Service Manual Instruction Manual

ManualsBrandsJLG ManualsSpecial machineryE300

Service and Maintenance Manual

Model

E300AJ

E300AJP

S/N 0300138358

to Present

P/N - 3121253

October 24, 2013

Summary of content (224 pages)

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Service and Maintenance Manual Model E300AJ E300AJP S/N 0300138358 to Present P/N - 3121253 October 24, 2013
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised A-2 - October 27, 2009 - February 3, 2010 - August 23, 2012 - October 24, 2013 – JLG Lift – 3121253
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 ii Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.11 3.13 3.14 TITLE PAGE NO. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Battery Charger Fault Codes . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM 6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Using the 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. 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. 4-1. 4-2. 4-3. 4-4. 4-2. 4-3. 4-4. 4-5. 3121253 TITLE PAGE NO. Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Operator Maintenance and Lubrication Diagram . . . . . . . .
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LIST OF FIGURES FIGURE NO. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-11. 5-12. 5-12. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 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. vi TITLE PAGE NO. Lower Boom Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 AJP Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 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. 3121253 TITLE PAGE NO. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 2-1 2-2 2-3 3-1 3-2 3-3 3-12 3-4 4-1 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 6-5 6-6 viii TITLE PAGE NO. Operating specifications - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operating specifications - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Dimensional Data - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-3. Dimensional Data - E300AJ Table 1-1. Operating specifications - E300AJ Capacity: Unrestricted: Maximum Travel Grade, stowed Position (Gradeability) 500 lbs. (227 kg) 25% Maximum Travel Grade, stowed Position (Side Slope) Drive Speed (High Drive) - 200 ft. (60.9 M) Drive Speed (Above Horz.) - 50 ft. (15.24 M) 5° 45-50 sec 55-68 sec (0.6 mph[0.
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SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES NOTE: Table 1-5. Capacities Hydraulic Oil Tank 2.9 Gal. (11 L) 2.1 Gal. ( 8 L) to Full Mark Drive Hub* 25.5 oz. (0.75 L)(1/2 Full) Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 11M is desired, contact JLG Industries for proper recommendations. 1.
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SECTION 1 - SPECIFICATIONS AIR TEMPERATURE 60 10 50 4 40 1 30 7 20 12 10 18 0 23 10 29 20 34 30 40 40 HYDRAULIC FLUID OPERATION CHART Properties Description Viscosity at 40° C (cSt, Typical) Fluid MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDRIES OUTLINED IN THE HYDRAULIC FLUID OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.
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SECTION 1 - SPECIFICATIONS 1.7 FUNCTION SPEEDS Machine Orientation When Doing Speed Tests Table 1-9. Function Speeds Function Speed in seconds (unless otherwise noted) NOTE: All tests are to be performed on a smooth, level surface. Lift: Boom Retracted. Telescope Retracted. Lift Up, Record Time, Lift Down, Record Time. Main Lift Up 24-27 Main Lift Down 20-23 Swing - Right & Left 75-90 Telescope Out 8-12 Telescope In 8-12 Platform Rotate, Left and Right* *Max.
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SECTION 1 - SPECIFICATIONS 6 6 3,4 2 1 5 5 Figure 1-2.
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SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE NOTE: 2. Swing Bearing/Worm Gear Teeth The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Diagram. Table 1-10. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).
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SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 5. Wheel Drive Hub OIL LEVEL CH AND FILL Lube Point(s) - Fill Cap Capacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full Mark Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. Lube Point(s) - Level/Fill Plug Capacity - 25.5 oz. (0.
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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 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 Operation and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly 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 2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage.
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SECTION 2 - GENERAL Cylinder Drift 4. Re-assembly of pinned joints using filament wound bearings. Table 2-2. Cylinder Drift Cylinder Bore Diameter a. Housing should be blown out to remove all dirt and debris...bearings and bearing housings must be free of all contamination. Max. Acceptable Drift in 10 Minutes inches mm inches mm 3 76.2 0.026 0.66 3.5 89 0.019 0.48 4 101.6 0.015 0.38 5 127 0.009 0.22 6 152.4 0.006 0.15 7 177.8 0.005 0.13 8 203.2 0.0038 0.10 9 228.6 0.
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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 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Tire Wear and Damage Inspect tires daily for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before replacing the machine into service. Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners.
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SECTION 3 - CHASSIS & TURNTABLE 5 3 * ** * ** 6 4 2 RIGHT SIDE VIEW WITH HUB REMOVED 1. 2. 3. 4. 5. 6. Axle Assembly Spindle Assembly Tie Rod Steer Cylinder Thrust Washer Thrust Bearing 1 3 * Torque 35 ft. lbs. (48 Nm) ** Threadlocker JLG P/N 0100011 2 Figure 3-1.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 1 2 Drive Motor Gasket Drive Brake Drive Hub Gasket Speed Sensor Tire & Wheel Lug Nut * 3 Note 1 * 4 6 Note 2 5 7 8 * Thread Locking Compound JLG P/N 0100019 Note 1: Torque to 240 ft. lbs. (325 Nm) Note 2: Before installing brake and motor, apply a light coat of grease to the splined shafts Figure 3-2.
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SECTION 3 - CHASSIS & TURNTABLE 3.2 SPINDLE Specifications The end play specification is 0.001”/0.010" (0.025 / 0.254 mm) for all units. Setting Wheel Bearing End Play Checking BE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT. 1. Tighten the spindle nut to assure the bearings are properly seated. The end play is checked by clamping the spindle in a fixture or vise and moving the hub parallel to the spindle centerline without rocking the hub. If the end play is set properly the following should apply: 1.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dust Cap Cotter Pin Spindle Nut Spindle Washer Stud Nut Bearing Cone Hub Bearing Cone Seal Spindle Figure 3-3.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB Main Disassembly 1. Perform Roll Check and Leak Check if applicable prior to disassembling the unit. Roll and Leak Testing Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit’s gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. 2. Drain oil from unit. Note the condition and volume of the oil. 3.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: On units with a ratio 48:1, the Sun Gear (11) and the Input Shaft (9) will need to be removed together. 12. Lift the Ring Gear (1F) off of the Housing (1G). 13. Remove the O-ring (18) from between the Housing (1G) and the Ring Gear (1F). 10. Remove the Output Stage Carrier Sub-assembly (4) 11. Loosen and remove the three Flat Head Bolts (19) that retain the Ring Gear (1F) to the Housing (1G). 1F. 1G. 2. 3. 4. 6. 6G.
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SECTION 3 - CHASSIS & TURNTABLE 1F. 1G. 4. 5. 6. 6G. Ring Gear Housing Output Carrier Subassembly Retaining Ring Cover Assembly Retaining Ring 9. 10. 11. 18. 19. 20. Input Shaft First Stage Sun Gear Second Stage Sun Gear O-ring Flat Head Bolts Retaining Ring Figure 3-5.
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SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 3. Using a 1/8" diameter punch, drive the Roll Pin (4G) out of the Planet Shaft (4E). NOTE: The Roll Pins (4G) should not be reused when reassembling the unit. 1. Using a 1/8" diameter punch, drive the Roll Pin (4G) into the Planet Shaft (4E) until it bottoms against the Carrier (3A). 4. Slide the Planet Gear Sub-assembly (4) out of the Output Carrier (4A) being careful to not drop the Needle Bearings (4C) in the process. 2.
