Service Manual Owner manual

ManualsBrandsJLG ManualsSpecial machinery80SL

Service & Maintenance Manual

Model

80SL

3121325

March 24, 2011

Summary of content (162 pages)

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Service & Maintenance Manual Model 80SL 3121325 March 24, 2011
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL 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 - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - February 6, 2007 Revised - March 5, 2007 Revised - June 7, 2007 Revised - November 20, 2007 Revised - March 10, 2008 Revised - July 26, 2010 Revised - March 24, 2011 b – JLG Lift – 3121325
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 2.5 2.6 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.1 3.2 3.
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TABLE OF CONTENTS 4.2 4.3 4.4 4.5 Deck Extension Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Lift Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Outrigger Cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Steer Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 6.3 6.4 iv Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Scale . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 2-1. 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. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 3121325 TITLE PAGE NO. Limit Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 4-10. 4-11. 4-12. 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. 4-31. 4-32. 4-33. 4-34. 4-35. 4-36. 4-37. 4-38. 4-39. 4-40. 4-41. 4-42. 4-43. 4-44. 4-45. 4-46. 5-1. 5-2. 5-3. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. 6-18. vi Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6-19. 6-20. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. 6-30. 6-31. 6-32. 6-33. 6-34. 6-35. 6-36. 6-37. 3121325 Electrical Schematic - Sheet 2 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 Electrical Schematic - Sheet 3 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Electrical Schematic - Sheet 4 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 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 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 4-1 4-2 4-3 4-4 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 6-1 viii TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-1. Operating Specifications Parameter 80SL Maximum Working Height: with outriggers deployed with outriggers stowed 87 ft (26.5 m) 72 ft (22 m) Maximum Platform Height: with outriggers deployed with outriggers stowed 80 ft (24.5 m) 65 ft (19.8 m) Turning Radius : Inside Outside 14.5 ft (4.4 m) 20.3 ft (6.1 M) Wheelbase 12.8 ft (3.
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SECTION 1 - SPECIFICATIONS 1.4 ENGINE 1.7 Table 1-4. Engine Specifications Platform Stowed/Jacks Retract Limit Switch Deutz F4L 2011; or Deutz D2011 L04 i Type Displacement Switch that senses when the platform is lowered to 10.5 ft (3.2 m). Cuts out lowering function, enables drive function when tilted, and enables outriggers retract when outriggers are deployed.
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SECTION 1 - SPECIFICATIONS 3 4 1 2 6 5 7 1. Platform Stowed/Jacks Retract Limit Switch 5. Tilt Sensor 2. High Drive Speed Cutout Limit Switch 6. Outrigger Sensor (all 4 outriggers) 3. Maximum Drive Height/Maximum Height without Outriggers Limit Switch 7. Oscillating Axle Limit Switches (rear axle) 4. Maximum Height Limit Switch Figure 1-1.
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SECTION 1 - SPECIFICATIONS 1.8 PRESSURE SETTING 1.11 LUBRICATION Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends setting the pressures with the operating temperature between 59° 68°F (15°- 20°C). JLG Industries Inc. also recommends the use of a calibrated gauge. The pressures may be set with a tolerence of 43.5 psi ( ± 3 bar). Hydraulic Oil Table 1-10.
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SECTION 1 - SPECIFICATIONS Figure 1-2.
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SECTION 1 - SPECIFICATIONS 1.12 TORQUE CHARTS Figure 1-3.
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SECTION 1 - SPECIFICATIONS Figure 1-4.
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SECTION 1 - SPECIFICATIONS Figure 1-5.
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SECTION 1 - SPECIFICATIONS Figure 1-6.
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SECTION 1 - SPECIFICATIONS Figure 1-7.
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SECTION 1 - SPECIFICATIONS Figure 1-8.
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SECTION 1 - SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3121325
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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 Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection 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 Bolt Usage and Torque Application 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. 1. Use bolts of proper length.
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SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION Changing Hydraulic Oil 1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed annually unless operating in extreme conditions. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual.
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SECTION 2 - GENERAL 2.4 OPERATOR MAINTENANCE TO AVOID PERSONAL INJURY, USE SAFETY PROPS FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED. NOTE: Be sure to lubricate like items on each side. NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.
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SECTION 2 - GENERAL NOTE: 3. Engine Compartment The following numbers correspond with those in Figure 2-1., Lubrication Diagram. a. Engine Oil Check/Fill 1. Arm Pins • Lube Points - 41 Grease Fittings • Capacity - As Required • Lube - MPG • Interval - As Required 2.
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SECTION 2 - GENERAL b. Oil Filter d. Air Filter • Maintenance - Replaceable Element (JLG P/N 7016331) • Interval - Change every 500 hours or 6 months, whichever comes first. Change filter every time engine oil is changed. • Maintenance - Replaceable Element (JLG P/N H005232 & 70000054) • Interval - Every 6 months or 300 hours of operation c. Fuel Filter e.
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SECTION 2 - GENERAL 6. Oscillating Axle 4. Tie Rod Ends • Lube Points - 2 Grease Fittings • Capacity - As Required • Lube - MPG • Lube Points - 3 Grease Fittings • Interval - As Required • Capacity - As Required • Lube - MPG 5. Spindles • Interval - As Required 7.
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SECTION 2 - GENERAL 8. Fuel Tank (Opposite Engine Compartment) 10. Upper Slide Pads • Capacity - 23.8 gal (90 L) • Lube - Diesel Fuel • Interval - Check fuel periodically during each shift • Lube Points - 2 Grease Fittings • Capacity - As Required • Lube - MPG 9. Deck/Arm Pivot Pin • Interval - As Required 11.
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SECTION 2 - GENERAL 2.5 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following method. Platform Drift NOTE: Test cylinder drift with machine oil at ambient temperature. 1. Place maximum work load onto platform (Refer to Table 1-1, Operating Specifications). 2. Extend lift cylinder to achieve a platform height 3 to 5 meters from fully stowed.
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SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 100 Hours (3 Months) 200 Hours (6 Months) 400 Hours (1 year) PLATFORM 1. Controller 1,11 2. Switches 1,11 3. Placards and Decals 1,2 4. Control Tags 1,2 5. Hoses and Cables 4,8 6. Wear Pads 8,12 7. Handrails and Chains 1,4 CHASSIS 1. Battery 3 5 2. Hydraulic Pump 1 5 3. Valves 1 5 1 5 5 3,4 8. Lift Cylinder 1,12 5,6,13 4 9. Limit Switch 1,7 4. Hydraulic Filter 5.
