM (S/N 0300077500 TO PRESENT) NOTE: +20° F (-6.6° C) is the low temperature limit for LP gas, for both starting and operation. This applies to all LP gas powered engines. Description The LPG system starts at the tank.
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SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid Figure 3-57.
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SECTION 3 - CHASSIS & TURNTABLE Lockoff Solenoid The lockoff solenoid is used to reduce the possibility of backfires. The EPM controls the opening and closing of the lockoff so that as a shutdown is commanded, the lockoff is closed, but the ignition system continues to operate to burn off unburned fuel in the manifold. This will cause longer than usual start times, because the manifold must fill up with fuel again before the engine will fire.
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SECTION 3 - CHASSIS & TURNTABLE DTC 362 - Megajector voltage supply low. a. Voltage - Check battery voltage. If the voltage at the battery is less than 9.5 volts: The battery is faulty 3.26 ELECTRIC GOVERNOR INSTALLATION AND ADJUSTMENTS - FORD LRG425 ENGINE (PRIOR TO S/N 0300065534) General or The charging system is faulty or The Megajector is faulty. DTC 363 - Megajector Internal Actuator Fault Detection. a.
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SECTION 3 - CHASSIS & TURNTABLE Mounting-Actuator The Actuator may be mounted in any attitude - there is no preferred orientation. With no power applied, the Actuator is spring-loaded to the minimum fuel position. The Actuator output shaft rotates toward the maximum fuel position against this spring through electrical power from the controller. This rotation is CW (clockwise) on one side of the Actuator, and CCW (counterclockwise) on the other.
PAGE 164
SECTION 3 - CHASSIS & TURNTABLE Many “governing” problems are really caused by binding of the butterfly and its shaft in the carburetor. This is caused by loading due to vacuum under the butterfly and atmospheric pressure above when the engine is running. These forces cannot be felt when the engine is not running. Therefore, start the engine while carefully controlling the speed by hand, and feel for binding or airload forces.
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SECTION 3 - CHASSIS & TURNTABLE Gain: This adjustment is made by turning the plastic screw clockwise (CW to increase governor sensitivity, counterclockwise (CCW) to decrease sensitivity. The adjustment range of the Factory pot is about 3/4 of a turn, AND OVERTURNING WILL BREAK THE INTERNAL STOPS, making further adjustments impossible.
PAGE 166
SECTION 3 - CHASSIS & TURNTABLE 3-110 – JLG Lift – 3120858
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SECTION 3 - CHASSIS & TURNTABLE 4. Carefully adjust Gain. You are looking for the best compromise between quick response and good stability. Make very small adjustments, then load and unload engine, or pull linkage back slightly and release. Usually, a good set-up is one that makes 1 to 3 small bounces and then steadies down after a large change. Too much Gain shows up as a rapid (bounce per second) instability, most commonly at light loads.
PAGE 168
SECTION 3 - CHASSIS & TURNTABLE 4. No speed signal to Governor. a. Once again, disconnect fuel system linkage from Governor output arm and control engine manually. 5. Damaged Controller or Actuator. (1.) No power - Use a multimeter to check for 12-15 VDC between terminals A & B on the controller. Check during engine off and engine running conditions. If voltage is absent or low, check for: b. Start engine, hold at a low speed, Governor arm should move to full-fuel position. c.
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SECTION 3 - CHASSIS & TURNTABLE d. Speed seems to slowly wander (5-15 second periods) around at speed, particularly at higher loads. See item 2a. 3 concerning excessive on Governor. (3.) Governor not tuned or adjusted for engine/application. 3.27 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ ENGINE (PRIOR TO S/N 0300065534) General The basic adjustment to set sensitivity/stability is the Gain pot. A good starting point for many engines is full CCW, then CW 1/3 turn. (See “Governor adjustment” section).
PAGE 170
SECTION 3 - CHASSIS & TURNTABLE Procedure Controller Status NOTE: Never run fuel tank dry. Diesel engines cannot be restarted after running out of fuel until fuel system has been air-vented or bled of air. See Deutz Instruction Manual for procedure. Clutch engaged no actuator movement 1. Power the ignition switch at the ground control panel. Set the mid rpm. 2. Supply 12 volts of power to the white wire on the controller. Set the high engine rpm.
PAGE 171
SECTION 3 - CHASSIS & TURNTABLE Failure Modes Action: 1. Inspect and clean wiring connections. Immediate Red Light 2. Examine throttle linkage for any damage or bent components and correct. 3. With linkage disconnected, check each potentiometer for operation. 4. Reconnect linkage and reset each potentiometer for correct operation. 5. If failure continues to occur, replace unit. Action: Only green light on and no actuator movement 1. Recycle power to determine if the problem is intermittent. 2.
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SECTION 3 - CHASSIS & TURNTABLE 3.28 DEUTZ EMR 2 (S/N 85331 TO PRESENT) The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are connected by means of separate cable harnesses to the EMR control unit.
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SECTION 3 - CHASSIS & TURNTABLE CONTROL ROD POSITION SENSOR/ACTUATOR COOLANT TEMPERATURE SENSOR POWER SUPPLY CAMSHAFT SPEED SENSOR GLOW PLUG JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE & FAULT REPORTING. OIL PRESSURE SENSOR Figure 3-59.
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Figure 3-60.
PAGE 175
Figure 3-61.
PAGE 176
Figure 3-62.
PAGE 177
Figure 3-63.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-64.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-65.
PAGE 180
Figure 3-66.
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Figure 3-67.
PAGE 182
Figure 3-68.
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Figure 3-69.
PAGE 184
Figure 3-70.
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SECTION 3 - CHASSIS & TURNTABLE 3.29 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for hardening, cracking, chafing, separation, split boot covers and proper fit Maintenance of the Drive Belt The serpentine drive belt utilizes a spring loaded tensioner which keeps the belt properly adjusted. The drive belt is an integral part of the cooling and charging systems and should be inspected frequently.
PAGE 186
SECTION 3 - CHASSIS & TURNTABLE 6. If the oil level is below the "ADD" mark, proceed to Step 7 and 8 and reinstall the dipstick into the dipstick tube. Coolant Fill Procedure - Dual Fuel Engine 7. Remove the oil filter cap from the valve rocker arm cover. DAMAGE TO THE ENGINE COULD OCCUR IF NOT PROPERLY FILLED WITH COOLANT.
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SECTION 3 - CHASSIS & TURNTABLE 5. Next, verify that the 2 coolant hoses on the EPR are warm. If they are not warm repeat step 3 and 4, otherwise continue to step 6. 2. Remove the radiator cap. Fill the radiator with coolant until coolant starts to appear from the previously removed hose at the EPR. Reinstall the hose back onto the EPR and continue to fill radiator with coolant. A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIATOR HOSE AND A WARM EPR HOSE.
PAGE 188
SECTION 3 - CHASSIS & TURNTABLE 3.30 GM ENGINE DUAL FUEL SYSTEM Electric Lock Off NOTE: +20° F (-6.6° C) is the low temperature limit for LP gas, for both starting and operation. This applies to all LP gas powered engines. The Dual Fuel system allows the operator to operate the vehicle on either gasoline or LPG by positioning a selector switch in the operator's platform. When the operator places the selector switch in the gasoline mode the gasoline fuel pump is energized.
PAGE 189
SECTION 3 - CHASSIS & TURNTABLE Low Pressure Regulator (LPR) Air Fuel Mixer The LPR is a combination vaporizer, pressure regulating device. The LPR is a negative pressure, two stage regulator that is normally closed when the engine is not running. When the engine is cranking or running, a partial vacuum is created in the fuel line which connects the regulator to the mixer. This partial vacuum opens the regulator permitting fuel to flow to the mixer.
PAGE 190
SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control (ETC) Engine Control Module Engine speed and load control is maintained by an ETC device. Speed and load control are determined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine. The Electronic Throttle Control device or "throttle body assembly" is connected to the intake manifold of the engine.
PAGE 191
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.
PAGE 192
SECTION 3 - CHASSIS & TURNTABLE Fuel Filter 3.31 GM ENGINE FUEL SYSTEM REPAIR After the fuel is drawn into the fuel pump, the fuel flows through the gasoline fuel filter. The fuel filter will trap small particles as the fuel passes through the filter to remove debris and prevents the fuel pressure and temperature manifold and fuel injectors from becoming damaged. Maintenance of the fuel filter is required as indicated in Section 1.
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SECTION 3 - CHASSIS & TURNTABLE Propane Fuel Filter Replacement 1 1 7 8 7 8 2 13 9 3 9 3 10 10 4 4 OR 5 5 11 6 11 12 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 Figure 3-81. Filter Lock Assembly REMOVAL INSTALLATION 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2.
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SECTION 3 - CHASSIS & TURNTABLE Electronic Pressure Regulator (EPR) Assembly Replacement 7. Remove the lock pin from the pressure sensor on the regulator housing and remove the Sensor and retain the pin. 8. Using a clamp pliers pinch off the hoses on the coolant lines to the regulator. 9. Remove the lock pin from both the water fittings on the regulator housing and remove the fittings and hoses and retain the pin. 10. Disconnect the EPR electrical connector. 11.
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SECTION 3 - CHASSIS & TURNTABLE 6. Install the electric lock off into the regulator inlet and tighten into proper location, connect the electrical connector. PRESSURE REGULATOR SECTION REMOVAL 1. Remove the EPR refer to EPR Removal Procedure. 2. Remove the six (6) regulator to voice coil screws using the special tool and separate the regulator from the actuator. 7. Connect the fuel supply line and tighten until fully seated. 8. Connect the EPR electrical connector. 9. Open the manual valve. 10.