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SECTION 3 - CHASSIS & TURNTABLE 5. Remove 4 Thrust Washers (4B), 28 Needle Rollers (4C) and the Thrust Spacer (4D) from the Second Stage Planet Gear (4F). 4B 4C 4D 4F 6. Repeat Steps 1 though 5 for the remaining two Planet Gears (4F). 7. Remove the Thrust Washer (4H) from the counterbore in the Output Carrier (4A). Thrust Washer Needle Bearing Thrust Spacer Planet Gear Figure 3-7.
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SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly (4G) should not be reused when reassembling the unit. 1. Using a 1/8" diameter punch, drive the Roll Pin (4G) into the Planet Shaft (3E) until it bottoms against the Carrier (3A). 4. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A). 2. Using a soft face hammer, tap the Planet Shaft (3E) out of the Carrier (3A). 5. Remove the 14 needle Bearings (3C) from the bore of the Planet Gear (3F). 3.
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SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Disassembly 6. If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end. 1. Place unit on bench with Spindle (1 A) end down. 7. Remove Seal (1B) from Hub (1G). 2. Remove Retaining Ring (1J) with appropriate tool. NOTE: The Seal (1B) should NOT be reused when reassembling the unit. 3. Remove Spacer (1N). 4. Remove Bearing Cone (1C) from Bearing Cup (1D) in Hub (1G). 8. Remove Bearing Cone (1E) from Hub (1G). 5.
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SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A). 1. Remove O-Ring (17) from groove in Cover (6A). 2. Remove Thrust Washer (2) from Cover (6A) pockets. 3. Unscrew two Hex Head Bolts (6C) and remove Disengage Cap (6B) from Cover (6A). 2 3A 6A 6B 6C 6D 6E 6F 17 5. Use appropriate tool to remove O-ring (6E) from internal groove in Cover (6A). 6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A).
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SECTION 3 - CHASSIS & TURNTABLE Input Carrier Assembly Output Planet Gear Assembly (Refer to Figure 3-8., Input Carrier) (Refer to Figure 3-7., Planet Gear) 1. Apply a liberal coat of grease to the bore of one Input Planet Gear (3F). 1. Apply a liberal coat of grease to the bore of one Output Planet Gear (4F). 2. Line the inside of the Planet Gear (3F) with 14 Needle Rollers (3C). NOTE: The last roller installed must be installed end wise.
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SECTION 3 - CHASSIS & TURNTABLE Output Carrier Assembly Hub-Spindle Assembly (Refer to Figure 3-9., Hub Spindle) (Refer to Figure 3-6., Output Carrier) 1. Place Thrust Washer (4H) into counterbore of Carrier (4A). BE SURE the small diameter side of Washer (4H) facing planet gear side. 2. Place Planet Gear Sub-assembly (4) into Carrier (4A). Visually align the planet gear bore with one of the planet shaft holes on the Carrier (4A). 3.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-11.
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SECTION 3 - CHASSIS & TURNTABLE 1A 1B 1C 1D 1E 1F 1G 1H 1J 1K 1L 1M 1Q 2 3A Spindle Lip Seal Tapered Bearing Cone Tapered Bearing Cup Tapered Bearing Cone Ring Gear Hub(Housing) Stud Retaining Ring Ext. Retaining Ring Int. Spring (1.460,1.
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SECTION 3 - CHASSIS & TURNTABLE Cover Subassembly NOTE: The output carrier sub-assembly does not need timed with the spindle splines. (Refer to Figure 3-10., Cover Assembly) 5. Place Output Carrier Sub-Assembly (4) into mesh with Spindle (1A) splines. 1. Grease O-Ring (6E) and insert into internal groove in Cover (6A). 2. Assemble Disengage Cap (6B) onto Cover (6A) using two Hex Head Bolts (6C). Torque bolts to 7080 in-lbs. 3.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Cup Pressing Tool Figure 3-14.
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SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover (21). Disassembly 1. Remove pressure plate (3) from cover (21) by removing the capscrews (1) and washers (2). NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. This should be five red springs evenly spaced. 5. Install dowel pins (20), spring retainer (16) and springs (5) in cover plate (21).
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SECTION 3 - CHASSIS & TURNTABLE 23 22 NOTE: The speed sensor port in the cover (21) should be 180° from the brake release port in the pressure plate (3). 19 21 18 17 16 20 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 23 1. 2. 3. 4. 5. 6. Capscrew Washer Pressure Plate Case Seal O-ring Backup Ring 7. 8. 9. 10. 11. 12. Piston O-ring Backup Ring Shaft Stator Disc Sensor Ring 13. 14. 15. 16. 17. 18. Rotor Disc Plate Spring Spring Retainer Retaining Ring Bearing 19. 20. 21. 22. 23.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive Brake Diagnosis Problem Brake slips Brake drags or runs hot Brake will not release 3-22 Cause Explanation Corrective Action Excessive pressure In hydraulic system If there is back pressure in the actuation line of the brake, holding torque will be reduced. Check filters. hose size, restrictions in other hydraulic components. Oil In brake if designed for dry use Wet linings generate 67% of the dry torque rating.
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SECTION 3 - CHASSIS & TURNTABLE 3.5 SPEED SENSOR ADJUSTMENT Speed Sensor Installation Verification The motor controller averages the readings from the right and left speed sensors and therefore, it can be difficult to detect if the speed sensors are adjusted properly. When the positrac keeps coming in and out while on level surfaces, this is a sure indication that one of the speed sensors is not adjusted properly. FOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2) MUST BE PROPERLY INSTALLED AND ADJUSTED.
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SECTION 3 - CHASSIS & TURNTABLE Verification w/ Analyzer Procedure 4. Use the right and left cursor keys on the analyzer to highlight "DIAGNOSTICS" and press enter. The motor controller averages the readings from the right and left speed sensors and therefore, it can be difficult to detect if the speed sensors are adjusted properly. Often operators report that posi-track keeps coming in and out while driving on level surfaces.
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SECTION 3 - CHASSIS & TURNTABLE 18. While watching the analyzer display select drive forward. Be ready to remove your foot from the footswitch if the machine lunges forward. 3.6 POSITRAC/TILT MODULE When installing a new positrac/tilt module, Refer to JLG Control System Analyzer Kit instructions. Use a standard bubble level in two different directions to ensure that the machine’s frame is level prior to installing the new positrac/tilt module. 19.
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SECTION 3 - CHASSIS & TURNTABLE BLACK WIRE RED WIRE WHITE WIRE GREEN WIRE NOTCH NOTCH BLACK WIRE WHITE WIRE GREEN WIRE SENSOR IN LEFT MOTOR BRAKE RED WIRE SENSOR IN RIGHT MOTOR BRAKE RED WIRE WHITE WIRE GREEN WIRE BLACK WIRE NOTCH BLACK WIRE GREEN WIRE NOTCH WHITE WIRE RED WIRE SENSOR IN RIGHT MOTOR BRAKE (MOTOR B) SENSOR IN LEFT MOTOR BRAKE (MOTOR A) Figure 3-16.
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SECTION 3 - CHASSIS & TURNTABLE FWD/REV CONTACTOR MAIN CONTACTOR POSI-TRAC CONTACTOR POSI-TRAC/TILT MODULE DRIVE MOTOR B POWER DIODE DRIVE MOTOR A Figure 3-17.
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3-28 NOTE: CURRENT SHUNT NOTE: DRIVE FORWARD/REVERSE CONTACTOR Figure 3-18. Contactor Wiring Diagram NOTE: CONNECTS TO PUMP MOTOR NEGATIVE. (-) ON POWER MODULE.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING MOTOR Figure 3-19. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY.