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SECTION 2 - GENERAL NOTES: 2-12 – JLG Lift – 3121325
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS 3.1 OPERATING CHARACTERISTICS 3.2 WHEEL ASSEMBLY Drive System ANYTIME SERVICING OF ELECTRICAL OR HYDRAULIC COMPONENTS IS REQUIRED, DISCONNECT BATTERY VIA THE DISCONNECT SWITCH ON THE GROUND CONTROL PANEL AND SHUT VALVE LEVERS AT THE BASE OF THE HYDRAULIC TANK TO STOP FLOW OF HYDRAULIC FLUID. Leveling Jacks The machine is equipped with auto leveling jacks.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Drive Hub 1 DRIVE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE WORKING PROPERLY. 2 4 The following information briefly outlines what to look for when performing these tests. IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH. 3 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Wheel Installation Table 3-1. Torque Hub Technical Specifications Max Torque 5.5 kNm Max Input Speed 4000 rpm Weight 101.4 lbs (46 kg) It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1. Wheel Nut (6 per tire) 5 2. Drive Hub 6 3. Bolt, M16 x 55mm (6 per wheel) 8 4. Flatwasher, M16 (6 per wheel) 7 5. Capscrew, M16 x 35mm (2 per wheel) 10 4 9 6. Double Shock Valve (Rear Wheels) 3 Travel Brake Valve (Front Wheels) (Not Shown) 7. Capscrew, M10 x 45mm (Rear) (4 per valve) 2 Capscrew, M10 x 55mm (Front) (Not Shown) (4 per valve) 8 Drive Motor 9 Bolt, M12 x 35mm (2 per motor) 10 Lockwasher, M12 (2 per motor) 1 Figure 3-2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1 Drive Motor Side 3 2 1. Torque to 354 lb ft Dry (480 Nm) 2. Torque to 230.9 lb ft Dry (313 Nm) 3. Torque to 230.9 lb ft Dry (313 Nm) Figure 3-3.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12 24 11 10 23 13 23 12 1 6 18 7 17 37 38 15 36 39 48 2 46 35 16 31 21 25 27 22 45 40 28 47 41 42 49 32 11 9 26 4 29 43 44 20 3 19 52 30 2 20 34 14 1. Spindle 14. Sun Pinion 27. Circlip 40. Screw 2. Hub 15. Piston 28. Plug 41. Screw 3. Gear Ring 16. Spring 29. O-Ring 42. Screw 4. Cover 17. Disc 30. O-Ring 43. Plug 5. Flange 18. Disc 31. O-Ring 44. Washer 6. Coupling 19. Lock Nut 32. O-Ring 45.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.3 DRIVE MOTOR 2 3 1 8 9 8 4 5 10 6 11 8 7 12 1. Dust Seal 6. Output Shaft 11. End Cover 2. Motor Housing 7. Cardan Shaft 12. Washer 3. Shaft Seal 8. O-Ring 13. Screw 4. Bearing Race 9. Distributor Plate 5. Axel Needle Bearing 13 10. Gear Wheel Set Figure 3-5. Drive Motor (OMR 100) Table 3-2. Drive Motor Specs 3121325 Displacement 99.8 cm³ Max Speed 600 rpm Max Torque 177 lb ft (240 Nm) Max Power 13 kw Max Oil Flow 15.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Motor Disassembly commutation slot leading up to the front annular channel. NOTE: For numbers in ( ), refer to Figure 3-5., Drive Motor (OMR 100). 7. Grease the O-Ring (8) and put it in the O-ring groove of the housing. 1. Place the Motor Housing (2) in a holding tool with the flange upwards. 8. Turn the Distributor Plate (9) so that the holes iine up. 2. Use a 13mm spanner socket to remove the screws (13) and washers (12). 9.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.4 STEERING ASSEMBLY 4 5 6 7 3 8 9 1 10 17 31 32 33 29 30 18 20 21 22 26 19 15 16 12 28 27 11 13 14 2 23 24 25 1. Right Spindle 10. Bushing* 19. Steer Cylinder 28. Grease Fitting 2. Left Spindle 11. Ring 20. Bolt, M12 x 150mm 29. Grease Fitting Cap 3. Cap 12. Pin 21. Flatwasher, M12 30. Grease Fitting 4. Grease Fitting Cap 13. Grease Fitting Cap 22. Washer 31. Bolt, M12 x 20mm 5. Grease Fitting 14. Grease Fitting 23. Washer 32.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.5 REAR AXLE Limit Switches 1. Rear Axle 2. Limit Switch Cover 3. Bolt, M12 x 70mm 4. Flatwasher, M12 5. Lockwasher, M12 6. Bushing 7. Limit Switch 8. Capscrews, M5 x 50mm 1 14, 15, 16 9. Plate 10. Bolt, M12 x 80mm 11. Lockwasher, M12 12. Bushing 6 13 9 12 13. Bushing 14. Capscrew, M20 x 80mm 11 10 7 5 8 2 15. Hardened Washer, 20mm 4 3 16. Nut, M20 Figure 3-7.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.6 OUTRIGGER CYLINDER REMOVAL 2 A 3 B 5 6 1 9 1. Cover 8 7 2. Bolt, M8 x 160mm 4 3. Lockwasher, M8 4. Outrigger Cylinder 5. Bolt, M8 x 50mm 6. Lockwasher, M8 7. Valve Assembly 8. Limit Switch Bracket 9. Limit Switch Figure 3-8. Outrigger Cylinder Removal - (Sheet 1 of 2) NOTE: Refer to Figure 3-8., Outrigger Cylinder Removal (Sheet 1 of 2) and Figure 3-9., Outrigger Cylinder Removal - (Sheet 2 of 2).
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS C D 16 10 11 16 12 13 15 14 10. Bolt, M6 x 16mm 14. Bolt, M12 x 70mm 11. Lockwasher, M6 15. Lockwasher, M12 12. Plate 16. Outrigger Cylinder 13. Gasket Figure 3-9. Outrigger Cylinder Removal - (Sheet 2 of 2) Installation: 1. Carefully insert Outrigger Cylinder (16) back into the frame and secure with the four Bolts (14) and Lockwashers (15). 2. Replace Gasket (13) and Plate (12). Secure with four Bolts (10) and Lockwashers (11). 5.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.7 ENGINE COMPARTMENT Hood Assembly VALVE SIDE 13 14 13 14 7 1. Hood 2. Gas Spring 8 9 15 15 10 11 12 3. Bolt, M8 x 30mm 6 4. Nut, M8 5. Cabinet Top Panel (Left) ENGINE SIDE 16 6. Cabinet Panel (Right) 5 2 16 13 14 7. Special Bolt 15 8 9. Air Intake Pipe 15 8. Flatwasher, M12 7 10. Bolt, M8 x 25mm 11. Flatwasher, M8 12. Locknut, M8 3 2 13. Bolt, M10 x 30mm 4 14. Nut, M10 2 15. Flatwasher, M10 16. Nut, M10 1 Figure 3-10.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Deutz Engine 4 3 1 2 1. Diesel Engine 3. Air Intake 2. Air Filter 4. Hydraulic Oil Tank Figure 3-11. Deutz F4L 2011 Table 3-4.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Tray Slide 3 3 1, 2 1, 2 1. Capscrew, M16 x 30mm 2. Lockwasher, M16 3. Capscrew, M16 x 60mm Figure 3-12. Engine Tray Slide The engine tray can slide outward approximately 5.9 in. (15 cm) when servicing components inside the engine compartment. 1. Remove the two Capscrews (1) and Lockwashers (2) on the front of the engine tray. 2. Loosen the two top Capscrews (3) at both ends of the engine compartment. Slide engine tray outward. 3.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Glow Plugs 1. 30 amp Fuses 2. Timer Relay N6 3. Relay K3 Figure 3-13. Glow Plugs Engine Solenoid Fuse 1. Solenoid 2. 30 amp Fuse Figure 3-14.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Hydraulic Pump Assembly 1. Hydraulic Pump 2. Bolt, M12 x 30mm 3. Lockwasher, M12 5 6 4 8 9 4. Flange 7 5. Capscrew, M10 x 25mm 6. Lockwasher, M10 7. Coupling 8. Hex Head Screw, M8 x 25mm - see installation note below 9. Lockwasher, M10 1 2 3 Figure 3-15. Hydraulic Pump Assembly REMOVAL: INSTALLATION: 1. Disconnect any hoses and/or wires on the Hydraulic Pump (1). 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Hydraulic Pump 1. Drain Port • tighten to 177 lb ft (240 Nm) 2. Pressure Port • tighten to 30 lb ft (40 Nm) 1 3. Inlet Port • tighten to 66 lb ft (90 Nm) 2 3 Figure 3-16. Variable Displacement Axial Piston Pump Pump Flow • Flow from the pump to the control valve is protected by THIS PUMP IS FACTORY SET FOR FLOW, PRESSURE, AND a full flow and a load sensing dump valve, both norHORSEPOWER CONTROL AND SHOULD NOT BE ADJUSTED. mally-open to tank ports.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust Pipe Assembly 8 9 3 7 6 4 2 1 5 1. Muffler 4. Exhaust Clamp 7. Tailpipe 2. Exhaust Clamp 5. Exhaust Flex Pipe 8. Bolt, M10 x 20mm 3. Exhaust Elbow 6. Exhaust Clamp 9. Lockwasher, M10 Figure 3-17. Exhaust Pipe Assembly NOTE: In the event any or all exhaust piping needs repaired or replaced follow the below steps. Refer to Figure 317., Exhaust Pipe Assembly. 5. Remove the Exhaust Flex Pipe (5) by loosening the Exhaust Clamp (6).