PAGE 196
SECTION 3 - CHASSIS & TURNTABLE Temperature Manifold Absolute Pressure (TMAP) Sensor Electronic Throttle Control Replacement See Figure 3-84. REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air intake duct. 3. Release the hose clamp on the vapor fuel line and remove the vapor hose. 4. Disconnect the TMAP electrical connector. 5. Disconnect the electronic throttle control connector. 6. Remove the manifold to throttle body adapter bolts and remove the throttle body mixer assembly. 7.
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SECTION 3 - CHASSIS & TURNTABLE 2. Install the two quad seals. Install one seal at a time to insure the seal does not roll. The seal must sit flat on the throttle body. 4. Place gasket on intake manifold and attach mixer/ throttle assembly to manifold. Figure 3-85. Mixer Assembly 3. Attach mixer and throttle body together. The two parts do not bolt together; they will be secured when you mount it on the intake. Notice the orientation of the air inlet and throttle body cover.
PAGE 198
SECTION 3 - CHASSIS & TURNTABLE Coolant Hose Replacement Engine Control Module Replacement REMOVAL REMOVAL 1. Drain the coolant. 1. Disconnect Negative battery cable. 2. Using hose clamp pliers, disconnect both hose clamps on each hose. 2. Remove controller from mounting bracket. 3. Remove the hose from each of the fittings. 3. Push connector lock back to unlock connector. 4. Unplug controller and remove. INSTALLATION INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.32 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel and that liquid fuel is being delivered to the LPR.
PAGE 200
SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2 2 Perform the On Board Diagnostic (OBD) System Check.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO -- Go to Step 14 Go to Step 16 12W - 16W Go to Step 15 Go to Step 23 13 1. Turn OFF the ignition. 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. 4. Crank the engine. The test light should illuminate. Does the test light illuminate? 14 Using a DVOM, check the resistance of the low pressure lock-off (LPL).
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SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 25 The fuel supply system is operating normally, if a failure of the control solenoids is suspected. Refer to Fuel Control System Diagnosis. -- System OK -- -- System OK -- 1. Install the test plug in the LPR secondary chamber. 2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic procedure. Is the action complete? 26 3-146 1.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp (MIL) The following components can cause intermittent MIL and no DTC(s): A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating. The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Exhaust System Checks Action Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis Hard Start DEFINITION: The engine cranks OK, but does not start for a long time.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Exhaust System Checks Action Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Hesitation, Sag, Stumble DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's severe enough. Preliminary Checks Refer to Important Preliminary Checks. Fuel System Checks Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Lack of Power, Sluggishness, or Sponginess DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks Fuel System Checks Sensor Checks Exhaust System Checks Engine Mechanical Check Additional Check Refer to Important Preliminary Checks.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Ignition System Checks Verify that the spark plugs are correct for use with LPG (R42LTS) Check the spark plugs.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Engine Mechanical Check Action Check the engine for the following: - Broken motor mounts - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes Surges/Chuggles DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-14.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-14.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: The outlet pipe must be centered within 1/4" (6.35 mm) minimum clearance to the exhaust venturi all around the venturi’s perimeter. If the exhaust pipe touches the venturi, it will transfer heat and melt the hood. If the exhaust pipe is not centered, adjust the muffler or outlet as needed to achieve the necessary clearance. A B C D A. Exhaust Venturi B. 1/4" (6.35 mm) minimum clearance all around. C. 3/4" (19.05 mm) minimum engagement D.
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SECTION 3 - CHASSIS & TURNTABLE B,C B,C A B,C A B,C B,C A. Actual Weight Stamping B. Apply Loctite #242 to Bolt Threads and to Threads in Counterweight. C. Torque to 285 ft. lbs. (386 Nm). Typical Four Places. Figure 3-88.
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM 4. Remove the six (6) bolts and locknuts securing the support to the rotator. Support Removal Figure 4-1. Location of Components Platform Support 1. Disconnect electrical cable from control console. 2. Remove the eight (8) bolts securing the platform to the platform support, then remove the platform. 5. Using a suitable brass drift and hammer, remove the rotator shaft, then remove the support from the rotator. 3.
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SECTION 4 - BOOM & PLATFORM Support Installation platform support. Torque the bolts to 75 ft. lbs. (102 Nm). 1. Using a suitable device, support the platform support and position it on the rotator. NOTE: The platform support weighs approximately 77 lbs. (35 kg). 2. Install the rotator center bolt. 6. Connect the electrical harness to the platform control console. Platform Sections Replacement The platform is made up of five sections: floor, right side, left side, back (console box mounting.) and gate.
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SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A,B,D E C,D A B C D E Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque to 480 ft. lbs. (650 Nm) Check torque every 150 hours of operation Torque to 85 ft. lbs. (115 Nm) Figure 4-3. Platform Support Torque Values 4.2 ROTATOR AND SLAVE CYLINDER 2. Remove hardware from pin #1. Using a suitable brass drift and hammer remove pin #1 from the fly boom. Removal 1.
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SECTION 4 - BOOM & PLATFORM 3. Supporting the rotator, remove the hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2 from the fly boom and remove the rotator. 6. Remove bolt #1 securing the push tube on the fly boom section. 4. Telescope the fly section out approximately 20 inches (50.8 cm) to gain access to the slave leveling cylinder. (800 AJ only) 5. Supporting the slave, cylinder remove the hardware from pin #3.
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SECTION 4 - BOOM & PLATFORM 3. Using a suitable brass drift and hammer, remove hardware securing the upper lift cylinder rod end pin to the base boom section. Remove the upper lift cylinder pin from base boom. Retract the upper lift cylinder by using the auxiliary power switch. d. Remove the bolt and keeper pin securing the master cylinder rod end pin to the upright. Remove the pin.
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SECTION 4 - BOOM & PLATFORM Disassembly 6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary. 1. Remove hardware securing telescope cylinder to back end of the base boom section. 2. Remove hardware which secures the wear pads to the base boom section; remove the wear pads from the top, sides and bottom of the base boom section. 3. Using overhead crane or suitable lifting device, remove fly boom assembly from base section. 4.
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SECTION 4 - BOOM & PLATFORM Installation b. Install the master cylinder rod end pin. Install the bolt and keeper pin securing the master cylinder rod end pin to the upright. 1. Using all applicable safety precautions, carefully lift boom assembly to align the pivot holes in the boom with those of the upright. NOTE: The upper boom alone weighs approximately 2226 lbs. (1010 kg). Including the slave cylinder, rotator, and platform support the assembly weighs approximately 3185 lbs. (1445 kg). 2.
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SECTION 4 - BOOM & PLATFORM 4.5 UPRIGHT 5. Disconnect the Upright Level Cylinder as follows: a. Using a suitable lifting device, support the Upright. Removal b. Remove mounting hardware securing hose bracket in upright, and remove the hose bracket. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. c. Remove mounting hardware securing the upright level cylinder to the upright.
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SECTION 4 - BOOM & PLATFORM Installation 4.6 NOTE: Steps 1 thru 4 are only necessary if the upright level cylinder is to be removed. Removal 1. Using a suitable lifting device, carefully install the upright lift cylinder into place in the tower boom. 2. Install the pin and mounting hardware at the barrel end of the upright lift cylinder. TOWER BOOM ASSEMBLY HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. 3.
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SECTION 4 - BOOM & PLATFORM surfaces are protected prior to installation. Replace pins as necessary. b. Remove mounting hardware that secures the powertrack to tower base boom and remove the powertrack. 5. Inspect inner diameter of upright attach point bearings for scoring, distortion, wear, or other damage. Replace bearing as necessary. c. Remove mounting hardware from tower boom telescope cylinder barrel and rod end. d.
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SECTION 4 - BOOM & PLATFORM Installation WHEN ASSEMBLING TOWER BOOM SECTIONS, ENSURE THAT THE BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS. 3. Align upright leveling cylinder with attach holes in tower fly boom. Using a soft head mallet, install the cylinder pin into tower fly boom and secure with mounting hardware. 1. Using a suitable lifting device, position boom assembly on turntable so that the pivot holes in both boom and turntable are aligned. 2.
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SECTION 4 - BOOM & PLATFORM Tower Out of Sync Tower is out of sync backwards, upright leaning toward the platform. 3. The counter/balance valve in the piston end of the upright level cylinder. There could be a leak path from the valve port to the pilot port. Replace the counter/balance valve. When towering down the upright cylinder bottoms out before the lower lift. Problems that could cause this are: 1.
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SECTION 4 - BOOM & PLATFORM Tower is out of sync forwards, upright leaning toward the steer axle. from the pilot port to the valve port. Replace the counterbalance valve. When towering down, the lower lift cylinder bottoms out before the upright level cylinder. This is caused by too much oil between the two cylinders. Problems that could cause this are: 1. The relief valve located in the upright (P/N: 4640929).
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SECTION 4 - BOOM & PLATFORM 4.7 ARTICULATING JIB NOTE: Pin numbers listed in the following procedures are referenced in Figure 4-8., Location of ComponentsArticulating Jib Removal 3. Remove mounting hardware from lift cylinder pin #7. Using a suitable brass drift and hammer, remove the cylinder pin from articulating jib boom. Inspection NOTE: When inspecting pins and bearings Refer to Section 2.5, Pins and Composite Bearing Repair Guidelines. 1.
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SECTION 4 - BOOM & PLATFORM 7. Disconnect hose that is to be replaced, and cap the male fitting. 7. Inspect structural units of articulating jib boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary. 8. Attach the new hose to the end of the hose to be replaced. Assembly 1. Align lift cylinder with attach holes in articulating jib boom. Using a soft head mallet, install cylinder pin #7 into articulating jib boom and secure with mounting hardware. 2.