PAGE 64
SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Swing Motor Troubleshooting Trouble Oil Leakage Significant loss of speed under load Cause 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit. 3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion.
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SECTION 3 - CHASSIS & TURNTABLE 20 18 8 25 16 8C 8E 15 14 19 14 8B 13 4 8A 8D 17 12 4 10 9 4 8 4 7 5 4 3 6 4 2 1 1. 2. 3. 4. 5. Bolt End Cover Seal Ring Seal Ring Commutator 6. Commutator Ring 7. Manifold 8. Rotor Set 8A. Rotor 8B. Stator Half 8C. Stator Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 11. Thrust Bearing 12. 13. 14. 15. 16. Coupling Shaft Inner Bushing Thrust Washer Thrust Bearing Seal 17. 18. 19. 20. 21.
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SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly flange or port bosses. Remove manifold port ORings if applicable. • Before you disassemble the motor unit or any of its components read this entire section. It provides important information on parts and procedures you will need to know to service the motor. • Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the motor. Remove rust or corrosion from coupling shaft.
PAGE 67
SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. 3. Remove the special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.
PAGE 68
SECTION 3 - CHASSIS & TURNTABLE these conditions exist, replace commutator and commutator ring as a matched set. tion of both sides of the manifold to ensure that same surface is reassembled against the rotor set. 9. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane to stator contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate.
PAGE 69
SECTION 3 - CHASSIS & TURNTABLE NOTE: A polished pattern on the wear plate from rotor rotation is normal. 12. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 10. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 degrees apart) and a roller vane centerline are on the same stator centerline.
PAGE 70
SECTION 3 - CHASSIS & TURNTABLE keyway. Replace coupling shaft if any of these conditions exist. 16. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 17. Remove seal (16) and back up ring (17) from housing (18) and backup washer (25). Discard both. NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 0.020 inches (0.51 mm) diametrically, replace coupling shaft.
PAGE 71
SECTION 3 - CHASSIS & TURNTABLE rosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly. replaced. If the housing has passed this inspection the disassembly of the motor is completed. 20.
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SECTION 3 - CHASSIS & TURNTABLE 21. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.
PAGE 73
SECTION 3 - CHASSIS & TURNTABLE RECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN ASSEMBLED. BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE REUSED. seal (20) must be pressed in until its’ flange is flush against the housing. 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 2.
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SECTION 3 - CHASSIS & TURNTABLE coupling shaft (12) into housing (18), seating it against the thrust bearing (15). 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the motor. NOTE: The motor requires one thrust washer (14) with thrust bearing (15). The coupling shaft will be seated directly against the thrust bearing. 7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.
PAGE 75
SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over 0.5 inch (12.
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SECTION 3 - CHASSIS & TURNTABLE NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link. 15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. NOTE: If necessary, go to the appropriate, "Rotor Set Component Assembly Procedure.
PAGE 77
SECTION 3 - CHASSIS & TURNTABLE of drive link (10) onto manifold (7) with seal ring side up. 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown below.
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SECTION 3 - CHASSIS & TURNTABLE cover and other components into place with a final torque of 25-30 ft. lbs. (34-41 N m). 1. Place stator onto wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure the seal ring is in place. 2.
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SECTION 3 - CHASSIS & TURNTABLE 4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. Two Piece Stator Construction A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures. 1. Place stator half onto wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure the seal ring is in place. 2.
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SECTION 3 - CHASSIS & TURNTABLE 8. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. 3.8 SWING DRIVE 9. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.
PAGE 81
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Bearing Oil Seal Capscrew Bolt Bolt Plug Pressure Vent 8. 9. 10. 11. 12. 13. Seal Grease Fitting Grease Fitting Grease Fitting Bolt Washer 14. 15. 16. 17. 18. 19. Slew Ring Bearing Ring Bearing Housing Gear/Pinion Cap 20. 21. 22. 23. 24. 25. Cover Plate Worm Cap Pinion Motor Adapter Face Seal Spacer 26. 27. 28. 29. 30. 31. Shim Shim Shim Machine Screw Worm Gear Worm Figure 3-21.
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SECTION 3 - CHASSIS & TURNTABLE 5. Using a press, disassemble the pinion and gear assembly. Support the worm gear (30) on the press with the pinion (22) down allowing room for pinion to be pressed out of gear. Press pinion out of bearing (17) spacer (25) and worm gear (30) Pressing on end of pinion. Remove face seal (24) from face of worm gear (30). Note how the seal is assembled. 5. Turn the assembly over and place the spacer (25) on the pinion against the gear hub so the large chamfer on the I.D.
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SECTION 3 - CHASSIS & TURNTABLE 11. Install the worm cap (21) using proper shims (28) to achieve 0.000 to 0.001" (0.000 to 0.025 mm) end play. Apply LocTite 242 to end of 1/2-13 x 1.25" grade 5 bolts (5) and LocTite #515 sealant to shims. Torque the bolts to 75 lbs-ft (101.5 Nm). 3.9 SWING BEARING 12. Place the pinion/gear assembly into the housing so the gear teeth mesh with the worm gear teeth. The worm or gear set may have to be turned by hand to achieve this.
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SECTION 3 - CHASSIS & TURNTABLE c. Lower the main boom to horizontal and fully extend the boom. d. At the position indicated on Figure 3-24., Swing Bearing Tolerance Boom Placement try and insert the.0015” feeler gauge between the bolt head and hardened washer at the arrow indicated position. Figure 3-23. Swing Bearing Tolerance Measuring Point 3. If a difference greater than 0.057 in. (1.40 mm) is determined, the swing bearing should be replaced. 4. If a difference less than 0.057 in. (1.
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SECTION 3 - CHASSIS & TURNTABLE JIB ELEVATED 90 DEGREES PLATFORM ROTATED 90 DEGREES MAIN BOOM FULLY ELEVATED AND FULLY RETRACTED AJP Models LOWER BOOM FULLY ELEVATED NOTE: MEASURING POINT Figure 3-24.
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SECTION 3 - CHASSIS & TURNTABLE MAIN BOOM FULLY EXTENDED MAIN BOOM HORIZONTAL LOWER BOOM FULLY ELEVATED NOTE: MEASURING POINT Figure 3-25.
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SECTION 3 - CHASSIS & TURNTABLE Replacement of Swing Bearing 2. Installation. a. Install bearing to rotation box with two cap screws, so that fill plug of bearing is as close to gear as bolt pattern will allow. Do not tighten cap screws. 1. Removal. a. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible. b. Line up high spot (blue) of bearing as shown below. Set backlash to 0.008 - 0.010 inch (0.20 0.25 mm).
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SECTION 3 - CHASSIS & TURNTABLE f. Following the torque sequence diagram shown i n F i g u r e 3 - 2 6 . , S w i n g B e a r i n g To r q u e Sequence, tighten the bolts to an initial torque of 140 ft. lbs. (190 Nm). Then following the same sequence, tighten to a final torque of 190 ft. lbs. (260 Nm). k. Following the torque sequence shown in Figure 3-26., Swing Bearing Torque Sequence, tighten the bolts to an initial torque of 150 ft. lbs. (200 Nm).
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SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY MAINTENANCE AND CHARGING Battery Charging, Daily NOTE: To avoid excessive battery charging time, do not allow batteries to become completely discharged. TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES. Battery Maintenance, Quarterly NOTE: To avoid electrolyte overflow, add distilled water to batteries after charging.