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Filter Assembly 1. Air Filter 2. Bolt, M8 x 45mm 3. Flatwasher, M8 4. Locknut, M8 5. Hose Clamp Clip 6. Air Intake Hose 12 13 11 8. Reducing Sleeve 7 5 10 7. Hose Clamp Clip 6 9. Clamp 10. Air Intake Elbow 11. Clamp 9 1 8 12. Air Intake Hose 13. Clamp 2 4 3 Figure 3-18. Air Filter Assembly NOTE: Refer to Figure 3-18. when dismantling the Air Filter for service and/or replacements.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1 2 1 2 1. Bolt, M12 x 110mm 2. Flatwasher, M12 4 3. Locknut, M12 1 2 2 3 4. Oil Drain Port 2 3 2 3 Figure 3-19. Engine Removal 5. Remove all 4 Bolts (1) and second set of Flatwashers. NOTE: Refer to Figure 3-19. when removing engine from engine compartment. 6. Carefully lift engine from engine compartment with appropriate lifting device. ENGINE REMOVAL REQUIRES HEAVY LIFTING DEVICES. USE EXTREME CAUTION WHEN REMOVING THE ENGINE.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Hydraulic Tank 1. Hydraulic Tank 2. Capscrew, M10 x 25mm 3. Flatwasher, M10 (2 per capscrew) 4. Nut, M10 5. Shutoff Valve Lever 6 6. Filler 2, 3, 4 1 2, 3, 4 Figure 3-20. Hydraulic Tank Removal Removal: Installation: 1. Close shutoff valve lever (5) to turn off flow of hydraulic fluld. Drain hydraulic fluid by opening the drain port on the underside of the Hydraulic Tank (1). Store fluid in appropriate receptacle. Disconnect all hoses. 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pressure Filter 1 1. Pressure Filter 2, 3 2. Capscrew, M10 x 20mm 3. Lockwasher, M10 Figure 3-21. Pressure Filter Removal Removal: Installation: 1. Disconnect hose(s) from the Pressure Filter (1). 1. Align the pressure filter so that the screw holes match up with the screw holes on the holding bracket. 2. Loosen and remove the four Capscrews (2) and Lockwashers (3). 3. Remove the Pressure Filter.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.8 FUEL TANK 9 10 9 10 8 1 1. Fuel Tank 2. Fuel Line Hose, 5.5 mm 3. Clamp 4. Hose Fitting 5. Fuel Line Hose, 7.5mm 6. Clamp 4 3 7. Hose Fitting 8. Fuel Tank Strap 2 9. Nut, M8 10. Lockwasher, M8 7 6 5 Figure 3-22. Fuel Tank Removal Removal: Installation: 1. Place Fuel Tank onto the chassis. Secure tank with Fuel Tank Strap. Fasten with Bolts and Lockwashers. NOTE: Drain Fuel Tank (1) before removing. Store diesel fuel in approved receptacle. 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.9 GROUND CONTROL PANEL 5 3 4 2 1 1. Ground Control Panel 3. Bolt, M6 x 20mm 2. Electrical Compartment 4. Nut, M6 5. Flatwashers, M6 Figure 3-23. Ground Control Panel Removal Removal: Installation: 1. Attach the Ground Control Panel to the Electrical Compartment with the Bolts, Flatwashers, and Nuts. DISCONNECT GROUND CONTROL PANEL (1) FROM BATTERY BEFORE REMOVING AND/OR SERVICING. 1. Disconnect all plugs and wires from the back of the control panel.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.10 BATTERY REMOVAL 1. Batteries 5 2. Battery Cable (Battery - to Battery +) 6 3. Battery Cable (Battery + to Battery Disconnector) 4 7 4. Battery Cable (Battery - to Engine) 5. Bolts, M8 x 35mm 6. Lockwashers, M8 2 7. Battery Hold Clamp 3 NOTE: Items 5, 6, and 7 are also located on the back side of the battery (not shown) 1 ENGINE CHECK BOX STARTER ENGINE Battery Schematic BATTERY DISCONNECTOR BATTERIES Figure 3-24.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.11 PLATFORM Platform Control Box 3 1 1. Control Box Lid 2. Control Box 3. Screw, M4 x 30 2 Figure 3-25. Platform Control Box For access to the inside of the platform control box, follow these steps: 1. Disconnect platform control box connector from the machine. NOTE: When assembling the platform control box, be careful not to pinch wires when replacing the lid back onto the box. 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Joystick Controller Figure 3-26. Joystick Table 3-6. Joystick Specifications Table 3-7. Plug Loading Chart Input Voltage 24V (±0.05V) Terminal Color Function Centered Output Voltage 12V (±0.25V) 1 Green Steer Left Reverse Voltage 5.5 - 6.5V 2 Yellow Steer Right Forward Voltage 17.5 - 18.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Receptacles 2, 3, 4 7, 8, 9 5 6 1 1. Receptacle Box 4. Nut, M6 7. Bolt, M5 x 16 2. Bolt, M6 x 20mm 5. 110V Receptacle 8. Flatwasher, M5 (qty 2) 3. Flatwasher, M6 (qty 2) 6. Platform Control Box Outlet 9. Nut, M5 Figure 3-27. Platform Receptacle Box Removal 5. The 110V Receptacle (5) can be removed from the box by removing the four screws on the backside. DISCONNECT BATTERY SUPPLY ON GROUND CONTROL PANEL BEFORE REMOVING RECEPTACLE BOX. 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Platform Side Rails 5 6 3 4 2 8 7 1 11 9 15 14 10 16 14 13 12 1. Side Rail 7. Locknut, M12 13. Chain Assembly Mounting Plate 2. Cotter Pin 8. Pin 14. Flatwasher, M10 3. Pin 9. Cotter Pin 15. Locknut, M10 4. Bar 10. Pin 5. Pin 11. Hinge Bracket 6. Bolt, M12 x 40mm 12. Bolt, M10 x 120mm 16. Tube Figure 3-28. Side Rails Removal 2. Remove the Cotter Pins (9) from the Pins (10) on all three Hinge Brackets (11).