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SECTION 4 - BOOM & PLATFORM UPPER SWITCH (DUAL CAPACITY BOOM ANGLE SWITCH) SHOWN FOR REFERENCE ONLY. SWITCH TO ACTIVATE WHEN UPPER BOOM IS RAISED 5° TO 10° ABOVE HORIZONTAL. SWITCH TO RESET WHEN UPPER BOOM IS LOWERED 1° BELOW TO 4° ABOVE HORIZONTAL. SUGGESTED INITIAL ARM POSITION SETTING MOUNTING SURFACE SUGGESTED INITIAL ARM POSITION SETTING MOUNTING SURFACE SWITCH ORIENTATION SWITCH ORIENTATION 0258217-L Figure 4-9. Boom Valve and Limit Switches Location.
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SECTION 4 - BOOM & PLATFORM See Section 4.10, Boom Valve Adjustment ADJUST GAP TO WITHIN 0.20 in. (5 mm) (PREFERRED GAP 0 . 2 5 i n . ( 6 . 3 5 m m ) W H E N LO W E R B O O M I S F U L LY RETRACTED AND AFTER VALVE IS ADJUSTED ADJUST SWITCH BY LOOSENING CLAMP ON TELE ROD AND SLIDING TO APPROXIMATE 0.25 in. (6.35 mm) GAP LED’s WILL LIGHT WHEN POWER IS ON AND TARGET IS WITHIN SENSING DISTANCE 1.0 in. (25.4 mm) CENTER PROXIMITY SWITCH IN MOUNT 0258217-L Figure 4-10. Boom Valve and Limit Switches Location.
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SECTION 4 - BOOM & PLATFORM See Section 4.10, Boom Valve Adjustment 0258217-L Figure 4-11. Boom Valve and Limit Switches Location.
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SECTION 4 - BOOM & PLATFORM 0258338-F Figure 4-12.
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SECTION 4 - BOOM & PLATFORM 0258384-C Figure 4-13. Transportation Switch Installation.
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Figure 4-14. Tower Power Track Installation.
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Figure 4-15. Tower Power Track Installation.
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SECTION 4 - BOOM & PLATFORM Dual Capacity Angle Limit Switch (800A only) Upper Boom Length Switch (800 A only) 1. Lift upper boom to approximately horizontal. 2. Telescope boom out until 500 lb. light comes on (may need to use auxiliary power to position boom correctly). NOTE: The boom position and location of the Upper Boom Dual Capacity Switch requires a working surface 20 ft. high to safely check and adjust the switch. 3. Mark the wear pad location on the main fly boom. 1.
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SECTION 4 - BOOM & PLATFORM 4.11 WEAR PADS Upper Boom Tower Boom 1. Shim up wear pads to within 1/32 inch (.79 mm) clearance between wear pad and adjacent surface. 1. Shim up wear pads until 1/32 inch (0.8 mm) clearance to adjacent surface. 2. Replace wear pads when worn within 1/16 inch (1.59 mm) and 1/8 inch (3.18 mm) - B, C, D of threaded insert. See Figure 4-16., Location And Thickness Of Wear Pads 2. Replace wear pads when worn to within 1/16 inch (1.59 mm) of threaded insert. 3.
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SECTION 4 - BOOM & PLATFORM 5. Remove the two (2) setscrews (4) from bottom of the actuator (1). Discard setscrew. 8. Remove piston sleeve (3) from housing (1). 6. Place two (2) 3/8"x16 NC bolts in threaded holes in bottom of the actuator. Using a suitable bar, unscrew the end cap (5). Remove the end cap from actuator (1). 9. Remove all seals and bearings from grooves. Discard seals. Inspection 1. Clean all parts thoroughly. 2. Closely inspect all parts for excessive wear, cracks and chips.
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SECTION 4 - BOOM & PLATFORM Assembly NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. 1. Install piston seal (7) and rod seal (6) on the piston sleeve (3). NOTE: Apply a coat of grease to the thrust ring before sliding onto the shaft. 2. Install new seal (8), thrust ring (10) and bearing (9) on shaft (2). NOTE: Apply a coat of grease to the thrust ring before sliding onto the end cap. 3.
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SECTION 4 - BOOM & PLATFORM Figure 4-18.
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SECTION 4 - BOOM & PLATFORM 4.13 ROTATOR ASSEMBLY (S/N 0300067538 TO PRESENT) The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the upper and lower thrust washers. The end cap is adjusted for axial clearance and locked in position by set screws or pins.
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SECTION 4 - BOOM & PLATFORM The seal tool is merely a customized standard flat head screwdriver. To make this tool you will need to heat the flat end with a torch. Secure the heated end of the screwdriver in a vice and physically bend the heated end to a slight radius. Once the radius is achieved round off all sharp edges of the heated end by using a grinder. There may be some slight modifications for your own personal preference. PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1.
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SECTION 4 - BOOM & PLATFORM PARTS 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap HARDWARE 103.1. Screw 103.2 . Washer 106.1. Port Plug 106.2. Port Plug 109 . Lock Pin 113. Capscrew SEALS 200. T-Seal 202. T-Seal 204. O-ring 205. Cup Seal 207. Backup Ring 304.1. Wiper Seal BEARINGS 302. Wear Guide 304. Thrust Washer ACCESSORIES 400. Stop Tube 420.1 Bushing 420.2 Bushing 421.1 Bushing Figure 4-20.
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SECTION 4 - BOOM & PLATFORM Disassembly 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out the entire pin. 1. Remove the cap screws (113) over end cap lock pins (109). 4. Install the end cap (4) removal tools provided with the Helac seal kit. 2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/ 16” (4.76mm). 5. Using a metal bar, or something similar, unscrew the end cap (4) by turning it counter clockwise. 3.
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SECTION 4 - BOOM & PLATFORM 6. Remove the end cap (4) and set aside for later inspection. 8. Every actuator has timing marks for proper engagement. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assembly.
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SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet. 11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O.D. gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2). 12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged. 3120858 13.
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SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove. 19. Remove the piston O.D. seal (202). 20. Remove the piston I.D. seal (200). You may now proceed to the inspection process. 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2).
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SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thickness (not less than 0.123” or 3.12 mm). 1.Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth. Assembly 2. Inspect the thrust washers (304) for rough or worn edges and surfaces.
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SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end cap (4). 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion. 3. Install the wiper seal (304.1/green 0-ring) into it’s groove on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304). 5. Install the wear guide (302) on the end cap (4) and shaft (2).
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SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using a circular motion. 7. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore. Install the outer T-seal (202) by stretching it around the groove in a circular motion. Each T-seal has 2 back-up rings (see drawing for orientation).
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SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) you can see if your timing marks are lining up. When they do, tap the piston (3) in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out. 11. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (2) with the gear teeth on the inside of the piston (3).
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SECTION 4 - BOOM & PLATFORM 14. Coat the threads on the end of the shaft with antiseize grease to prevent galling. 17. Tighten the end cap (4). In most cases the original holes for the lock pins will line up. 15. Install the 0-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4). 18. Place the lock pins (109) provided in the Helac seal kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole. 16.
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SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Refer to Figure 4-21., Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Loctite. 2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing. 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve.
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SECTION 4 - BOOM & PLATFORM Testing the Actuator If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the pressure at which the shaft begins to rotate — should be approximately 400 psi (28 bar). Cycle the actuator at least 25 times at 3000 psi (210 bar) pressure. After the 25 rotations, increase the pressure to 4500 psi (315 bar) to check for leaks and cracks. Perform the test again at the end of the rotation in the opposite direction.
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SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. 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 4.14 DRIVE CARD SETUP PROCEDURES 4. Set the ramp up and the ramp down times. Step 2 must be performed before continuing with procedure. Power up the card, but do not start the engine. Place the current meter in series with the “A” output. Move the joystick from the center position to the extreme position. Watch the meter for the time it takes the output to go to from 0 current to maximum current. This is the ramp up time.
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SECTION 4 - BOOM & PLATFORM 3. Set the ramp up and the down times. Step 2 must be completed before continuing with this procedure. Power up the card, but do not start the engine. Place the current meter in series with the "A" output. Turn the input potentiometer to its extreme position and operate the telescope function. watch the meter for the time it takes the output to go from 0 current to maximum current. This is ramp up time. Adjust P1 until this time matches the time in Table 4-3.
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SECTION 4 - BOOM & PLATFORM 4.15 LOAD SENSING SYSTEM MACHINES BUILT TO S/N 0300062045 A QUALIFIED PERSON BEFORE RESUMING OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY. DO NOT PLACE LOADS IN THE PLATFORM TO CAUSE AN OVERLOAD. IF AN OVERLOAD CONDITION IS REACHED, IMMEDIATELY STOP OPERATION, REMOVE EXCESS LOAD, AND RETRACT THE UPPER BOOM AND LOWER THE PLATFORM TO THE GROUND. NO FUNCTIO NS ARE CUT OUT BY THIS SYSTEM.
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SECTION 4 - BOOM & PLATFORM Figure 4-24. Calibration Potentiometers The display unit consists of three lights, an audio alarm, and a test button. The green light signifies that the platform load is within limits. The yellow light signifies that the platform load is approaching an overload condition. The red light signifies that the platform is overloaded. The audio alarm beeps when the yellow light is lit and the platform is approaching an overload condition.
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SECTION 4 - BOOM & PLATFORM 4.16 LOAD SENSING SYSTEM MACHINES BUILT S/N 62045 TO 67883 4.18 UPRIGHT MONITORING SYSTEM The UMS provides a visual and audible warning to the operator when the limits of the upright assembly alignment have been reached. In addition, the UMS will not allow the tower boom to be lowered when the upright assembly is misaligned in a direction oriented away from the work platform. Calibration 1. Select Access Level from Main Menu. 2. Enter 33217. 3.