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SECTION 3 - CHASSIS & TURNTABLE 3.11 BATTERY CHARGER Maintenance Instructions 1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer. LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS AWAY FROM BATTERIES.
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SECTION 3 - CHASSIS & TURNTABLE 1* 2 3** 4 5 6 9 11 7 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Battery Terminal Grease Left Battery Box Dielectric Grease Battery Connector Draw Latch Battery Battery Hold Down Right Battery Box Left Cover Right Cover Latch * Apply to Battery Terminal Connections Only ** Apply to Contacts of Connectors Only 10 1001108560-B Figure 3-27.
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SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger. 1. Check the connections to AC power. Check for AC voltage between 90 and 260 VAC at the charger. 2. If the AC voltage is verified to be correct at the connection to the charger, and the charger still displays no lights at all, return the charger for service.
PAGE 93
SECTION 3 - CHASSIS & TURNTABLE [5 Flashes] - Over Temperature This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge time will be extended significantly. 1. This fault indication will not clear automatically, but the charger will restart charging automatically when the temperature drops. The fault indicaiton must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.
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SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger Algorithm 3. Remove the AC power from the charger and reconnect the charger’s positive connector to the battery. It is recommended to check a newly changed algorithm by repeating the above steps 1 and 3. The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Algorithms. NOTE: Contact JLG if your specific battery model is not listed. Table 3-4.
PAGE 95
SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) is intended to indicate to the operator conditions that could make the direction of movement of the chassis different than the direction of movement of the drive/steer control handle. The system indicates to the operator the need to match the black and white directional arrows on the platform control panel to the arrows on the chassis.
PAGE 96
SECTION 3 - CHASSIS & TURNTABLE 56.0° WHEN BOOM IS OUTSIDE THIS 56° WINDOW OVER REAR TIRES, DRIVE ORIENTATION OVERRIDE MUST BE ACTIVATED TO ALLOW DRIVE TO BE ENABLED. +.00 -.13 CLEARANCE FOR SWITCH TO TARGET WITH HORIZONTAL SLOTS IN ITEM #14 .25 SWITCH MOUNTING BRACKET UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN INCHES. PROXIMITY SWITCH DRIVE TARGET CAM Figure 3-29.
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SECTION 3 - CHASSIS & TURNTABLE * AJ = 6188 ± 130 lbs. (2807 ± 59 kg) * AJP = 6406 ± 130 lbs. (2906 ± 59 kg) COUNTERWEIGHT* RETAINING HOOK TURNTABLE RETAINING BOLT, NOTE A, NOTE B A - Torque 285 ft.lbs. (388 Nm) B - Apply JLG P/N 0100019Thread Locking Compound Figure 3-30.
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SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-64 – JLG Lift – 3121253
PAGE 99
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE 14. Unbolt the power track from the boom and remove the power track and hoses/lines from the boom. Removal of the Main Boom 15. Remove the cover at the rear of the boom. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. 1. Raise the boom to a horizontal position. 2. Place blocking in the tower boom for support and prevent it from lowering.
PAGE 100
SECTION 4 - BOOM & PLATFORM 5 8 7 4 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 3 1 Tower Lift Cylinder Tower Upright Upper Upright Upper Lift Cylinder Master Cylinder Level Cylinder Boom Assembly Jib Rotator Jib 7 8 9 6 Figure 4-1.
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SECTION 4 - BOOM & PLATFORM NOTE: The telescope cylinder weighs approximately 53 lbs. (24 kg). Assembly of the Main Boom 6. Using a suitable lifting device, remove telescope cylinder from the rear of the boom sections. 7. Remove hardware securing the front wear pads on base boom section, remove wear pads and shims, noting the location and amount of shims to aid in reassembly. NOTE: The fly boom section weighs approximately 188 lbs. (85 kg). 8.
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SECTION 4 - BOOM & PLATFORM MODERATELY APPLY BOOM GREASE TO ALL FOUR OUTER SURFACES OF FLY BOOM TUBE IN SPECIFIED LOCATION JLG P/N 3020022 MODERATELY APPLY BOOM GREASE TO OUTER SURFACE OF WEAR PADS ON FLY BOOM (8X) JLG P/N 3020022 12” ± 1” 46” ± 1” (30.5 cm ± 2.5 cm) (116.8 cm ± 2.5 cm) MODERATELY APPLY BOOM GREASE TO ALL FOUR INNER SURFACES OF BASE BOOM TUBE IN SPECIFIED LOCATION JLG P/N 3020022 12” ± 1” (30.5 cm ± 2.5 cm) 39” ± 1” (99 cm ± 2.5 cm) Figure 4-2.
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SECTION 4 - BOOM & PLATFORM POSITION BOTH LEVEL CYL HOSES TO THE OUTSIDE OF PUSH TUBE AS SHOWN PLATFORM SUPPLY HOSE PLATFORM RETURN HOSE LOWER BOOM CONTROL HARNESS WELD LEAD OR AIR LINE A/C CABLE ROUTED ON TOP OF JIB CYL HOSES JIB CYL EXTEND HOSE JIB CYL RETRACT HOSE LEVEL (MASTER) RETRACT HOSE LEVEL (MASTER) EXTEND HOSE Figure 4-3. Power Track Hoses 8. Connect all the hose/line couplings on the side of the boom as tagged during removal. Install the clamp blocks securing the hoses/lines.
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SECTION 4 - BOOM & PLATFORM ORIENT CLAMP BLOCK SECTIONS USING ALIGNMENT HOLES AS SHOWN PUSH NUT CLAMP BLOCK INSTALLATION INSTRUCTIONS 1. TO PROVIDE ORIENTATION OF THREADED STUDS, LOOSELY INSTALL THREADED STUD INTO CLIP NUT UNTIL FIRST SECTION OF CLAMP BLOCK IS INSTALLED 2. TORQUE THREADED STUD TO 10 FT.LB. (13.5 Nm) 3. CONTINUE INSTALLING HOSES, CABLES, AND CLAMP BLOCK SECTIONS CLAMP BLOCK 4. INSTALL PUSH NUTS ONTO THREADED STUDS TO HOLD CLAMP BLOCKS IN POSITION WHILE COVER IS INSTALLED. Figure 4-4.
PAGE 105
SECTION 4 - BOOM & PLATFORM * * * * * * * Use JLG P/N 0100011 Thread Locking Compound or equivalent Figure 4-2.
PAGE 106
SECTION 4 - BOOM & PLATFORM A B A B A B B A A - Torque35 ft.lbs. (48 Nm) B - Torque 85 ft.lbs. (116 Nm) Figure 4-3.
PAGE 107
SECTION 4 - BOOM & PLATFORM 1 6 10 9 4 5 8 2 7 3 10 1. 2. 3. 4. 5. Link Level Link Lower Boom Mid Boom Timing Link 6. 7. 8. 9. 10. Upper Upright Tower Upright Tower Lift Cylinder Bumper Hose Channel Figure 4-4.
PAGE 108
SECTION 4 - BOOM & PLATFORM * * * * * * * * * * * Use JLG P/N 0100011 Thread Locking Compound or equivalent Figure 4-5.
PAGE 109
SECTION 4 - BOOM & PLATFORM B B B A B A B B B B A - Torque35 ft.lbs. (48 Nm) B - Torque 85 ft.lbs. (116 Nm) Figure 4-6.
PAGE 110
SECTION 4 - BOOM & PLATFORM 1 3 2 3 6 8 5 4 7 3 2 1 5 4 1. 2. 3. 4. 5. 6. 7. 8. Platform Rotator Jib Rotator Upper Jib Link Jib Link Jib Cylinder Platform Support Jib Rotator Center Bolt Platform Rotator Center Bolt 6 Figure 4-7.