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Platform End Rails 3 2 11 6 1 10 8 9 7 5 8 4 1. End Rail (right side) 5. Cotter Pin 9. Chain Assembly Mounting Plate 2. End Rail (left side) 6. Pin 10. Locknut, M10 3. Gate 7. Bolt, M10 x 120mm 11. Hinge 4. Platform 8. Flatwasher, M10 Figure 3-29. End Rail Removal Removal: Installation: 1. If applicable, disconnect end rails (1,2,3) from side rails. (see removal instructions for side rails on previous page).
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Extension Side Rails 1 13 12 10 8 15 2 9 16 3 14 11 7 65 4 1. Extension Side Rail 7. Chain Assembly Mounting Plate 13. Locknut, M12 2. Cotter Pin 8. Cotter Pin 14. Chain Assembly Mounting Plate 3. Pin 9. Pin 15. Bolt, M10 x 25mm 4. Bolt, M6 x 16mm 10. Extension Rail Bracket 5. Lockwasher, M6 11. Bolt, M12 x 100mm 6. Flatwasher, M6 12. Flatwasher, M12 16. Lockwasher, M10 Figure 3-30. Extension Side Rails Removal 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Extension End Rail 1. Extension End Rail 2. Cotter Pin 3. Pin 4. Hinge Bracket 5. Bolt, M10 x 120mm 6. Locknut, M10 4 1 7. Flatwasher, M10 2 6 8. Chain Assembly Mounting Plate 3 7 9. Tube 9 7 8 5 Figure 3-31. Extension End Rail Removal Removal Installation 1. If applicable, detach the end rail (1) from the side rails (see removal instructions for side rails on previous page). 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Removal 1. Platform Pivot Pin 2. Bolt, M12 x 25mm 3. Lockwasher, M12 2, 3 1 NOTE: Illustration shows scissor arm assembly connection point to underside of platform at the front of the platform. Figure 3-32. Platform Removal - 1 of 2 (Front of Platform) Machine Stabilization: NOTE: Procedures apply to both left and right sides. The arm stack can be supported by using an overhead crane, Figure 4-31.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 2, 3 2, 3 1. Platform Retaining Bracket 2, 3 2. Bolt, M10 x 16mm 3. Lockwasher, M10 2, 3 1 2, 3 2, 3 NOTE: Illustration shows scissor arm assembly connection point to underside of platform at the rear of the platform. Figure 3-33. Platform Removal - 2 of 2 (Rear of Platform) Platform Removal: Installation: 1. The removal steps should be followed in reverse order when installing the platform. NOTE: Procedures apply to both left and right sides. 1.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.12 LADDER INSTALLATION 1. Ladder 2. Bolt, M10 x 25mm 3. Spring Lockwasher, M10 4. Flatwasher, M10 (if applicable) 1 2 3 4 Figure 3-34. Ladder Installation Removal: Installation: 1. The ladder can easily be removed from the chassis by removing the four Bolts (2), Spring Lockwashers (3), and Flatwashers (4). 1. Lift ladder so that the four mounting brackets align with the bolt holes on the chassis. 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.13 BEACON INSTALLATION (OPTION) Front Beacon Rear Beacon 1 Harness 5, 7 2 4 Position W11 3 7 6 8 Front and Rear MTB Underside 1. Beacon & Protective Cage 5. Bolt, M4 x 25mm 2. Mounting Bracket 6. Nut, M4 3. Screw, 6mm x 16mm 7. Washer 4. Washer, 6mm 8. Guiding Rods Figure 3-35. Beacon Installation Removal: NOTE: Procedures apply to both the Front and Rear Beacons. 1. Disconnect electrical supply. 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.14 SCISSOR ARMS Limit Switches 6 5 8 7 1 2 3 4 1. Platform Stowed/Jacks Retract Limit Switch 5. Cam 1 2. High Drive Speed Cutout Limit Switch 6. Cam 2 3. Max Drive Height/Max Height without Outriggers Limit Switch 7. Cam 3 4. Max Height Limit Switch 8. Cam 4 Figure 3-36. Limit Switch Adjustment Cam Adjustment: 3. Adjust Cam 3 (7) to activate Max Drive Height/Max Height without Outriggers Limit Switch (3) when platform is at a height of 65 ft (20 m).
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Scissor Arm Assembly Removal 3. Secure scissor arm assembly with two lifting straps attached to an overhead lifting device. EXTREME CAUTION MUST BE USED WHILE REMOVING ANY LARGE COMPONENTS. THESE COMPONENTS ARE EXTREMELY HEAVY AND CAN CAUSE SERIOUS INJURY OR DEATH IF NOT REMOVED CAUTIOUSLY. NOTE: Scissor arm assembly weighs approximately 15,653 lbs (7100 kg). Straps and lifting device must be capable of lifting the scissor assembly.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Remove one pin from the steering linkage to gain access to the scissor arms pin behind the wheel. (see Section 3-6., Steering Assembly). 8. Remove the Coverplates (3) from both sides of the machine by removing the two Bolts (1) and Lockwashers (2). Once the coverplates are removed the Pin (4) can be pushed out. 5. Remove the cable from the ground control socket in the valve compartment.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 11. Lift the arm stack up and to the front. The lift cylinder (1) is still attached to the chassis and the arm stack will pivot about the Pin (2). When sufficient clearance is achieved between the lift cylinder and frame, secure the cylinder. 12. Disconnect the Lift Cylinder from the arm stack by removing the Bolt (3) and Lockwasher (4). Pull out the Pin (2). NEVER EXTEND THE LIFT CYLINDER WHEN THERE IS NO LOAD ON THE CYLINDER.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Lift Cylinder Removal 6. Carefully raise the Lift Cylinder (1) from the chassis using an overhead crane or other suitable lifting device.. USE CAUTION WHEN REMOVING AND MOVING THE LIFT CYLINDER. THE LIFT CYLINDER ASSEMBLY WEIGHS APPROXIMATELY 992 LBS (450 KG). USE APPROPRIATE LIFTING DEVICES. 1. Follow the procedures on the previous pages to remove the platform and scissor arm assemblies. 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Scissor Arms Disassembly 6. Move to the right side of the machine. The Arm Pin (1) can now be pulled out of the scissor arm stack. Remove the four Bushings (2), two Ball Thrust Bearings (3), and two Bushings (4). INDIVIDUAL SCISSOR ARMS ARE HEAVY. USE CAUTION WHEN REMOVING. USE APPROPRIATE LIFTING DEVICES. 1. Disconnect battery and shutoff flow of hydraulic fluid by closing the shutoff levers on the hydraulic tank (see Figure 3-20.). 2 3 1 2.
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SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTES: 3-44 – JLG Lift – 3121325
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SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 CYLINDERS - THEORY OF OPERATION Deck Extension Cylinder: The deck is extended and retracted by means of a double acting cylinder controlled by the first section in the main control valve (see Figure 4-37., Main Valve Block). The service line relief valve in the control valve is set at 1160 psi ( 80 bar) for extend and 3046 psi (210 bar) for retract.
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SECTION 4 - HYDRAULICS 4.3 CYLINDER CHECKING PROCEDURE 4.4 CYLINDER REPAIR NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected. 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. There will be some initial weeping of hydraulic fluid which can be caught in a suitable container.