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4-48 90° CORRECT 90° UPRIGHT MUST BE 90° (VERTICAL) RELATIVE TO THE CHASSIS. – JLG Lift – 90° Figure 4-27. Boom Upright Positioning CORRECT INCORRECT 90° TO AVOID TIPPING IF THIS OCCURS: -LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNCTIONS. HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE.
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SECTION 4 - BOOM & PLATFORM Calibration - Pre ADE Machines a. In access level 1, scroll through the menu items until "CALIBRATIONS" is displayed on the second line of the analyzer screen as shown below. C A L I B R AT I O N O F T H E U P R I G H T M O N I T O R I N G S Y S T E M REQUIRES THE MACHINE TO BE ON A FIRM AND LEVEL SURFACE WITH SUFFICIENT OVERHEAD CLEARANCE TO FULLY ELEVATE THE TOWER BOOM. 1. Refer to Section 6 for operating instructions and menu structures for the hand-held analyzer, #2901443.
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SECTION 4 - BOOM & PLATFORM c. Press "ENTER" , and the following screen will be displayed asking if you wish to calibrate the upright monitoring system. THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION. e. Verify the machine is level and press "ENTER" . The screen will display the following, asking you to fully elevate the main boom. NOTE: By pressing the left or right arrow keys in this screen, you may view the output of the sensor. d. Press "ENTER" the following: and the screen will display f.
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SECTION 4 - BOOM & PLATFORM NOTE: By pressing the left or right arrows in this screen, you may view the output of each sensor. If the calibration is executing properly, you shall see the following display: g. Pull and hold the red re-leveling knob on the hydraulic tank while lifting the tower boom. Raise the tower boom six (6) feet or two (2) meters. After elevating the tower the required distance, press "ENTER" . If the UMS did not detect adequate sensor activity, the screen will display: h.
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SECTION 4 - BOOM & PLATFORM After the required activation time has passed, release the function switch and press "ENTER" If the calibration has not been completed successfully, the display will automatically change to: . The analyzer will display the following message: Repeat step i until the calibration time requirement has been satisfied. If the calibration has been completed successfully, the screen will automatically change to: DO NOT RAISE THE TOWER BOOM AGAIN DURING CALIBRATION. j.
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SECTION 4 - BOOM & PLATFORM Calibration - ADE Equipped Machines 1. Connect the JLG Hand-held analyzer to the original analyzer connection in the ground box. b. After pressing 'ENTER" screens will be displayed: one of the following DO NOT CONNECT TO THE ANALYZER CONNECTION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE. 2. Pull out the emergency stop button at the ground control station and start the engine from the ground controls. 3.
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SECTION 4 - BOOM & PLATFORM e. Press "ENTER" and the next screen will display the following, asking if the machine is on a level surface: IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THE GROUND CONTROL MODULE AT THIS TIME. HOWEVER, WHEN THE TILT SENSOR IN THE GROUND CONTROL MODULE IS RECALIBRATED, THE UPRIGHT MONITORING SYSTEM TILT SENSOR MUST BE RECALIBRATED AS WELL. d. After selecting "UMS SENSOR", the following screen will appear: THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION. f.
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SECTION 4 - BOOM & PLATFORM g. After the main boom has been fully elevated, press "ENTER" the following: . The analyzer will display NOTE: By pressing the left or right arrows in this screen, you may view the output of each sensor. h. With the aid of an assistant, pull and hold the red re-leveling knob on the hydraulic tank while lifting the tower boom. Raise the tower boom six (6) feet or two (2) meters.
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SECTION 4 - BOOM & PLATFORM i. When viewing "ENTER" lowing: the above display, press . The screen will display the fol"ENTER" . The analyzer will display the following message: j. Lower the tower boom onto the boom stop. Continue to hold the tower boom down function for at least twenty (20) seconds WITHOUT RELEASING THE FUNCTION SWITCH. The calibration must recognize continuous activation of the tower down function switch for the required time.
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SECTION 4 - BOOM & PLATFORM If the calibration has not been completed successfully, the display will automatically change to: Calibration Faults CAL Failed-Chassis Not Level In the event the turntable tilt switch input is logic low indicating that the machine is not level the UMS calibration screens shall display this fault. CAL Failed-UMS Sensor Raw Output Out Of Range The control system shall display a fault in the event the raw sensor output is greater then 5° for the UMS sensor.
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SECTION 4 - BOOM & PLATFORM Function Check 4. Scroll through the top level menu until SERVICE ON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANALYZER CONNECTION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE. MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will be displayed: 1. Connect the hand-held analyzer at the ground control station using the four-pin connector. 2.
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SECTION 4 - BOOM & PLATFORM 6. The controller will now display the following: 8. From the ground controls, raise the tower boom several feet. Verify that the tower boom will not lower. 9. To end the system test, press the Emergency Stop Switch (EMS) at the ground controls. Upon loss of power (pressing the EMS) to the system, the upright monitoring system will reset and all functionality will be restored to the machine.
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SECTION 4 - BOOM & PLATFORM 4. Scroll through the top level menu until SERVICE MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will be displayed: 5. Scroll left to right through the above menu items until "TOWER LIFT DOWN?" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key. 6.
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SECTION 4 - BOOM & PLATFORM 7. Enter the service code "81075" and press the 8. When the "ENTER" key is pressed, the UMS will be disabled and the display will read: "ENTER" key. The controller display will now display the following, 9. Before using tower lift down adhere to the following: followed by: • Make sure the main boom is fully retracted. • Make sure the tower boom is fully retracted. • Slowly lower the tower boom. 10.
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SECTION 4 - BOOM & PLATFORM THIS SENSOR ON NON ADE MACHINES ONLY Figure 4-28.
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SECTION 4 - BOOM & PLATFORM ADE MACHINES NON-ADE MACHINES Figure 4-29.
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SECTION 4 - BOOM & PLATFORM J1 J2 1 IGN POWER (7-33V) 1 +5V ANALOG EXCITATION 2 GROUND 2 ANALOG INPUT 0 3 DIGITAL INPUT 0 3 ANALOG GROUND 4 DIGITAL INPUT 1 4 +5V ANALOG EXCITATION 5 DIGITAL INPUT 2 5 ANALOG INPUT 1 6 DIGITAL INPUT 3 6 ANALOG GROUND 7 DIGITAL OUTPUT 0 (PWM, IF) 7 ANALOG INPUT 2 8 DIGITAL OUTPUT 1 (PWM, IF) 8 ANALOG INPUT 3 (NOT POPULATED) 9 DIGITAL OUTPUT 2 (PWM, IF) 9 CANBUS HIGH 10 DIGITAL OUTPUT 3 (PWM, IF) 10 CANBUS LOW 11 DIGITAL OUTPUT 4 (PWM
PAGE 279
SECTION 4 - BOOM & PLATFORM 4.19 UMS TROUBLESHOOTING AND FAULT MESSAGES - NON-ADE MACHINES Tower Lift Down Permanently closed 2/2 FUNCTION LOCKED OUT - TOWER LIFT DOWN PERMANENTLY CLOSED The control system shall illuminate lamps and sound the alarm at startup for one second on and one second off. If the control system detects the TOWER LIFT DOWN, it shall report a fault.
PAGE 280
SECTION 4 - BOOM & PLATFORM UMS Sensor Not Calibrated Message Platform Indicator Output Short to Ground or Open Circuit 8/1 UMS SENSOR NOT CALIBRATED If the control system detects a sensor out of range condition or a not calibrated fault with the UMS angle sensor, the control system shall report a fault and disable Tower Lift Down and activate the ground boom malfunction indicator lamp, upright tilted lamp and platform alarm continually.
PAGE 281
SECTION 4 - BOOM & PLATFORM Turntable Sensor Faulted Forward Stability Concern Message 8/1 TURNTABLE FAULTED 2/5 UMS SENSOR FORWARD LIMIT REACHED If the system detects that the Chassis tilt sensor frequency outside the 100Hz +/- 5Hz range or the duty cycle is outside 50% +/- 21% range the control system shall report a fault When the upright angle relative to the turntable is less than –4.0° for longer than 1.
PAGE 282
SECTION 4 - BOOM & PLATFORM Out of Usable Range Message Incompatible Software Detected Message 8/1 UMS SENSOR OUT OF USABLE RANGE 9/9 INCOMPATIBLE SOFTWARE DETECTED When both the Chassis tilt sensor and the UMS sensor read greater than 10 in the same direction the UMS will be disengaged until the condition no longer exists and a fault shall be raised.
PAGE 283
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM When assembling connectors in the hydraulic that use oring fittings, it is necessary to lubricate all fittings with hydraulic oil prior to assembly. To lubricate the fittings, use one of the following procedures. 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated.
PAGE 284
SECTION 5 - HYDRAULICS Dip Method Spray Method 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. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this manner: 2. Hold the fitting over a suitable catch can. • A small leak proof container 3. Spray the entire o-ring surface with a medium coat of oil.
PAGE 285
SECTION 5 - HYDRAULICS 5.2 VALVES - THEORY OF OPERATION 5.3 1. Start the machine and warm the hydraulic system to operating temperature. Solenoid Control Valve - Rexroth Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit with the opposite work port opening to reservoir.
PAGE 286
SECTION 5 - HYDRAULICS 5. Check the Tower lift up holding valve function as follows: a. Fully retract and fully lower the main boom and tower boom assemblies. b. Install a 5000 psi (345 bar) pressure gauge to the pressure tap connection installed on port #7 or port MX7 of the main control valve block. This pressure test connection was installed in earlier steps. c. Hold the tower boom lift up function between 2 and 5 seconds, and then release the function. d.