PAGE 111
SECTION 4 - BOOM & PLATFORM A,E,F A A B,E,F C,F A A D,F NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A B C D E F Torque to 35 ft.lbs. (48 Nm) Torque to 85 ft.lbs. (115 Nm) Torque to 250 ft. lbs. (339 Nm) Torque to 480 ft. lbs. (650 Nm) JLG P/N 0100011Thread Locking Compound Check torque every 150 hours of operation Figure 4-8.
PAGE 112
SECTION 4 - BOOM & PLATFORM NOTE: UPPER BOOM ANGLE TO BE 1° BELOW HORIZONTAL TO 3° ABOVE HORIZONTAL TO ACTIVATE SWITCH. UPPER BOOM ANGLE TO BE 1° TO 4° BELOW HORIZONTAL TO RESET SWITCH. NOTE: LOWER BOOM ANGLE TO BE 1° TO 5° ABOVE HORIZONTAL TO ACTIVATE SWITCH. LOWER BOOM ANGLE TO BE 0° TO 5° BELOW HORIZONTAL TO RESET SWITCH. Figure 4-9.
PAGE 113
SECTION 4 - BOOM & PLATFORM 4.2 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the powertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be different. 1. Clamp the bar and poly roller tightly so they do not spin when removing the screw. With a small ¼” ratchet and a t-20 torx bit, remove the 8-32 x 0.500 screw from one side.
PAGE 114
SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together must be removed. Use a right-angle pneumatic die grinder with a ¼” ball double cut bur attachment. 4. insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled over part of the rivet falls off. Repeat this step for all the rivets that must be removed. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
PAGE 115
SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet out by using a center punch with a hammer. 6. Using a flat head screwdriver between the links, twist the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.
PAGE 116
SECTION 4 - BOOM & PLATFORM 7. Remove the link from the other section of the powertrack using a screwdriver. Installing a New Link 1. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section.
PAGE 117
SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new link and slide the peanut end of the track section into it. a screwdriver may be necessary to do this. 3121253 – JLG Lift – 3. After the new link is installed in the powertrack the round half-shears will not fit properly in the peanut cut-outs yet.
PAGE 118
SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the new connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs. 6. Push pin thru center hole then slide washer on pin. 7. Install the snap ring in the groove on the pin. Repeat the pin installation steps for all center holes that have the rivets removed. 5. The parts shown below will be used to connect the new link to the powertrack.
PAGE 119
SECTION 4 - BOOM & PLATFORM 8. Hold new aluminum round bar tightly, then install new 8-32 x 0.500 self-threading torx head screw into one end. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. NOTE: Maximum tightening torque is 18-20 in-lbs.
PAGE 120
SECTION 4 - BOOM & PLATFORM 9. Pull up on the other end of the round bar and slide the new poly roller onto the bar. 10. Install a new 8-32 x 0.500 self threading screw on the other side. NOTE: When tightening screws make sure screw head is seated against link with no space in between the link and underside of screw head. Maximum tightening torque is 18-20 in-lbs.
PAGE 121
SECTION 4 - BOOM & PLATFORM Replacing Fixed End Brackets CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. 1. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND 2. Parts used: Bracket Center Pin and Center Pin Snap Ring.
PAGE 122
SECTION 4 - BOOM & PLATFORM 3. Take the new bracket and install bracket center pin and snap ring. Repeat on the other bracket if replacing it as well. Replacing Moving End Brackets NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. 1. Remove existing pins and center rivet. Remove the rivet the same way as shown in the link removal instructions. Repeat on other bracket if replacing it as well.
PAGE 123
SECTION 4 - BOOM & PLATFORM MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. 3121253 – JLG Lift – 2. Take new bracket and install center pin with snap ring.
PAGE 124
SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and install snap rings. Repeat with other moving end if replacing as well. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY 4. When complete make sure that both brackets rotate correctly.
PAGE 125
SECTION 4 - BOOM & PLATFORM 4.3 BOOM CLEANLINESS GUIDELINES 4.4 TILT SENSOR CHECK The following are guidelines for internal boom cleanliness for machines that are used in excessively dirty environments. 1. JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom.
PAGE 126
SECTION 4 - BOOM & PLATFORM 4.7 ROTARY ACTUATOR Required Tools Theory of Operation The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03).
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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 4-10.
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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 4-11.
PAGE 129
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 capscrews (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. 3121253 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). 6.
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SECTION 4 - BOOM & PLATFORM Each T-seal has 2 back-up rings (see drawing for orientation). Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion. Make sure the wedged ends overlap correctly. Repeat this step for the outer seal (202). 3121253 – JLG Lift – 7. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore. 8.
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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 Testing the Actuator Refer to Figure 4-12., 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 Figure 4-12.
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SECTION 4 - BOOM & PLATFORM Installation and Bleeding After installation of the actuator on the equipment, it is important that all safety devices such as tie rods or safety cables are properly reattached. 1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two bleed nipples. Secure them with hose clamps. Place the vinyl tubes in a clean 5-gallon container to collect the purged oil.
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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 NOTES: 4-44 – JLG Lift – 3121253
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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.
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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. 3. Spray the entire o-ring surface with a medium coat of oil.
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SECTION 5 - HYDRAULICS 5.2 HYDRAULIC CYLINDERS GLAND SEAL DISASSEMBLY Disassembly 3 NOTE: Disassembly of the cylinder should be performed on a clean work surface in a dirt free work area. 5 4 2 1 1. Drain the oil from the cylinder. 2. Place the cylinder in a suitable holding fixture. 3. Position the cylinder vertically or horizontally. 4. Use the bottom and pin hole to prevent the cylinder from turning and secure the axis.
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SECTION 5 - HYDRAULICS 21 2 21 5 4 7 6 3 8 10 14 12 9 11 16* 13 22 15 19 20 19 18** 23 23 ** 17 *** * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max *** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max 1 1001107886-D 1. 2. 3. 4. 5. 6. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring Rod Seal 7. 8. 9. 10. 11. 12. Backup Ring Bushing O-ring Backup Ring O-ring Piston 13. 14. 15. 16. 17. 18.
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SECTION 5 - HYDRAULICS 23 2 23 5 4 7 6 8 3 11 10 9 18* 16 17 14 21 12 24 22 21 13 20** 15 23 1 ** 19 * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max *** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max *** 23 1001106880-D 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. 17. 18. 19. 20.
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SECTION 5 - HYDRAULICS 16 2 16 5 4 7 6 3 8 11 10 9 13 14 12 15 16 17 1 16 17 1001105989-B 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. Bearing 17. Plug Figure 5-4.
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SECTION 5 - HYDRAULICS 16 2 16 5 4 7 6 3 8 11 10 9 21 13 19 14 19 18* 20 12 20 15 17* 16 1 16 * Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 1001105153-C 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. 17. 18. 19. 20. Bearing Counterbalance Valve Counterbalance Valve Plug Plug 21. Phase Valve Figure 5-5.
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SECTION 5 - HYDRAULICS 24 24 2 17 5 4 7 16 6 3 8 13 14 12 10 9 11 15 18** 1 20* 21 * Torque 18-20 ft. lbs. (24.5-27 Nm) Max ** Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 6. 7. 8. 9. 10. 21 21 22 23 21 19** 1001106878-C Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. 17. 18. 19. 20.