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SECTION 4 - HYDRAULICS NOTE: Step 3 applies only to the Axle Lockout Cylinder. 3. To prevent damage, remove the load check valve from the barrel. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 5. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting. Load Check Valve DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 6.
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SECTION 4 - HYDRAULICS 9. Using a spanner wrench, loosen and remove the cylinder head from the barrel. 11. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 12. If applicable, loosen and remove the setscrew which attaches the piston to the rod, and remove the piston. Cylinder Rod Pistons Cylinder Head Barrel Setscrews Figure 4-5. Cylinder Head Removal Figure 4-7.
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SECTION 4 - HYDRAULICS 14. Remove and discard the piston o-rings, seal rings, and, if applicable, the snap ring. Snap Ring (Outrigger Cylinder Only) 17. Remove the cylinder head from the cylinder rod. Cylinder Head O-Ring Cylinder Rod Piston Piston Seal Figure 4-11. Cylinder Head Removal Figure 4-9. Piston Seals 15. If applicable, remove the spacer from the rod. 18. If applicable, remove and discard the cylinder head seal, rod seal, wiper, o-ring(s), back-up ring, and snap ring.
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SECTION 4 - HYDRAULICS Cleaning and Inspection d. Using an arbor of the correct size, carefully press the bushing(s) into bushing housing on the cylinder rod and cylinder barrel, if applicable. 1. Clean all parts thoroughly in an approved cleaning solvent. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. Bushing Housing 3. Inspect threaded portion of rod for excessive damage.
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SECTION 4 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual 3121326. Always replace seals when servicing cylinders. Wiper Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.
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SECTION 4 - HYDRAULICS 5. Carefully slide the piston spacer onto the cylinderrod. 9. If applicable, carefully thread the piston clock-wise on the cylinder rod hand tight until it abuts the spacer, ensuring that the o-ring, snap ring, and piston seals are not damaged or dislodged. Spacer Piston Cylinder Rod Spacer Cylinder Rod Figure 4-17. Spacer Installation 6. If applicable, correctly install new o-ring and snap ring in the inner piston diameter groove. 7.
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SECTION 4 - HYDRAULICS Cylinder Rod EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 13. With the barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading oring and seal ring are not damaged or dislodged. Cylinder Head Cylinder Head Barrel Cylinder Rod Figure 4-22.
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SECTION 4 - HYDRAULICS Load Check Valve Limit Switch Safety Valve Outrigger Cylinder Cylinder Barrel NOTE: Axle Lockout Cylinder only. Figure 4-24. Load Check Valve Installation NOTE: Outrigger Cylinders only. Figure 4-25. Safety Valve and Limit Switch Installation NOTE: Refer to Figure 1-3., Torque Chart (SAE Fasteners Sheet 1 of 3) to Figure 1-8., Torque Chart (METRIC Fasteners - Sheet 3 of 3) for setscrew torques.
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SECTION 4 - HYDRAULICS 2 2 8 9 7 5 1 10 11 3 6 2 4 18 13 2 14 17 12 16 13 15 1. Piston Rod 7. Cylinder Head 13. Solenoid Valve 2. Bushing 8. Wiper 14. Check Valve 3. Piston 9. Rod Seal 15. Capscrew (M8 x 120mm) 4. Piston Seal 10. O-Ring 16. Hydraulic Block 5. O-Ring 11. Cylinder Barrel 17. Pressure Sensor 6. Setscrew 12. Lift/Lower Valve 18. O-Ring Figure 4-26.
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SECTION 4 - HYDRAULICS 12 2 10 9 1 1. Barrel 2. Bushing 3. Piston 7 4. Piston Seal 5. Setscrew 6. Spacer 7. Head 8. Head Seal 11 9. Rod Seal 8 10. Wiper 6 5 11. O-Ring 12. Rod 3 4 2 Figure 4-27. Steering Cylinder Assembly Table 4-1. Steer Cylinder Specs Max Working Pressure 3045.7 psi (210 bar) Piston Head Torque (Apply Loctite 242 before tightening) 191.8 lb ft (260 Nm) 1.6 ft/sec (0.
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SECTION 4 - HYDRAULICS 2 7 1. Barrel 2. O-Ring 6 3. Cap 4. Mounting Flange 5. Stop 8 6. Piston 9 1 10 7. Snap Ring 8. Piston Seal 11 9. Spacer 12 10. O-Ring 11. O-Ring 18 13 3 12. Back-up Ring 13. Head 14. Rod Seal 14 4 15 15. Wiper 16. Snap Ring 16 17. O-Ring 17 18. Rod Assembly 5 Figure 4-28. Outrigger Cylinder Assembly Table 4-2. Outrigger Cylinder Specs Max Working Pressure 2683.
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SECTION 4 - HYDRAULICS 2 2 1. Barrel 2. Bushing 3. Load Check Valve 5 3 1 6 4. Piston 5. Piston Seal 4 6. Setscrew 7. Head Seal 7 8. Backup Ring 9. O-Ring 8 10. Head 9 11. Rod Seal 14 12. Wiper 10 13. Rod 14. O-Ring 11 13 12 2 2 Figure 4-29. Axle Locking Cylinder Assembly Table 4-3. Axle Locking Cylinder Specs Max Working Pressure 2900.7 psi (200 bar) Piston Head Torque (Apply Loctite 242 to Piston Head before tightening 737.8 lb ft (1000 Nm) Max Speed 0.5 m/sec.
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SECTION 4 - HYDRAULICS 12 13 7 1 8 10 1. Barrel 2. Piston 6 3. Setscrew 4. Piston Seal 11 5. Spacer 6. Head 7. O-Ring 9 8. Wiper 9. O-Ring 5 10. Wiper 11. Head Seal 3 12. Rod 2 13. Bushing 4 Figure 4-30. Extension Cylinder Assembly Table 4-4. Deck Extension Cylinder Specs Max Working Pressure 3045.7 psi (210 bar) Full Bore Relief Pressure 1160.3 psi (80 bar) Piston Torque (Apply Loctite 242 to Piston Thread before tightening) 147.5 lb ft (200 Nm) Setscrew Torque 14.
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SECTION 4 - HYDRAULICS REMOVE ANY LOAD FROM PLATFORM. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING. STRAP STRAP ARM SAFETY PROP Figure 4-31.
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SECTION 4 - HYDRAULICS 4.5 VALVES Valve Compartment 1. Pressure Switch, Drive Enable & Brake Valve 2. Drive Valve 3. Main Valve Block 4. Hand Pump 4 3 2 1 Figure 4-32. Valve/Hydraulic Compartment Pressure Switch, Drive Enable • Operate the lower function to retract the jacks and adjust the switch (screw on the top of the switch) to trip at 2683 psi (185 bar) Figure 4-33.
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SECTION 4 - HYDRAULICS Brake Valve 2 1 VALVE SCHEMATIC 1. Torque to 5 ft lbs (6.8 Nm) 2. Torque to 20 ft lbs (27.1 Nm) A • Operating Pressure: 3000 psi (207 bar) • Voltage: 24VDC P T Figure 4-34. Brake Valve Brake Valve Adjustment: • To achieve smooth deceleration when the joystick is returned quickly from the max forward or backward position to the neutral position, completely close the valve knob (shown to the left) then open the knob 1/2 of a revolution. Figure 4-35.