PAGE 287
SECTION 5 - HYDRAULICS 5.5 CYLINDER CHECKING PROCEDURE Cylinders With Single Counterbalance Valve NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected. Cylinders Without Counterbalance Valves Master Cylinder and Steer Cylinders 1. Using all applicable safety precautions, activate engine and fully extend cylinder to be checked. Shut down engine. 2. Carefully disconnect hydraulic hoses from retract port of cylinder.
PAGE 288
SECTION 5 - HYDRAULICS Cylinders With Dual Counterbalance Valves (Articulating Jib Boom Lift, and Slave, Slave Level, Tower 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.
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SECTION 5 - HYDRAULICS 5.6 CYLINDER REPAIR 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the eight (8) cylinder head retainer cap screws, and remove cap screws from cylinder barrel. NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.
PAGE 290
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Rod Piston Head Bushing 6. 7. 8. 9. 10. Not Used Bolt Counterbalance Valve O-ring Plug O-ring Plug 11. 12. 13. 14. 15. Bleeder Valve Wiper Rod Seal O-ring Backup Ring 16. 17. 18. 19. 20. Wear Ring Wear Ring T-Seal O-ring Backup Ring 21. 22. 23. 24. 25. Loctite #242 Locking Primer (Not Shown) Washer Ring Not Used Bolt Figure 5-3.
PAGE 291
SECTION 5 - HYDRAULICS 9 12 10 12 8 10 11 2 26 7 14 15 6 14 17 20 19 18,24,25 22 16 15 17 21 3 4 5,23,24 12 1 12 1684497 A 1683546 H 1. 2. 3. 4. 5. 6. Rod Barrel Head Washer Ring Bolt Piston 7. 8. 9. 10. 11. Tapered Bushing Valve Cartridge Valve Cartridge O-ring Plug O-ring Plug 12. 13. 14. 15. 16. bushing Not Used Lock Ring Seal Washer Ring 17. 18. 19. 20. 21. Backup Ring Wiper Rod Seal Wear Ring O-ring 22. 23. 24. 25. 26.
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SECTION 5 - HYDRAULICS 6 8 1A 1 8 8 6 26 11 14 13 9 15 10 15 16 14 17 19 21 20 22 18 16 12 2 5 3 4 5A 1683609 G 1. 2. 3. 4. 5. 6. Barrel Head Ring Washer Bolt Rod Counterbalance Valve 7. 8. 9. 10. 11. Not Used O-ring Plug O-ring Plug Piston Tapered Bushing 12. 13. 14. 15. 16. Tube Spacer Setscrew Lock Ring Piston Seal O-ring 17. 18. 19. 20. 21. Backup Ring O-ring Backup Ring Seal Wiper 22. 23. 24. 25. 26. Wear Ring Loctite #242 Locking Primer Loctite #RC609 Capscrew Figure 5-5.
PAGE 293
SECTION 5 - HYDRAULICS 19 1 21 5 19 26 24 4 17 31 16 3 11 10 11 22 16 18 15 14 30 7 6 13 8 12 19 2 19 1683547 J 1. 2. 3. 4. 5. 6. 7. Barrel Rod Piston Tapered Bushing O-ring Plug Head Ring Washer 8. 9. 10. 11. 12. 13. Bolt Not Used O-ring Backup Ring Wiper Rod Seal 14. 15. 16. 17. 18. 19. O-ring Backup Ring Wear Ring T-Seal Seal Bushing 20. 21. 22. 23. 24. 25. Not Used Valve Cartridge Orifice Loctite #242 Check Valve Locking Primer 26. 27. 28. 29. 30. 31.
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SECTION 5 - HYDRAULICS 10 1 10 7 6 8 6 26 21 9 14 15 17 16 17 5 15 14 18 19 20 13 12 2 22 4 10 10 1683537 G 1. 2. 3. 4. 5. 6. Barrel Head Not Used Rod Piston O-ring Plug 7. 8. 9. 10. 11. O-ring Plug Valve Cartridge Valve Cartridge Bushing Not Used 12. 13. 14. 15. 16. O-ring Lock Ring Seal Lock Ring O-ring 17. 18. 19. 20. 21. Backup Ring Wear Ring Seal Wiper Tapered Bushing 22. 23. 24. 25. 26. Capscrew Loctite #242 Locking Primer Loctite RC609 Bolt Figure 5-7.
PAGE 295
SECTION 5 - HYDRAULICS 4 4 8 24 3 11 18 10 22 6 15 16 15 11 14 21 20 12 17 7 13 19,1,2 9 5 1683608 F 1. 2. 3. 4. 5. Loctite #242 Locking Primer Tapered Bushing Bushing Bushing 6. 7. 8. 9. 10. Tube Spacer Head Barrel Rod Piston 11. 12. 13. 14. 15. Wear Ring Backup Ring Washer Ring Wear Ring Backup Ring 16. 17. 18. 19. 20. O-ring O-ring Setscrew Capscrew Wiper 21. 22. 23. 24. Seal T-Seal Loctite RC609 Capscrew Figure 5-8.
PAGE 296
SECTION 5 - HYDRAULICS 5 5 8 12 4 3 21 10 22 13 14 16 14 12 21 17 15 11 18,1,2 7 19 20,2,23 9 6 1683682 C 1. 2. 3. 4. 5. Loctite #242 Locking Primer Capscrew Tapered Bushing Bushing 6. 7. 8. 9. 10. Bushing Head Barrel Rod Piston 11. 12. 13. 14. 15. Wear Ring Lock Ring Backup Ring Backup Ring Washer Ring 16. 17. 18. 19. 20. O-ring O-ring Capscrew Rod Seal Wiper 21. Seal 22. Tube Spacer 23. Loctite RC609 Figure 5-9.
PAGE 297
SECTION 5 - HYDRAULICS 5 25 9 24 5 10 3 9 7 4 12 20 11 20 16 17 16 12 23 14 13 18 15 6 22 19 21 5 8 5 1. 2. 3. 4. 5. Loctite #242 Locking Primer Capscrew Tapered Bushing Bushing 6. 7. 8. 9. 10. Head Barrel Rod Plug Plug 11. 12. 13. 14. 15. 1683610 E 1684408 A 1683677 B 1684228 A Piston Lock Ring Backup Ring Wear Ring Washer Ring 16. 17. 18. 19. 20. Backup Ring O-ring O-ring Capscrew Seal 21. 22. 23. 24. Wiper Seal Tube Spacer Cartridge Valve Figure 5-10.
PAGE 298
SECTION 5 - HYDRAULICS 14 5 14 1 2 7 11 3 8 9 10 13 12 14 6 4 14 1683605 A 1683740 B 1. 2. 3. 4. 5. Locknut Piston Seal O-ring Barrel 6. 7. 8. 9. 10. Rod Head O-ring Backup Ring Retainer Ring 11. 12. 13. 14. Seal Spanner Nut Wiper Bushing Figure 5-11.
PAGE 299
SECTION 5 - HYDRAULICS 18 26 26A 6 20 4 11 9 16 16 21 23 21 23 25 5 16 10 12 14 3 17 22 13 8 15 24 3 19 7 10 1683607 G 1683672 G 1. 2. 3. 4. 5. 6. Loctite #242 Locking Primer Bolt Tapered Bushing Tube Spacer Barrel 7. 8. 9. 10. 11. 12. Rod Head O-ring Plug Wear Pad Piston Plate 13. 14. 15. 16. 17. Wear Ring Backup Ring Wear Ring O-ring O-ring 18. 19. 20. 21. 22. Capscrew Capscrew Bolt Backup Ring Rod Seal 23. 24. 25. 26. 27.
PAGE 300
SECTION 5 - HYDRAULICS 25 30 24 22 23 1 24 26 18 5 16 17 4 3 7 15 6 14 15 17 16 13 11 12 10 9 20 21 35 27 2 34 24 36 19 34 32 34 33 19 1683606 J 1. 2. 3. 4. 5. 6. Barrel Rod Piston Tapered Bushing Bolt Tube Spacer 7. 8. 9. 10. 11. 12. Bolt Not Used Wiper Seal O-ring Backup Ring 13. 14. 15. 16. 17. 18. Wear Ring O-ring Backup Ring Seal Lock Ring O-ring Plug 19. 20. 21. 22. 23. 24. O-ring Plug Head Washer Ring Support Pad Support Pad Flatwasher 25. 26. 27. 28. 29. 30.
PAGE 301
SECTION 5 - HYDRAULICS EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 5-15. Tapered Bushing Removal 14. Screw the piston counter clockwise (CCW), by hand, and remove the piston from cylinder rod. 15.
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SECTION 5 - HYDRAULICS 10. Inspect threaded portion of head for damage. Dress threads as necessary. Assembly 11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.
PAGE 303
SECTION 5 - HYDRAULICS NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(See magnified insert in Figure 5-21.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other. Figure 5-19. Wiper Seal Installation 3. Place a new “o”ring and back-up seal in the applicable outside diameter groove of the cylinder head. Figure 5-21. Piston Seal Kit Installation Figure 5-20. Installation Of Head Seal Kit 4.
PAGE 304
SECTION 5 - HYDRAULICS 10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing. NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. WHEN REBUILDING THE MASTER, SLAVE, LOWER LIFT, UPPER LIFT, ARTICULATING FLY BOOM LIFT, UPRIGHT LEVEL, TOWER TELESCOPE, OR UPPER TELESCOPE CYLINDERS, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY. (SEE TABLE 5-1 AND TABLE 5-2 TORQUE SPECIFICATIONS).