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SECTION 5 - HYDRAULICS 18 18 2 5 4 7 6 3 8 11 9 10 20 19* 14 13 12 15 14 16 21 19* 1 17 * Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 17 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal Piston Ring O-ring 16. 17. 18. 19. 20. Hex Nut Bearing Bearing Counterbalance Valve Plug 21. Plug Figure 5-7.
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SECTION 5 - HYDRAULICS 17 2 17 5 4 3 10 9 11 8 7 6 18 18 13 14 12 15 1 16 16 1001108310-B 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. Bearing 17. Bearing 18. Plug Figure 5-8.
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SECTION 5 - HYDRAULICS 24 24 2 16 17 5 4 7 13 14 12 6 3 8 15 10 9 11 18** 1 20* 21 21 21 * Torque 18-20 ft. lbs. (24.5-27 Nm) Max ** Torque 25-30 ft.lbs. (34-40.5 Nm) Max 22 23 21 19** 1001106879-D 1. 2. 3. 4. 5. Tube Assembly Rod Assembly Gland Dust Wiper Retaining Ring 6. 7. 8. 9. 10. Rod Seal Backup Ring Bushing O-ring Backup Ring 11. 12. 13. 14. 15. O-ring Piston Piston Seal O-ring Hex Nut 16. 17. 18. 19. 20.
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SECTION 5 - HYDRAULICS 4. Withdraw the O-ring and back up ring carefully as not to damage the seals. 11. Inspect the cylinder head outside diameter for damage, ovality and tapering. If necessary, replace it. 5. It is impossible to disassemble the bushing because it is pressed on. Remove it by using a press. 12. Inspect rod and tube bearings for signs of excessive wear or damage.
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SECTION 5 - HYDRAULICS 4. Push the piston to the rod assembly to the end of the thread and then install the piston nut. When installing the piston nut, gland and valve, refer to Table 5-1, Cylinder Assembly Torques. Table 5-1. Cylinder Assembly Torques The phase valve is a back-to-back pair of check valves, one of which is mechanically actuated. This valve is installed in the piston of the level cylinder and is used to keep the master and level cylinders in phase.
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SECTION 5 - HYDRAULICS 5.3 PRESSURE SETTING PROCEDURE SWING RIGHT / LEFT – 750 PSI (52 BAR) Adjustments made at the Main Valve Bank MAIN PRESSURE RELIEF VALVE – 3000 PSI (207 BAR) SWING RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank. MAIN RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank. 2. Activate Swing Right or Left and hold to the turntable stop. Take pressure reading. 3.
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SECTION 5 - HYDRAULICS STEER LEFT – 2000 PSI (138 BAR) STEER RIGHT – 1400 PSI (97 BAR)) STEER LEFT RELIEF VALVE STEER RIGHT RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank. 2. Activate Steer Right and hold to end of stroke. Take pressure reading. 3. After loosening relief valve jam nut, adjust valve clockwise to increase pressure or counterclockwise to reduce pressure accordingly. 4. Tighten relief valve jam nut and repeat step 2 to verify setting. 3121253 – JLG Lift – 1.
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SECTION 5 - HYDRAULICS Adjustments made at the Boom Function Valve Bank JIB LIFT DOWN – 1200 PSI (83 BAR) JIB LIFT UP – 2000 PSI (138 BAR) JIB DOWN RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank. JIB UP RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank. 2. Activate Jib Lift Down and hold to end of stroke. Take pressure reading. 2. Activate Jib Lift Up and hold to end of stroke. Take pressure reading. 3.
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SECTION 5 - HYDRAULICS PLATFORM LEVEL UP – 3000 PSI (207 BAR) • at port M15 of Boom Function Valve PLATFORM LEVEL UP RELIEF VALVE 1. Refer to the Main Pressure Relief Valve procedure and temporarily set Main Pressure Relief Valve to 3300 psi (227.5 Bar). • at port 15 of Boom Function Valve 2. Disconnect, cap, & plug the platform level up hose & adapter either at the platform level master cylinder or at port 15 of the Boom Function Valve.
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SECTION 5 - HYDRAULICS • at end of platform level up hose (do not use this location if port 15 was chosen in step 2.) PLATFORM LEVEL DOWN – 1200 PSI (83 BAR) PLATFORM LEVEL UP HOSE 4. Activate Platform Level Up and hold. Take pressure reading. 5. After loosening relief valve jam nut, adjust valve clockwise to increase pressure or counterclockwise to reduce pressure accordingly. PLATFORM LEVEL DOWN RELIEF VALVE 6. Tighten relief valve jam nut. Repeat step 4 and verify the pressure setting. 7.
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SECTION 5 - HYDRAULICS 4. After loosening relief valve jam nut, adjust valve clockwise to increase pressure or counterclockwise to reduce pressure accordingly. 5. Tighten relief valve jam nut. Repeat step 3 and verify the pressure setting. Option 2: 1. Disconnect, cap, and plug the platform level down hose and adapter either at the platform level master cylinder, at the platform level slave cylinder, or at port “16” of the Boom Function Valve Bank.
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SECTION 5 - HYDRAULICS NOTE: Coil Resistance (@ 68° F [20° C]) is 7.2 Ohms for Tower Lift Up, Main Lift Up, and Flow Control. All other coils have 9.8 Ohms resistance. These values are all ± 15%. TT-SWG-RT (OUTSIDE COIL) BRK-PRES-SW TWR-LFT-UP TT-SWG-LT (INSIDE COIL) BRAKE STEER-RT (OUTSIDE COIL) MAIN-LFT-UP STEER-LT (INSIDE COIL) FLOW-CNTL Figure 5-10.
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SECTION 5 - HYDRAULICS 13 14 14 14 1 12 9 10 5 11 11 4 10 4 3 11 2 11 11 4 10 14 7 8 6 Table 5-3. Main Valve Torques # Description Ft. Lbs. Nm # 1 Description Ft. Lbs.
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SECTION 5 - HYDRAULICS NOTE: Coil Resistance (@ 68° F [20° C]) is 9.8 Ohms ± 15%. TELE-OUT (OUTSIDE COIL) PLTF-ROT-LT (INSIDE COIL) PLTF-ROT-RT (OUTSIDE COIL) TELE-IN (INSIDE COIL) JIB-LEFT (INSIDE COIL) JIB-RIGHT (OUTSIDE COIL) JIB-UP (OUTSIDE COIL) JIB-DN (INSIDE COIL) PLATF-LVL-UP (OUTSIDE COIL) PLATF-LVL-DN (INSIDE COIL) Figure 5-11.
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SECTION 5 - HYDRAULICS 16 13 13 5 3 3 13 4 12 13 8 10 15 13 7 13 2 11 11 16 11 11 3 E300AJ 13 E300AJP 9 2 11 11 11 11 1 13 AJP ONLY 6 13 12 6 2 11 11 Table 5-4. Boom Function Valve Torques # Description Ft. Lbs. Nm # Ft. Lbs. Nm # 1 Solenoid Valve 20 27 7 Manual Valve Description 25 34 13 Port Plug Description Ft. Lbs. Nm 15 20 2 Solenoid Valve 20 27 8 Hand Pump 30 40.
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SECTION 5 - HYDRAULICS D A HYDRAULIC TANK ELECTRIC MOTOR & PUMP B MAIN CONTROL VALVE BOOM FUNCTION VALVE c BOOM FUNCTION VALVE PUMP HANDLE ELECTRIC MOTOR & PUMP c B Torque Ft-Lbs. Nm A 14-18 19-24.5 B 17-23 23-31 C 6-9 8-12 D 16-20 22-27 Figure 5-12.