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SECTION 4 - HYDRAULICS Drive Valve SCHEMATIC Rear C4 Front Rear Front Rear C4 C3 C2 C1 C4 C3 C2 C1 D4 D3 D2 D1 D4 D3 D2 D1 D4 C3 D3 C2 D2 C1 D1 C4 D4 C3 D3 C2 D2 C1 D1 C4 Front C4 C3 C2 C1 D4 D3 D2 D1 D4 C3 D3 C2 D2 AB A B P T Drive 2 Valve A A D1 AB A B A B A B P T P T P T PT B C1 PT Drive 1 Valve Passive Parallel 4-Wheel Drive B Drive 2 Valve A Not Used B Drive 1 Valve Active A Active Fast 2-Wheel Drive B B Drive 2 Va
PAGE 100
SECTION 4 - HYDRAULICS Main Valve Block 1. Main Pressure Block 2. Platform 3. Drive 2 4. Lift 5. Steer 6. Rear Right Jack 7. Rear Left Jack 10 9 8. Front Right Jack 9. Front Left Jack 8 10. Drive 1 7 6 4 3 2 1 DRIVE 1 LEVELING FRONT RIGHT LEVELING FRONT RIGHT LEVELING REAR LEFT LEVELING REAR RIGHT STEERING LIFTING DRIVE 2 PLATFORM VALVE SCHEMATIC Figure 4-37.
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SECTION 4 - HYDRAULICS Adjust main pressure on top of the Main Pressure Block • remove the cap and attach a pressure gauge to pressure test port (see Figure 4-38.) • remove rubber plug from adjustment port • pressure should be set to maximum of 210 bar (3045.8 psi). Adjust the setting screw fully in clockwise direction.(see Figure 4-39.) Figure 4-38. Pressure Test Port Figure 4-39. Proportional Valve Pressure Adjustment Pump Engage/Disengage Valve 1 1. Torque to 5 ft lbs (6.8 Nm) 2.
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SECTION 4 - HYDRAULICS Hand Pump 8 11 2 10 Pump Assembly 6 3 9 11 13 17 7 5 12 11 10 16 11 14 9 36 15 17 27 19 1 21 20 37 20 4 20 12 21 32 33 27 34 25 20 19 35 29 20 28 19 30 Valve Assembly 23 20 20 26 31 24 Pump Assembly 12. Ball Valve Assembly 28. Spring 1. Valve, Suction 13. Ring 18. Body 29. Nut M10 2. Plug 14. Washer 19. Ball 30. Seal 3. Plug 15. RIng, Internal Retaining 20. Ring 31. Setscrew 4. Body 16. Seal 32. Relief, Valve 17. Spring 21.
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SECTION 4 - HYDRAULICS VALVE SCHEMATIC B S Figure 4-42. Hand Pump Valve Schematic Load Holding Valve 1 1. Torque to 5 ft lbs (6.8 Nm) 2. Torque to 20 ft lbs (27.1 Nm) 2 • Operating Pressure: 3000 psi (207 bar) • Voltage: 24VDC Axle Lockout Cylinder Figure 4-43.
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SECTION 4 - HYDRAULICS Lift/Lower Valve Block Solenoid Valves (Qty. 2) 1. Torque to 5 ft lbs (6.8 Nm) Lift Cylinder Lift/Lower Valve Block 2. Torque to 60 ft lbs (44.25 Nm) • Operating Pressure: 3500 psi (240 bar) Check Valve 3 Check Valve 3. Torque to 20 ft lbs (27.1 Nm) 2 1 Solenoid Valves • Operating Pressure: 3500 psi (240 bar) Figure 4-44.
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SECTION 4 - HYDRAULICS Outrigger Safety Valves Front Outriggers: Outrigger Cylinder Safety Valve • Operating Pressure: 116 psi (8 bar) Rear Outriggers: • Operating Pressure: 14.5 psi (1 bar) Figure 4-46.
PAGE 106
SECTION 4 - HYDRAULICS NOTES: 4-26 – JLG Lift – 3121325
PAGE 107
SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 MAIN TERMINAL BOX CIRCUIT BOARDS KVS TRIGGER CONTROL PNP5 K1 1 2 K2 3 4 5 6 7 8 K1 KTC KT KD2 KL K3 9 10 11 12 LEVEL SENSOR X1 4 = TT 3 = TB 2 =BT 10A FUSE 1 = BB J7 C2 J1A N2J1 N2J10 C2 J1B C2 J2B J8 J5 C2 J2A J6 COMPLEX 2 NIVOLUX 2 Figure 5-1.
PAGE 108
SECTION 5 - JLG CONTROL SYSTEM 5.2 CONTROL CARD COMPLEX 2 Figure 5-2. Control Card Complex 2 Board General Description of Components and Functions position, adjust the TP1 potentiometer to obtain the correct creep drive speed of 0.5 km/h. • TP2 - This is used to adjust the ramp time to engage and disengage the drive control valve section.
PAGE 109
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. J1 Connector Table 5-2.
PAGE 110
SECTION 5 - JLG CONTROL SYSTEM Drive Signal (during Steering) J1/1 1 1 Analog J1/6 Lift J1/5 1 1 Lower J1/3 1 1 Right Steer J1/9 1 Left Steer J1/10 1 SER/PAR J1/12 1 Differential Lock J1/18 1 Platform In J1/19 1 Platform Out J1/22 1 1 1 X 1 1 1 1 1 1 1 1 1 X (1) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 LED S2.5M (Fast Drive Available) J3/2 1 Horn J1/23 1 X 1 (1) 1 J3/4 1 1 1 J3/3 J1/13 S 2.
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SECTION 5 - JLG CONTROL SYSTEM 5.3 NIVOLUX - AUTOMATIC SELF-LEVELING SYSTEM Figure 5-3. Nivolux Control Board Introduction Normally the operation of leveling the chassis on a Mobile Elevating Work Platform (MEWP) is very time consuming. The Liftlux NIVOLUX automatic self-leveling system eliminates this additional time, as it is a feature, when selected, of the normal lift and lowering operation. The estimated time saved over conventional systems can be in excess of 60%.
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SECTION 5 - JLG CONTROL SYSTEM • When the system completes the leveling process (sensed angle is within 0.5° of set point in both axis), the NIVOLUX system checks that all 4 outriggers have ground contact and then powers up the lift valve. NOTE: If ground contact is lost on any one of the 4 outriggers, the lift function will be cut. In this event, the platform should be fully lowered and the ground conditions checked before attempting to re-level the chassis.
PAGE 113
SECTION 5 - JLG CONTROL SYSTEM Lower (From Plat Down LS) +VS (k VS) X- Leveling (<7.5V) X+ Leveling (>7.5V) Y- Leveling (<7.5V) Y+ Leveling (>7.
PAGE 114
SECTION 5 - JLG CONTROL SYSTEM 5.4 PNP5 CIRCUIT BOARD Table 5-7. Connector J1 System The PNP5 circuit board is an electronic printed circuit board mounted on the Din rail situated in the MTB (refer to Figure 5-1., Main Terminal Box). Drive In J1/1 Power 24V J1/2 Series Parallel Out Series Parallel In J1/3 J1/4 Drive Out J1/5 Operation Table 5-8. Connector J2 The circuit acts on the control system in the following ways: Ground 1.