PAGE 305
SECTION 5 - HYDRAULICS Table 5-1. Cylinder Torque Specifications Table 5-2. Holding Valve Torque Specifications CYLINDER HEAD AND TAPERED BUSHING TORQUE SPECIFICATIONS HOLDING VALVE TORQUE SPECIFICATIONS Description Description Head Torque Value (Wet) Tapered Bushing Torque Value (Wet) Upper Lift Cylinder 420 ft. lbs. (570 Nm) 60 ft. lbs. (81 Nm) Lower Lift Cylinder 420 ft. lbs. (570 Nm) 30 ft. lbs. (41 Nm) Articulating Lift Cyl. 30 ft. lbs. (41 Nm) 5 ft. lbs.
PAGE 306
SECTION 5 - HYDRAULICS 5.7 CYLINDER REMOVAL AND INSTALLATION 6. Remove mounting hardware securing the Upper Lift Cylinder rod end to the base boom. 7. Using a suitable brass drift, carefully drive upper liftcylinder rod end pin from the base boom. Upper Boom Telescope Cylinder Removal 8. Use the auxiliary control to retract the upper lift cylinder. 1. Place machine on a flat and level surface, with upper boom in the horizontal position.
PAGE 307
SECTION 5 - HYDRAULICS Upper Boom Telescope Cylinder Installation Upper Lift Cylinder Removal 1. Attach a hydraulic power supply to the telescope cylinder ports. Using suitable supports or lifting devices at each end of the cylinder, extend the rod so that the cylinder pin attach holes are the same distance apart as the boom pin attach holes. 1. Place the machine on a flat and level surface.
PAGE 308
SECTION 5 - HYDRAULICS Upper Boom Lift Cylinder Installation Upright Level Cylinder Removal 1. Using suitable lifting device and sling, lift the upper boom to allow enough space to lower the upper lift cylinder to align with pin mounting holes of the tower fly boom and barrel end of upper lift cylinder. 1.
PAGE 309
SECTION 5 - HYDRAULICS Upright Level Cylinder Installation Tower Boom Lift Cylinder Removal 1. Place the leveling cylinder in position in the tower boom, then align holes in tower boom and leveling cylinder. Install leveling cylinder rod end attach pin, using a suitable rubber mallet. 1. Place machine on a flat and level surface. Place the upper boom in a horizontal position with the telescope cylinder fully retracted. Place the tower boom in a fully elevated and fully retracted position. 2.
PAGE 310
SECTION 5 - HYDRAULICS Tower Lift Cylinder Installation Tower Telescope Cylinder Installation 1. With the upper boom and tower boom supported. Place the tower lift cylinder in position on the turntable and secure in place. 1. Slide the telescope cylinder into the boom, aligning the cylinder port block end with slotted holes in Base Boom. Secure telescope cylinder with mounting hardware. 2. Align holes in turntable and lift cylinder.
PAGE 311
SECTION 5 - HYDRAULICS Slave Cylinder Installation 5.9 1. Remove fittings from old cylinder and install in new slave cylinder. Plug the port block holes in the old cylinder with the plugs removed from the new cylinder. 2. Position the new cylinder in place using suitable slings or support. Align barrel end mounting holes with main fly holes. 3. Using a suitable plastic or rubber hammer, drive the barrel end attach pin into place and install retaining hardware. 4.
PAGE 312
SECTION 5 - HYDRAULICS MACHINES S/N 0300121643 TO PRESENT 2. Set High pressure relief 1. Set Stand by pressure or load sense pressure.
PAGE 313
SECTION 5 - HYDRAULICS Figure 5-27.
PAGE 314
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Front Steer Right Solenoid Front Steer Relief Load Sensing Cartridge Swing Right Solenoid Main Lift Relief 6. 7. 8. 9. Load Sensing Cartridge Main Lift Up Solenoid Load Sensing Dump Valve Flow Control Valve 10. 11. 12. 13. Tower Lift Check Main Tele In Solenoid Tower Lift Down Solenoid Platform Rotate Right 14. 15. 16. 17. Platform Level Down Relief Tower Tele Relief Platform Level Up Solenoid Tower Tele Out Solenoid Figure 5-28.
PAGE 315
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Front Steer Left Solenoid Load Sensing Cartridge Front Steer Relief Swing Relief Swing Left Solenoid 6. 7. 8. 9. Load Sensing Cartridge Main Lift Down Solenoid Load Sensing Cartridge Main Tele Out Solenoid 10. 11. 12. 13. Tower Lift Up Platform Rotate Flow Regulator Platform Level Up Relief Orifice 14. 15. 16. 17. Platform Level Check Platform Rotate Left Solenoid Platform Level Down Solenoid Tower Tele In Solenoid Figure 5-29.
PAGE 316
SECTION 5 - HYDRAULICS A B C D Ft. Lbs. Nm 18-20 25-27 33-37 60 in. lbs. 24.5-27.2 34-36.7 44.9-50.3 6.7 NOTE: When removing control valves from the manifold, it is important to observe the tag on the face of the valve, as the new valve must be installed with the tag facing the same way as the tag on the valve that was removed.
PAGE 317
SECTION 5 - HYDRAULICS A B C D Ft. Lbs. Nm 18-20 25-27 33-37 60 in. lbs. 24.5-27.2 34-36.7 44.9-50.3 6.7 NOTE: When removing control valves from the manifold, it is important to observe the tag on the face of the valve, as the new valve must be installed with the tag facing the same way as the tag on the valve that was removed.
PAGE 318
SECTION 5 - HYDRAULICS SECOND: Adjustments Made at the Main Valve Block 5. Platform Level Down Install a high pressure gauge at the “M4” port located on the left of the valve near the bottom. To get a gauge on this point, activate level up to the end of stroke (the pressure in the down side will go to 0, allowing you to snap a gauge on). Activate level down to the end of stroke, reading 1800 psi. The level down relief valve is located on the right side of the block above the “M4” port.
PAGE 319
SECTION 5 - HYDRAULICS 4 WHEEL STEER (IF EQUIPPED) 5. Remove the o-ring plug, (#10 size) on top of the Rexroth load sense pump. The plug is removed until the oil flows out of the pump. This insures that the pump cases are full of oil before starting. Install the plug after there is a steady flow of oil. 1. At the platform console using the steer select switch activate “2 wheel steer”. 2. Install a pressure gauge in port "G" on the control valve. 6.
PAGE 320
SECTION 5 - HYDRAULICS 11. Disconnect the 1/4" hose at the port marked "MT" (plug the port). Drain the hose into a container that will hold approx. 2 gallons (8 L). Activate platform rotate and hold for approx. 60 seconds each direction. Reconnect the hose to port "MT" 12. Raise the tower boom to the end of stroke. Disconnect the hose from port #1 (plug the port) and drain into a container that will hold approx. 3 gallons (11.5 L). Activate tower telescope out.
PAGE 321
SECTION 5 - HYDRAULICS The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check the inlet line for property tightened fittings and make sure it is free of restrictions and air leaks. NOTE: In most cases, the reservoir is above the pump inlet so that the pressure head created by the higher oil level helps to keep the inlet pressures within an acceptable range and prevent high vacuum levels.
PAGE 322
SECTION 5 - HYDRAULICS 5.12 REXROTH VARIABLE DISPLACEMENT PUMP PRIOR TO S/N 0300121643 The variable displacement axial piston pump is a swashplate design for hydrostatic drives in open circuits. The flow is proportional to the speed and the displacement. By adjusting the swashplate, it is possible to vary the flow steplessly. See Figure 2-43 for pressure settings and schematic. 1. Variable, swashplate design SAE nominal pressure 3600 psi (248 bar), peak pressure 4600 psi (317 bar). 9.
PAGE 323
SECTION 5 - HYDRAULICS Figure 5-33. Variable Displacement Pump.
PAGE 324
SECTION 5 - HYDRAULICS 5.13 SAUER PISTON PUMP S/N 0300121643 TO PRESENT Table 5-3.
PAGE 325
SECTION 5 - HYDRAULICS Initial start-up procedures 5. Install a gauge at port M2 to monitor system pressure during start up. Follow this procedure when starting-up a new pump or when the pump has been removed. 6. While watching the pressure gauge installed at M2, jog the engine or run at the lowest possible speed until system pressure builds to normal levels (minimum 160psi [11 bar]). Once system pressure is established, increase to full operating speed.
PAGE 326
SECTION 5 - HYDRAULICS Table 5-6. Actuator Response Is Sluggish Item Description Action Check external system relief valve setting. Low external relief valve setting will slow down system. Adjust external relief valve setting per manufacturer’s recommendations. External relief setting must be above Pressure Compensator setting for proper operation. Check Pressure Compensator and LS control setting. Low Pressure Compensator setting will prevent the pump from achieving full stroke.
PAGE 327
SECTION 5 - HYDRAULICS Table 5-8. Low Pump Output Flow Item Description Action Check fluid level in reservoir. Insufficient hydraulic fluid will limit output flow and cause internal damage to pump. Fill the reservoir to proper level. Hydraulic fluid viscosity above acceptable limits. Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly.
PAGE 328
SECTION 5 - HYDRAULICS Table 5-10. System Pressure Not Reaching Pressure Compensator Setting Item Description Action Check Pressure Compensator control setting. System pressure will not rise above Pressure Compensator setting. Adjust Pressure Compensator to appropriate setting. Refer to Adjustments. Check external relief valve. External relief valve setting below Pressure Compensator setting will prevent pressure compensation. Adjust external relief valve per manufacturer’s recommendations.