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SECTION 5 - HYDRAULICS 5.4 INITIAL HYDRAULIC PUMP START-UP PROCEDURE 4. Insert the other end of the pressure test hose into the hydraulic reservoir’s breather/filler port. This procedure must be used when the hydraulic pump or pump/motor assembly is removed or replaced to ensure there is no air trapped in the hydraulic system. Having air in the system can cause damage to the pump. Procedure 1. Fill the hydraulic reservoir approximately 3/4 full of hydraulic fluid.
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SECTION 5 - HYDRAULICS 6. Continue activating the platform rotate switch momentarily until the assistant sees a clear, uniform stream of hydraulic fluid flowing from the test hose into the hydraulic reservoir. NOTE: An audible change in the tone of the gear pump should be heard when the air is purged from the gear pump. 7. Disconnect the pressure test hose from the MP port on the Main Control Valve. 8. Remove the hose end from the hydraulic reservoir’s breather/filler port. 9.
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SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Introduction WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS. IT 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.
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SECTION 6 - JLG CONTROL SYSTEM The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubleshooting. Optional equipment includes an hour meter, beacon light, function cutout, and ground alarm. These options may be added later but must be programmed into the motor controller when installed.
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SECTION 6 - JLG CONTROL SYSTEM 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 ACTIVATE TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE (level 1 only) 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.
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SECTION 6 - JLG CONTROL SYSTEM Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit of the password, 3. Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password.
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SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE. GROUND ALARM: 2=DRIVE ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
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SECTION 6 - JLG CONTROL SYSTEM Figure 6-2.
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SECTION 6 - JLG CONTROL SYSTEM POSITION J1 J2 J3 J4 J5 J6 MATING CONNECTOR 4460321 4460326 4460265 4460225 4460265 4460265 MATING TERMINAL PIN MATING TERMINAL 4460226 1 ANALYZER PWR (12V) POWER PIN OUTPUT 4460226 1 FSWIN DIGITAL 4460226 2 RS-232 RECEIVE SERIAL INPUT 4460226 2 SOFT TOUCH O/R INPUT DIGITAL 4460226 3 INPUT RS-232 TRANSMIT SERIAL OUTPUT 4460226 3 PLATF LEVEL DOWN INPUT DIGITAL INPUT 4460226 4460226 4 ANALYZER GROUND POWER OUTPUT 4460226 4 P
PAGE 176
SECTION 6 - JLG CONTROL SYSTEM Figure 6-4.
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SECTION 6 - JLG CONTROL SYSTEM POSITION MATING CONNECTOR J1 J2 J4 J5 J6 4460321 4460321 4460434 4460265 4460265 TYPE MATING CONNECTOR TERMINAL PIN TERMINAL PIN 4460226 1 N/C N/C N/C 4460227 1 TOWER LIFT UP INPUT DIGITAL 4460226 2 CAN HIGH (1) SERIAL I/O 4460227 2 TOWER LIFT DOWN INPUT DIGITAL POSITION FUNCTION TYPE FUNCTION INPUT INPUT 4460226 3 CAN LOW (1) SERIAL I/O 4460227 3 MAIN LIFT UP INPUT DIGITAL INPUT 4460226 4 CAN SHIELD (1) POWER DRAIN 446022
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SECTION 6 - JLG CONTROL SYSTEM Figure 6-6.
PAGE 179
SECTION 6 - JLG CONTROL SYSTEM CONNECTOR J1 J2 J3 J4 J5 J7 J8 J9 P2 PIN TAGNAME FUNCTION 1 PLTEMS PLATFORM EMS VBAT TYPE INPUT 2 GNDEMS GROUND EMS VBAT INPUT 3 FSW IN FOOTSWITCH DIGITAL INPUT 4 IGN GROUND MODULE POWER +12V OUTPUT 5 FSW OUT FOOTSWITCH SIGNAL PASSTHROUGH DIGITAL OUTPUT 6 IGN GROUND MODULE POWER +12V OUTPUT OUTPUT 7 IGN TILT MODULE POWER +12V 8 GND GROUND MODULE GROUND GROUND INPUT 9 N/C NOT CONNECTED +12V OUTPUT 10 GND TILT MODULE GR
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SECTION 6 - JLG CONTROL SYSTEM CONNECTOR PIN 1 2 3 J1 4 5 6 TAG NAME ENCPWR SPD GND DIR N/C N/C FUNCTION CONNECTOR PIN 1 2 J2 3 4 TAG NAME N/C CANH CANL SHD FUNCTION CONNECTOR PIN 1 2 J3 3 4 TAG NAME N/C CANH CANL SHD FUNCTION CONNECTOR PIN 1 2 J4 3 TAG NAME FSWIN ING GND CONNECTOR PIN 1 2 J5 3 TAG NAME GND ARMB ARMA TYPE POWER OUTPUT (12V) POWER SPEED DIGITAL OUTPUT INPUT GROUND RETURN POWER INPUT DIRECTION DIGITAL INPUT N/C N/C N/C N/C N/C N/C TYPE N/C N/C CAN HIGH SERI
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION ACCEL ACT A/D AMB.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION S/C MEANING SHORT CIRCUIT SEL SELECTOR SN SERIAL NUMBER SPD STOW STOWD SW SPEED STOWED STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ.
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3121253 – JLG Lift – (001) DATALOG: RENTAL XXXhXXm DATALOG: ERASE RENTAL SYSTEM: DRIVE CUTOUT OP SYSTEM: ELEV. CUTOUT OP SYSTEM: DOS OFF SYSTEM: BRAKES LOW PRES. BOOM: SWING 0% BOOM: LEVEL 0% BOOM: TELE 0% BOOM: ROTATE 0% BOOM: JIB (U/D) 0% BOOM: JIB (L/R) 0% BOOM: PUMP POT 0% BOOM: CREEP ACTIVE DRIVE: POSITRAC OFF DRIVE: STEER 0% DRIVE: BRAKES LOCKED DRIVE: CREEP ACTIVE DRIVE: DOS LIM SW OP DRIVE: DOS O//R SW OP 0% 1 VERSIONS: ANALYZER vX.X VERSIONS: POSITILT vX.X VERSIONS: GROUND vX.
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6-16 – JLG Lift – 2 DRIVE: POSITRAC 170 A MAIN LIFT : CREEP DOWN 55% MAIN LIFT : MAX DOWN 63% MAIN LIFT : MIN DOWN 30% MAIN LIFT : CREEP UP 30% MAIN LIFT : MAX UP 80% MAIN LIFT : MIN UP 18% MAIN LIFT : DECEL 0. 3s MAIN LIFT : ACCEL 1. 0s LIFT : MAIN LIFT 2 2 2 2 2 2 2 2 2 22% TELE: MAX OUT 40% TELE: MIN OUT 16% TELE: MAX IN 50% TELE: MIN IN TELE: DECEL 0. 5s TELE: ACCEL 1.