PAGE 115
SECTION 5 - JLG CONTROL SYSTEM Relay K3 5.6 LIMIT SWITCH & SENSOR OPERATION 1. Energized when there is a trigger output at 3. 2. The analogue input signal 4 passes through a set of N.O. contacts to produce an analogue output on 11. 3. The pump input signal 10 or lower input signal 9 passes through a set of N.O. contacts. This ouptu signal maintains the Trigger input signal 2 which energizes relay K1.
PAGE 116
SECTION 5 - JLG CONTROL SYSTEM • When the platform is below the maximum height, this switch is closed. One contact passes a 24V signal to the Control System (Complex 2 Board) to enable lift up. • The other contact passes 24V from Relay KT contacts to the Ground control Lift Up Switch. Adjustment: Place the machine on a flat level surface. Using a digital level, ensure the chassis is level. Adjust the X and Y axis nuts to place the top mounted bubble level in the center.
PAGE 117
SECTION 5 - JLG CONTROL SYSTEM 5.7 ENGINE CONTROL SYSTEM ehbelectronics ehbelectronics Vertragshandler Vertragshandler OR Air Glow Temp. Oil Alt. Start Start OK 1001094781 H005559 Functional Description c. When a start signal is applied to X1/2 (50e) and the input on X2/10 remains zero, after 1 second of cranking, the output X2/7 is cut and the G LED turns on (no input from alternator). NOTE: For desciptions in ( ), refer to Figure 6-23., Electrical Schematic - Sheet 6 of 15 1.
PAGE 118
SECTION 5 - JLG CONTROL SYSTEM remains on, even if the switch resets, until the ignition input X1/1 (15) is recycled. 8. The monitoring system will shut the engine down (ouput to X1/7 is cut) if one of the following fault input signals is present for 3 seconds: Table 5-13. Deutz Engine Connector X1 Ignition X1/1 a. No frequency on W - X2/10 Start X1/2 b. Input on Oil - X2/1 RPM X1/3 c. Input on Temp - X2/3 9.
PAGE 119
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL This section contains 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. 6.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
PAGE 121
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
PAGE 122
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test.
PAGE 123
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 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. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector Assembly (2 of 4)). 2. Pull back on the contact wire with a force of 1 or 2 lbs.
PAGE 125
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7. 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. Figure 6-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
PAGE 127
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 6-12. DT/DTP Contact Installation 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. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 6-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal 11.
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– JLG Lift – 8 7 6 5 4 3 X4A/1 X4A/1 12 11 +VS 4 X4A/3 X4A/3 -blue/green- SUPPLY SJOYSTICK Rev D X4A/4 X4A/4 1 START 5 LIFTLUX 2A-J +24V 2 START S EMERGENCY STOP X4A/9 X4A/9 13 2 1 SELECTOR -PLATFORM -DRIVE -LIFT 3 2 1 -LEFT X4A/13 X4A/14 X4A/5 X4A/13 X4A/14 X4A/12 X4A/12 8 RIGHT Front E 3 9 F X4A/16 X4A/10 7 DIFF LOCK 3 1 X4A/8 X4A/8 X4A/15 X4A/15 SELECTOR -DIFF LOCK -SLOW -FAST 2 2 Page: 1 Control Panel X4A/16 X4A/10 SCHEMATIC ELECTRICAL X4
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8 7 6 5 4 3 2 +24V +VS A2 A1 3B/7G J1/21 SJOYSTICK DDiesel PLATFORM 6D 3A X1/ GND J1/4 J2/2 J2/14 X4A/14 J2/12 K TC 24 Analog output Analog input K TC 21 X4A/12 J2/16 9I 9I J2/10 X4A/16 X4A/10 DIFF LOCK J2/8 X4A/8 J2/15 J2/6 X4A/15 X4A/6 G 4E/9E J1/1 X1/31 J1/3 J1/5 J1/9 D Lift J1/10 4D 3H/7G 3I/7E 4B 4B 4C X1/15 J1/12 5A X1/19 J1/18 5E X1/21 J1/19 Page: 2 Circuit Board COMPLEX 2 X1/14 X1/32 X1/39 X1/18 X1/17 J1/6 X1 = Terminal in lower control st
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6-14 – JLG Lift – 8 7 6 5 4 3 2 1 12 11 X1/35 12 11 22 21 Rev D X1/34 7G 7H +VS (K VS) J8/10 DRIVE OK NIVOLUX +VS (K VS) J8/9 S2 OSCILLATING AXLE (2 limit switches) S1 OSCILLATING AXLE 12 S DRIVE HEIGHT 11 S DRIVE HEIGHT X1/36 2I B X1/37 (bridge) (only for 67 LS) +VS (K VS) 2B A LIFTLUX GND 2C 2J C 12 OSCILLATING AXLE PNP5/J2/4 & PNP5/J1/1 Module X1/12 DRIVE 2D/4E S MAX HEIGHT X1/6 +24V X1/GND +VS (K VS) PNP5/J2/3 T4 PNP5/J1/2 6I 2I X1/29 X1/34
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3121325 – JLG Lift – 8 7 6 5 4 3 2 1 GND X1/17 LEFT 2F Rev B X1/GND X1/18 RIGHT 2E B LIFTLUX 3J STEER A 220 µF C SER/PAR + X1/GND SER/PAR X1/16 T8 X1/14 X1/GND DL BY255 X1/32 LOWER 3H DRIVE ANALOG 2D E F DLI LIFT X1/38 3I PNP5/J1/5 PNP5/J1/2 Module X1/GND Page: 4 DIGISOUND X1/60 DF X1/13 PNP5/J1/1 X1/12 Drive input J2/7 9E (Trigger control) 9E J2/8 Drive output DRIVE 2D/3D SCHEMATIC ELECTRICAL SER/PAR +24V D X1/6 6I PNP5/J2/1 PNP5/J1/3 PNP5
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6-16 – JLG Lift – 8 7 6 5 4 3 2 1 X1/20 C X1/GND X1/GND (according to type : 2 valves) X1/20 Rev A DIFFERENTIAL LOCK X1/GND X1/GND GND X1/19 DIFFERENTIAL LOCK 2F B LIFTLUX 4J FD4 A X1/41 X1/41 255 255 DP3 DP2 X1/56 X1/21 F X1/GND X1/41 RPM PNP5/J2/5 t PNP5/J2/2 Module Page: 5 X1/GND PNP5/J2/1 PNP5/J2/6 X1/22 6A PLTF. OUT 2G PLATFORM PLTF.
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8 7 6 5 4 3 2 X1/GND 255 RPM LS P 1 5F X1/41 Yellow Rev C TK 31 Glow time control H Glow heater plugs H T 31 Temp 30 A 30 A 15 50e P> 6 qmm X2/4 grey Air P> green X2/1 Oil h Start X1/1 ni Ig E orange black r SCHEMATIC ELECTRICAL brown X2/9 Sig 50 te ar St X1/2 3H GROUND PANEL LIFT X1/7 F G ON START OFF violet M = D+ X2/10 30 ALTERNATOR B- W grey/green W B+ G white X2/2 D+ G 31 Page-Nr: 6 Deutz Diesel X2/7 50f X16/3 X2/6 70 qmm BATT
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8 7 6 5 4 3 2 IN black FRONT LEFT 1 A2 A1 GND J7/1 K2 GND OUT J7/2 DRIVE OK X1/34 IN J7/4 J10/2 FRONT RIGHT 2 R(ear) F(ront) +X J7/3 J10/1 X1/42 Jacks LIFTLUX GND 3E (drawn: outriggers ON) Jacks J7/6 IN REAR RIGHT 3 J7/7 J8/2 X1/26 S 2.