PAGE 329
SECTION 5 - HYDRAULICS Shaft Seal Replacement 4. Using the appropriate snap ring pliers, install the seal retaining ring. 5. Remove the installation sleeve. K010 K020 Control Assembly C118 6mm C138 6mm C136 C117 C116 C117 C135 C114 C134 Figure 5-34. Shaft Seal and Retaining Ring C115 C133 A lip type shaft seal is used in the pump and can be replaced without major disassembly of the unit. Replacement of the shaft seal requires removal of the pump from the machine. C102 (2pl.
PAGE 330
SECTION 5 - HYDRAULICS 4. Remove the plug (C103), O-ring (C103A),and Pressure Compensator spool (C132) from the control housing; discard the O-ring. Note orientation of the spool for reassembly. REASSEMBLY 1. Install the Pressure Compensator spool, spherical end first, into the Pressure Compensator bore. The Pressure Compensator spool is the shorter of the two. Using a new O-ring, install the plug (C103). Torque to 8-10 ft.lb. [11-14 Nm]. 5. Remove the plug (C107) and O-ring (C107A); discard the O-ring.
PAGE 331
SECTION 5 - HYDRAULICS Plug and Fitting Sizes and Torques is a composite. Your configuration may differ but the appropriate wrench size and torque can be found here. If any plugs or fittings are removed from the unit during service, install and torque as indicated here.
PAGE 332
SECTION 5 - HYDRAULICS NOTES: 5-50 – JLG Lift – 31208858
PAGE 333
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) SECTION 6. JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 6.1 INTRODUCTION NOTE: All 800A and 800AJ machines from S/N 65534 incorporate ADE (JLG Control System). The following machine serial numbers prior to S/N 65534 also utilize ADE: 62045, 62797, 63013, 63665, 63975, 64000, 64007, 64009, 64015, 64017, 64390, 64392, and 64411.
PAGE 334
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations 6-2 ABBREVIATION MEANING ABBREVIATION MEANING ACCEL ACCELERATE LEN LENGTH ACT ACTIVE LIM LIMIT A/D ANALOG DIGITAL CONVERTER COUNT LVL LEVEL AMB.
PAGE 335
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Figure 6-2.
PAGE 336
6-4 DRIVE: ACCEL X.XS TO MENU: MACHINE SETUP STEER: MAX SPEED X% PERSONALITIES: DRIVE MENU: PERSONALITIES RIGHT TRACK: ELEV R MAX X% RIGHT TRACK: CREEP F MAX X% RIGHT TRACK: CREEP R MAX X% LEFT TRACK: MIN REVERSE X% LEFT TRACK: MAX REVERSE X% LEFT TRACK: ELEV F MAX X% LEFT TRACK: ELEV R MAX X% LEFT TRACK: CREEP F MAX X% LEFT TRACK: CREEP R MAX X% DRIVE: MIN REVERSE X% DRIVE: MAX REVERSE X% – JLG Lift – DRIVE: ELEV.
PAGE 337
3120858 UPPER TELESCOPE: MAX IN X% UPPER TELESCOPE: MIN OUT X% UPPER TELESCOPE: MAX OUT X% TOWER LIFT: MAX UP X% TOWER LIFT: MIN DOWN X% TOWER LIFT: MAX DOWN X% UPPER TELESCOPE: DECEL X.XS TOWER LIFT: DECEL X.XS UPPER TELESCOPE: MIN IN X% UPPER TELESCOPE: ACCEL X.XS TOWER LIFT: ACCEL X.
PAGE 338
6-6 – JLG Lift – ENGINE: 5=CAT. 3024C ENGINE: 6=CAT. 3044C MODEL NUMBER: 5=800A MODEL NUMBER: 6=800S GEN SET/WELDER: 1=BELT DRIVE SOFT TOUCH: 1=YES GEN SET/WELDER: 2=HYD.
PAGE 339
Figure 6-6. Analyzer Flow Chart, Prior to Version 5.
PAGE 340
6-8 – JLG Lift – Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 NOTE: Some screens may not be available depending upon machine configuration.
PAGE 341
Figure 6-8. Analyzer Flow Chart, Version 5.
PAGE 342
6-10 TO: MENU: CALIBRATIONS MENU: MACHINE SETUP FROM: MENU: PERSONALITIES – JLG Lift – GEN SET CUTOUT: MOTION ENABLED GEN SET CUTOUT: MOTION CUTOUT GEN SET/WELDER: NO GEN SET/WELDER: BELT DRIVE CABLE SWITCH: YES CABLE SWITCH: NO FLYWHEEL TEETH: 133 TEETH FLYWHEEL TEETH: 110 TEETH FUNCTION CUTOUT: DRIVE CUT E&T LOAD SYSTEM: SPECIAL 1 FUNCTION CUTOUT: DRIVE CUTOUT FUNCTION CUTOUT: BOOM CUTOUT FUNCTION CUTOUT: NO TILT: 3 DEGREES + CUT TILT: 4 DEGREES + CUT TILT: 3 DEGREES TILT: 4 DEGREES
PAGE 343
3120858 – JLG Lift – MENU: SYSTEM TEST MAIN TELESCOPE: IN XXX% TOWER TELESCOPE: IN XXX% TOWER LIFT: DOWN XXX% JIB LIFT: UP PLATFORM CONTROL VALVE: OFF FUNCTION SPEED: PUMP POT XXX% CREEP SWITCH: CLOSED CREEP MODE: OFF STEER TYPE: NORMAL BRAKES STATUS: LOCKED CREEP SWITCH: CLOSED CREEP MODE: OFF 2-SPEED SWITCH: OPEN 2-SPEED VALVE OUTPUT: OFF HIGH ENGINE SWITCH: OPEN DRIVE MODE: MID ENGINE SYSTEM TEST: ACTIVATE? PLATFORM ROTATE: RIGHT XXX% RIGHT TRACK OUTPUT: FWD XXX% XXX% PLATFORM LEVE
PAGE 344
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Figure 6-11.
PAGE 345
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-12.
PAGE 346
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 6.2 CANBUS COMMUNICATIONS 6.4 CANbus: CAN (Control Area Network) is a two wire differential serial link between the Platform Module and Ground Module providing bi-directional communications. USING THE ANALYZER With the machine power on and the analyzer connected properly, the analyzer will display the following: Two-wire: One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal; both wires ”float” (2.
PAGE 347
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS SYSTEM TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS (view only) DRIVE BOOM SYSTEM DATALOG VERSIONS If you press ENTER, at the HELP: PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen.
PAGE 348
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Then using the RIGHT arrow key, position the cursor to the 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. Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly: 6.
PAGE 349
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 6.7 MACHINE SETUP When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS.
PAGE 350
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S 1 MARKET: 2 0 1 2 3 4 5 ANSI USA ANSI EXPORT CSA CE AUSTRALIA JAPAN 0 ENGINE: 3* * Engine selections vary depending on model selection.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit GLOW PLUG: 5 ENGINE SHUTDOWN: 6 TILT: 7* * Certain market selections will limit tilt options. Number Description 0 NO GLOW PLUGS: No glow plugs installed. 1 W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description GEN SET CUTOUT: 12* 0 MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / Welder Menu selection is not 0. 1 MOTION CUTOUT: Motion cutout in platform mode only. H & T LIGHTS: 13 0 NO: No head and tail lights installed. 1 YES: Head and tail lights installed.
PAGE 353
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description GROUND ALARM: 18* 0 NO: No ground alarm installed. * Certain market selections will alter default setting. 1 DRIVE: Travel alarm sounds when the drive function is active (Option). 2 DESCENT: Descent alarm sounds when lift down is active (Option).
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit ENGINE: 3* * Engine selections vary depending on model selection. Number 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1) 4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1) 5 CAT. 3024C: CAT 3024C Diesel (Tier 2) 6 CAT.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit ENGINE SHUTDOWN: 7 Number 0 DISABLED: No engine shutdown. 1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI. TILT: 8* * Certain market selections will limit tilt options and alter default setting.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit Number GEN SET CUTOUT: 13* * Only visible if Gen Set / Welder Menu selection is not 0. 0 MOTION ENABLED: Motion enabled when generator is ON. 1 MOTION CUTOUT: Motion cutout in platform mode only. H & T LIGHTS: 14 0 NO: No head and tail lights installed. 1 YES: Head and tail lights installed.
PAGE 358
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Digit Number FUNCTION CUTOUT: 18* * Only visible under certain market selections. * Certain market selections will limit function cutout options or alter default setting. 0 NO: No drive cutout. 1 BOOM CUTOUT: Boom function cutout while driving above elevation. 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
PAGE 359
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit ENGINE: 3* * Engine selections vary depending on model selection. Number 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1) 4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1) 5 CAT. 3024C: CAT 3024C Diesel (Tier 2) 6 CAT.
PAGE 361
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit STARTER LOCKOUT: 6 Number 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow. 1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished. 0 DISABLED: No engine shutdown.
PAGE 362
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit GEN SET/WELDER: 12 Number 0 NO: No generator installed. 1 BELT DRIVE: Belt driven setup. GEN SET CUTOUT: 13* * Only visible if Gen Set / Welder Menu selection is not 0. 0 MOTION ENABLED: Motion enabled when generator is ON. 1 MOTION CUTOUT: Motion cutout in platform mode only.
PAGE 363
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Number LOAD SENSOR: 17* * Only visible if Load Sensor Menu selection is not 0 and under certain market selections. * Certain market selections will limit load sensor options. 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module.
PAGE 364
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Digit Number LEVELING MODE: 22* * Only visible on 800S models. 0 ALL FUNCTIONS: Platform level with all functions. 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only. DRIVE CONTROL: 23 0 NORMAL: Drive coils are energized from the Ground Module. 1 PROPULSION: Drive coils are energized from the Propulsion Module.
PAGE 365
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 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. Shaded cells indicate a hidden menu or selection.
PAGE 366
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 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. Shaded cells indicate a hidden menu or selection.