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3121253 1 1 MACHINE CALS: FLOW@0% 30% MACHINE CALS: FLOW@100% 50% MACHINE CALS: TLIFT@0% 30% MACHINE CALS: TLIFT@100% 50% MACHINE CALS: MLIFT@0% 30% CONTROLLER CALS: 1 TRACTION I 1.28 CONTROLLER CALS: 1 PUMP I 1.26 CONTROLLER CALS: 1 TILTdelayIN 62! CONTROLLER CALS: 1 TILTdelayOUT 6! – JLG Lift – 1 1 MACHINE CALS: SWINGcalSw OFF MACHINE CALS: SWINGL@0% 43% 1 1 1 1 MACHINE CALS: SPEEDprop2 16 MACHINE CALS: SPEEDint 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Default Number Description NOTE: When configuring the E300 machine, the machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit 7 (Platform Alarm) 8 (Load) 9 (Level inhibit) 10 (ALARM dB) Number Default Number Description 0 No - Sounds continuously when above elevation and tilted only. 1 Fault Code - Sounds continuously when above elevation and tilted, and in conjunction with fault code flashes.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults Adjustment Adjustment Range Default Value DRIVE ACCEL 0.5 to 5 sec 1.5s DECEL 0.1 to 2 sec 0.5s MIN 0 to 25% 3% MAX 0 to 100% 95% ELEVATED MAX 0 to 25% 20% CREEP MAX 0 to 45% 30% POSITRAC 0 to 60 sec 10s POSITRAC 50 to 250 amps 170A 0.5 to 5 sec 1.0s LIFT LOWER LIFT ACCEL DECEL 0.1 to 3.0 sec 0.5s MIN UP 0 to 50% 18% MAX UP 0 to 100% 83% MIN DOWN 0 to 50% 36% MAX DOWN 0 to 100% 58% 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults Adjustment Adjustment Range Default Value MIN OUT 0 to 50% 16% MAX OUT 0 to 100% 35% 0.5 to 5 sec 1.0s PLATFORM LEVEL ACCEL DECEL 0.1 to 3 sec 1.0s MIN UP 0 to 50% 15% MAX UP 0 to 80% 30% MIN DOWN 0 to 50% 10% MAX DOWN 0 to 80% 22% PLATFORM ROTATE ACCEL 0.1 to 5 sec 0.5s DECEL 0.1 to 3 sec 0.5s MIN LEFT 0 to 50% 13% MAX LEFT 0 to 100% 22% MIN RIGHT 0 to 50% 13% MAX RIGHT 0 to 100% 22% 0.5 to 5.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes DTC Flash Code Fault Message Description 001 00 EVERYTHING OK The "normal" help message in platform mode 002 00 GROUND MODE OK The "normal" help message in ground mode 0010 00 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" while the vehicle is out of transport position. 0011 00 FSW OPEN A drive or boom function has been selected but footswitch is open.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes DTC Flash Code 2514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configured to not allow simultaneous drive & boom operation. 2516 25 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom functions are selected AND is configured to not allow simultaneous drive & boom operation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes DTC Flash Code 33364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized. This maybe due to an open circuit traction motor or power wiring error 33369 33 REVERSE CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when reverse contactor was energized.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4.
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SECTION 6 - JLG CONTROL SYSTEM System Self Test up switch. When the controller sees that the tower lift up switch has been closed, it will move on to the next input. If the switch is faulty or the wiring is faulty, the controller will not move on to the next input. The controller will continue to wait for the closure of the input. If the operator knows the switch is faulty and wants to continue the tests he must simply press the enter key on the analyzer to continue.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages RUNNING 3121253 Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BAD POWER WIRING The capacitor bank is not charged or pump point A is low or traction point A is high or low. Check all power wiring. LINE CONT WELDED The capacitor bank is at battery voltage. Check line contactor.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open-and short- circuit valve coils. The valves are tested in the order: STEER L, STEER R, BRAKE, FLOW, TWR U, MAIN U, SWING L, SWING R, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, JIB L, JIB R, TELE I, TELE O NOTE: in platform mode, the footswitch must be closed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends. If ENTER is pressed, each operator input is prompted for in turn.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL Polarity This section contains basic electrical information and schematics 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.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connections: • Main Boom Rotary sensor connections (on Celesco Sensor), • LSS Modules connections, • Deutz EMR 2 ECM connection.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only. NOTE: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal more difficult. Deutsch HD, DT, DTM, DRC Series The Deutsch connector system is commonly used for harsh environment interconnect. Follow the installation instructions.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs AMP Mate-N-Lok Follow the installation instructions. 3121253 Exclusions A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application. Dielectric grease may not be required in properly sealed enclosures.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion and an o-ring seal for moisture integrity. If dielectric grease is mistakenly applied to this connector system, the low-force contacts cannot displace the grease to achieve electrical contact. Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required).
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-9.). Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-7.). Proceed as follows: Figure 7-7. Connector Assembly Figure 1 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-9.). Figure 7-8.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. 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 7-10.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-11.). Figure 7-11. Connector Assembly Figure 4 Figure 7-10.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 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.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13.
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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 7-14. DT/DTP Contact Installation Figure 7-15. 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.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A C C Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp barrel. 9. Hold connector with rear grommet facing you. 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. 11.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FOOTSWITCH PLATFORM FLOODLIGHTS POS NEG INVERTER J11 J9 J8 STROBE LIGHT J7 J6 J5 J4 J3 J2 J1 PLATFORM CONTROL BOX BATTERY CHARGER DRIVE ORIENTATION SWITCH GRD MOD J11 J10 J9 J8 J7 A B+ PWR MOD P2 J6 J5 J4 J3 J14 J2 J1 J2 J3 J4 J5 DIAGNOSTIC ANALYZER J7 J8 J9 J12 GROUND CONTROL BOX J1 P B– ACCY Figure 7-20.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AC POWER AT PLATFORM BATTERIES POSI-TRACK/ TILT MODULE S2 A2 S1 A1 J2 J3 J4 J5 J1 A1 S1 A2 S2 RH DRIVE BRAKE/MOTOR LH DRIVE BRAKE/MOTOR PUMP MAIN BOOM LIFT CYLINDER MAIN BOOM LIMIT SWITCH 300AMP FUSE (UL Only) BOOM FUNCTION VALVE TOWER BOOM LIMIT SWITCH MAIN VALVE TOWER BOOM LIFT CYLINDER Figure 7-21.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS INDICATOR LAMP PANEL PINK 26-3 N/C TAN 6-3 TAN 5-3 PINK 25-3 GRAY 24-2 GRAY 23-2 WHT/BLK 58-5 BROWN 14-3 WHT/RED 57-5 WHT/RED 57-6 RED SHIELD BLACK N/C 14 12 8 7 6 5 15 13 10 11 9 4 3 1 2 LEFT STEER WHT/BLK 58-6 CREEP SWITCH RIGHT PUMP SPEED AND CREEP-MODE SWITCH ASSEMBLY FWD RED REV TRACTION CONTROL PLATFROM ROTATE TELE.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SEE ZONE G-5 1 2 3 4 5 6 7 8 9 10 11 12 WHT/RED 57-5 WHT/BLK 58-8 1 2 3 4 J9 6 PIN J3 9 PIN FOOTSWITCH N/C N/C N/C N/C 3 7 1 2 4 5 6 8 DOWN WHT/RED 57-9 WHITE BLACK YEL/RED 2-4-2 RIGHT SPEED SENSOR CONNECTIONS SUPPLY - RED GROUND - BLACK SPEED - WHITE DIRECTION - GREEN RED 1-3 (12) POWER MODULE BLACK GREEN ORN/RED 49-16 WHITE RED J2 6 SOCKET ORN/RED 49-17 ARMATURE A A2 ORN/RED 49-12 WHT/RED 57-2 ORN/RED 49-18 ORN/RED 49-13
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-24.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001112910-A Figure 7-25.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001112910-A Figure 7-27.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-22 – JLG Lift – 3121253
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3121253 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 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.