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3121325 – JLG Lift – H I Rev A SCHEMATIC ELECTRICAL Page: 8 PNP5-Module Diesel 80 SL / 67 SL Page 5 Page 5 Page 3 Page 3 Page 2 5 8 X 1/GND X1/23 COMPLEX J1/16 (Pump 2) VALVES OSCILLATING AXLE (only for 80 LS) X 1/26 (only for 67 LS) X 1/24 X 1/41 4 8 GND PUMP 2 OSCILLATING AXLE S 2,5m PUMP 2 RPM 3 7 1 2 3 4 5 6 J2 Page 4 Page 2 Page 4 Page 2 J 7 + X1/12 COMPLEX J1/1 (DRIVE) X1/6 (+ 24V) X 1/16 (Ser/Par-Valves) X1/15 COMPLEX J1/12 (Ser/Par) X 1/13 (DRIVE) G 6 LIFTLUX 220 µ
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– JLG Lift – 8 7 6 5 4 3 2 J2/12 J2/1 LIFTLUX Rev C Trigger-Control OP 1 X1/GND GND X1/8 +24V 2C SUPPLY B J2/4 9 2/ (J Co K1 C p m xle ar Bo 2C J2/9 J2/3 2H X1/9 J2/6 J2/5 rd oa K2 B 17 x1/ le (J mp o C ) 4E 4E X1/12 J2/8 J2/7 ) rd oa K3 B 1 x1/ le (J mp o C SCHEMATIC ELECTRICAL d) J2/2 X4A/9 2H 2C E J2/10 J2/9 K1 G DEADINP SUPPLY K TC 6A 14 11 X1/11 X1/31 X1/GND A2 A1 2J H 6 l /1 Cab 4 A rs (Xisso Sc 2E I DRVOUTP DWNINP GND STARTOUTP
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3121325 – JLG Lift – 8 7 6 5 4 3 2 1 1 2 E 4 Trigger control J2/1 8 Motor Control Box Ignition FD4 (Cathode) S 2,5m /12 34 S Max Height /12 Rev D 34 Ground panelS Jacks DL (Anode) K VS /A1 33 SCHEMATIC ELECTRICAL Nivolux J8/9 K VS /14,24 A B A B A B A B A B Page: 10 Terminals Complex J1/15 +VS FD 1 (Cathode) Ground panel.
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6-22 – JLG Lift – 8 7 6 5 4 3 2 1 # ST3 /22 ST2 /14 ST3 /14 49 ST3 /13 50 ST4 /13 S Tilt Diff Lock Valve 1 Diff Lock Valve 2 Lift Steer Drive Rev D Motor Control Box Horn Pump 1 LS Pump 1 Drive 2 Digisound KL /A2 KTC / A2 KT / A2 K VS PNOZZ K1 PNOZZ Nivolux PNP5 J2/1 FD4 FD1 Complex DF (Cathode) SCHEMATIC ELECTRICAL Oscillating Axle Valves Platform Trigger control J2/12 Serial/Parallel Brake KD2 /A2 Load Holding Valves FD3 Digisound DLI(Cathode) Battery KT / 11
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– JLG Lift – 8 7 6 5 4 3 2 LIFTLUX X1/32 X1/21 Rev D P: O- CONNECTOR GROUND PANEL P: J- CONNECTOR GROUND PANEL B 5 S KEY GROUND PANEL STATION B+ALTERNATOR BATTERIE + 70 qmm 2x 12V 6 qmm 6 qmm SCHEMATIC ELECTRICAL X1/5 X2/5 70 qmm 14 13 DL 4 4 START ON Page-Nr: 12 I 2+5 1 J P: V- CONNECTOR GROUND PANEL X1/34 P: Q- CONNECTOR GROUND PANEL X1/42 P: H- CONNECTOR GROUND PANEL X1/9 Jacks Jacks OFF 3 2 Diesel 80 SL / 67 SL X1/1 P: A- CONNECTOR GROUND PANEL GROUND PAN
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6-24 Drive Lift Steer F – JLG Lift – M 20 G M 12 I M 12 J Rev D SCHEMATIC ELECTRICAL Page: 13 Cable Inlet Brake M 12 Lower M 12 M 12 S Pressure (Nivolux) M 12 S Plattform Down Outrigger Valves M 20 Diesel 80 SL / 67 SL Ser/Par M 12 Horn M 12 M 12 5 4 3 8 Free M 12 S Drive Height Ground Panel M 12 M 12 8 LIFTLUX M 16 M 16 Pump 2 S Max Height Scissors Cable Socket S Oscillating axle Oscillating axle valves M 20 S 2,5m M 16 M 16 S Tilt 7 Platform M 25 M 16 M
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3121325 – JLG Lift – TP1 TP2 SCHEMATIC ELECTRICAL Complex-Board D25 D24 D23 D21 D22 I Page: 14 Diesel 80 SL / 67 SL J1 S2 H J 6 5 4 3 2 1 8 Rev D S1 G Input/Ouput Control Panel Jumper Jumper (for ANSI) Velocity slow (S 2,5m operated) Brake Ramp F Pump (not used) Drive (S Drive Height) Max.
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6-26 – JLG Lift – 8 7 6 5 4 3 2 1 IST X C D Rev A TP1 TP2 J6 GND J8 F G H D42 D43 D44 D45 D54 Page: 15 (grey) (blue) (green) (yellow) (red) D60 Nivolux-Board J1 Left high Right high Front high Rear high No Drive J7 I Diesel 80 SL / 67 SL D59 D58 Pressure switch/ Security relay PNOZZ X-Pendulum (1-red/2-black/3-blue) Y-Pendulum (1-red/2-black/3-green) Outrigger valves Complex-Nivolux Key switch: Outriggers ON/OFF D61 J10 J1 J5 J6 J7 J8 J10 E SCHEMATIC ELECTRICAL J5
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1. Main Terminal Box Wiring Description Wire Number Type GGN 121 122 123 Position 1 NC Position 2 Label (External Harness) NC LIYYJZ2X1 UL S. OSCILLATING AXLE ader 1 PNP5 J2/3 Splice4/L ader 2 X1/I-2 Splice5/L LIYYJZ2X1 UL ader 1 Splice4/R ader 2 Splice5/R LIYYJZ2X1 UL ader 1 Splice4/R ader 2 Splice5/R 124 UL1569 18ZW 1 125 UL1569 18ZW 2 126 LIYYJZ25X0.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 6-1. Main Terminal Box Wiring Description Wire Number Type S4 CSS 1009 S5 CSS 1003 (7x) S6 CSS 1003 S7 CSS 1002 S8 CSS 1003 (2x) S9 CSS 1005 S10 CSS 1007 Position 1 Position 2 Label (External Harness) E900066 C NOTE: Position 1 = Termination point in the Main Terminal Box (There are 4 connections at each terminal position on X1. These are designated as 1 = Top Top, 2 = Tob Bottom, 3 = Bottom Top, and 4 = Bottom Bottom.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121325 – JLG Lift – 6-37
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Diagram STROBE LIGHTS Figure 6-33.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BATTERY DISCONNECT SWITCH PLATFORM CONSOLE BOX Figure6-34.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Diagram Figure 6-35.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-36.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Hydraulic Schematic Figure 6-37.
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3121325 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.