PAGE 367
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-5.
PAGE 368
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-5. Machine Configuration Parameters 6 7 8 9 10 11 12 6-36 Tilt: Tower Lift: Tower Tele: Jib: 4ws soft touch generator 1=5Deg 2=4Deg 3=3Deg 0=NO 1=YES 0=NO 1=YES 0=NO 1=YES 2=SIDESWING 0=NO 1=YES 0=NO 1=YES 0=NO 1=YES Displays/adjusts tilt sensor function 1 5 degree – reduces the maximum speed of all boom functions to creep when tilted and above elevation.
PAGE 369
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-5.
PAGE 370
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-5. Machine Configuration Parameters 20 21 6-38 PLATFORM ALARM Tower Prox Switches 0=NO 1=FAULT CODE 0=NO 1=YES Displays/adjusts platform alarm presence/functions Displays presence/ function of Tower Proximity switches for the models specified. – JLG Lift – 0 Sounds Continuously When Above Elevation And Tilted Only. 1 Sounds Continuously When Above Elevation And Tilted, And In Conjunction With Fault Code Flashes.
PAGE 371
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) 6.9 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-6. Personality Ranges/Defaults FUNCTION DRIVE PERSONALITY 0.1 to 5.0s 2.0 DECELeration 0.1 to 3.0s 2.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-6. Personality Ranges/Defaults FUNCTION SWING PERSONALITY 0.1 to 5.0s 2.0 DECELeration 0.1 to 3.0s 1.8 MINimum LEFT speed 0 to 50% 35 MAXimum LEFT speed 0 to 100% 69 CREEP maximum LEFT speed 0 to 65% 35 MINimum RIGHT speed 0 to 50% 35 MAXimum RIGHT speed 0 to 100% 73 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.
PAGE 373
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-6. Personality Ranges/Defaults FUNCTION BASKET ROTATE PERSONALITY 0.1 to 5.0 1.8 DECELeration 0.1 to 3.0 0.3 MlNimum LEFT speed 0 to 65 34 MAXimum LEFT speed 0 to 100 50 MINimum RIGHT speed 0 to 65 34 MAXimum RIGHT speed 0 to 100 50 800 to 2900 1500 Lift ACCELeration 0.1 to 5.0 5.0 Lift DECELeration 0.1 to 3.0 1.
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SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 Fault Flash Code None Communicated (Displayed on Analyzer) Fault Description No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
PAGE 375
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 2/3 Flash code 2/3 indicates problems with boom function selection. LIFT/SWING JOYSTICK FAULTY The lift or swing joystick center tap is out of valid range, or the wiper is wire-off. LIFT/SWING LOCKED JOYSTICK MOVED BEFORE EMS/FSW Platform upper lift or swing was selected before and during footswitch closure.
PAGE 376
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 2/8 Flash code 2/8 indicates that the hydraulic filter is being bypassed. RETURN FILTER BYPASSED Hydraulic return filter clogged CHARGE PUMP FILTER BYPASSED Charge pump filter clogged 3/1 Flash code 3/1 indicates that a contactor did not close when energized. NOT REQUIRED 3/2 Flash code 3/2 indicates that a contactor did not open when energized.
PAGE 377
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 6/6 Flash code 6/6 indicates problems with the CAN bus. CAN BUS FAILURE: The ground module or platform module is not receiving. This is probably due to wiring problems between the platform and ground modules. 7/7 Flash code 7/7 indicates problems with a motor. NOT REQUIRED 8/1 Flash codes 8/1 indicate sensor issues.
PAGE 378
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code None 6-46 Communicated (Displayed on Analyzer) Fault Description Priority No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
PAGE 379
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code 2/2 3120858 Communicated (Displayed on Analyzer) Fault Description Flash code 2/2 indicates problems with drive & steer selection. Except where noted, these faults are not reported during 2 second power-up sequence. DRIVE LOCKED – JOYSTICK MOVED BEFORE FOOTSWITCH Drive was selected before and during footswitch closure.
PAGE 380
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code 2/3 Communicated (Displayed on Analyzer) Fault Description Flash code 2/3 indicates problems with boom function selection. LIFT/SWING LOCKED – JOYSTICK MOVED BEFORE FOOTSWITCH Priority 3 Platform upper lift or swing was selected before and during footswitch closure.
PAGE 381
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code 2/5 2/7 2/8 Communicated (Displayed on Analyzer) Fault Description Flash code 2/5 indicates that a function is prevented due to a cutout. Priority 4 BOOM PREVENTED – DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.
PAGE 382
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8.
PAGE 383
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description BASKET UP OVERRIDE OPEN CIRCUIT Only occurs on machines with electronic leveling systems. BASKET UP OVERRIDE SHORT TO BATTERY Only occurs on machines with electronic leveling systems.
PAGE 384
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8.
PAGE 385
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT Description Priority Only occurs on machines with electronic basket leveling.
PAGE 386
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code Communicated (Displayed on Analyzer) Fault Description COOLANT TEMPERATURE SHORT TO GROUND If a Deutz engine is installed, this indicates that the coolant temperature is reading below 0.1 volts. FORD FAULT CODE ## All Ford fault codes except 63 are simply passed through from the FORD ECM.
PAGE 387
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present Fault Flash Code 9/9 Communicated (Displayed on Analyzer) Fault Description Flash code 9/9 indicates problems with the controller. PLATFORM MODULE SOFTWARE UPDATE REQUIRED Priority 11 Platform module code is too old to support the EIM or BPE load sensor and the machine is configured to use one of these two sensors.
PAGE 388
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 389
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 390
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 391
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 392
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 393
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 394
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 395
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-9.
PAGE 396
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item is selected by pressing ENTER; pressing ESC steps back to the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow keys alter a value if allowed Table 6-10.
PAGE 397
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-10.
PAGE 398
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-10.
PAGE 399
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-11. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES … Displays brake control system status CREEP … Displays pump pot creep switch status TWO SPEED ...
PAGE 400
SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT) Table 6-11. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC.
PAGE 401
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 7.
PAGE 402
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.
PAGE 403
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 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.
PAGE 404
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet.
PAGE 405
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
PAGE 406
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
PAGE 407
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11.
PAGE 408
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly A A B B C C D Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4.
PAGE 409
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A B C C Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt.
PAGE 410
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18.
PAGE 411
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19.
PAGE 412
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20.
PAGE 413
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21.
PAGE 414
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22.
PAGE 415
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-23.
PAGE 416
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SOFT TOUCH SYSTEM LIMIT SWITCH PLATFORM WORK LIGHTS GENERATOR SWITCH J2 J5 J6 J1 J7 FOOTSWITCH J8 MAIN BOOM ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH (TOWER) BOOM LENGTH LIMIT SWITCH PLATFORM CONTROL BOX TOWER TELE & LIFT PROXIMITY SWITCHES DIAGNOSTIC ANALYZER (DEUTZ/GM ONLY) J4 J3 J2 J7 J1 J8 GROUND CONTROL BOX HEADLIGHTS TAILLIGHTS Figure 7-24.
PAGE 417
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2500W GENERATOR GENERATOR CONTROL BOX 2500W GENERATOR RELAY 7500W GENERATOR CONTROL BOX 7500W GENERATOR PLATFORM BOX LP CONVERTOR (FORD) THROTTLE ACTUATOR (CAT) ALTERNATOR BOSCH FUEL REGULATOR (GM) FUEL REGULATOR (GM HARNESS) FUEL PUMP (FORD UL SPEC) FUEL PUMP (CAT) 7500W GENERATOR RELAYS 7500W SKYPOWER GENERATOR THROTTLE CONTROL (FORD) LP ASSIST VALVE (FORD UL SPEC) ENGINE CONTROL (DEUTZ) FUEL SHUT OFF SWITCH (CAT) FUEL ON SOLENOID (DEUTZ
PAGE 418
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26.
PAGE 419
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870063 I Figure 7-27.
PAGE 420
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28.
PAGE 421
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870062 B Figure 7-29.
PAGE 422
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30.
PAGE 423
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-31.
PAGE 424
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32.
PAGE 425
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870100 G Figure 7-33.
PAGE 426
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870120 G Figure 7-35.
PAGE 428
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36.
PAGE 429
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: SEE SCHEMATIC 1001096461 FOR PLATFORM AND MAIN TERMINAL BOX WIRING. THIS SCHEMATIC CAN BE USED FOR ENGINE WIRING. 1870160 C Figure 7-37.
PAGE 430
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-38.
PAGE 431
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870134 C Figure 7-39.
PAGE 432
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-40.
PAGE 433
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870134 C Figure 7-41.
PAGE 434
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-42.
PAGE 435
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-43.
PAGE 436
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-44.
PAGE 437
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-45.
PAGE 438
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-46.
PAGE 439
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-47.
PAGE 440
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-48.
PAGE 441
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-49.
PAGE 442
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-50.
PAGE 443
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-51.
PAGE 444
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-52.
PAGE 445
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-53.
PAGE 446
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-54.
PAGE 447
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001096461 C Figure 7-55.
PAGE 448
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-56.
PAGE 449
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001096461 C Figure 7-57.
PAGE 450
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-58.
PAGE 451
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001096461 C Figure 7-59.
PAGE 452
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792351-F Figure 7-60.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally.
PAGE 454
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-61.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-62.
PAGE 456
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-63.
PAGE 457
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-64.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-65.
PAGE 459
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792629 B Figure 7-66.
PAGE 460
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-67.
PAGE 461
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792629 B Figure 7-68.
PAGE 462
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-69.
PAGE 463
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792629 B Figure 7-70.
PAGE 464
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-64 – JLG Lift – 3120858
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3120858 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 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.