Service Manual Manual

ManualsBrandsJLG ManualsSpecial machineryE300

Service and Maintenance Manual

Model

E300A

E300AJ

E300AJP

P/N - 3120772

January 23, 2009

Summary of content (174 pages)

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Service and Maintenance Manual Model E300A E300AJ E300AJP P/N - 3120772 January 23, 2009
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised A-2 November 15, 2000 October 1, 2001 April 10, 2002 June 4, 2002 November 3, 2006 January 14, 2008 January 23, 2009 – JLG Lift – 3120772
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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. Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6 SECTION 3 - CHASSIS & TURNTABLE 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 ii Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Tire Wear and Damage .
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TABLE OF CONTENTS SECTION NO. 3.10 TITLE PAGE NO. Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49 Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Charging Sequence of Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 SECTION 4 - BOOM & PLATFORM 4.1 4.2 4.3 4.4 4.5 4.6 Boom Maintenance . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Using the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3120772 TITLE PAGE NO. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. vi TITLE PAGE NO. Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 6-1. 6-2. 6-3. 6-4. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 3120772 TITLE PAGE NO. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22 2-1 2-2 2-3 3-1 3-2 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 viii TITLE PAGE NO. Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operating Specifications - E300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Table 1-3. Operating Specifications - E300AJ Table 1-1. Capacities Capacity: Unrestricted: Hydraulic Oil Tank 3.0 gallons (11.35 liters) Hydraulic System (Including Tank) 4.0 gallons (15.14 liters) Torque Hub, Drive* 17 ounces (0.50 L) *Torque hubs should be one half full of lubricant. 1.2 OPERATING SPECIFICATIONS Table 1-2. Operating Specifications - E300A Capacity: Unrestricted: 500 lbs.
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SECTION 1 - SPECIFICATIONS 1.7 HYDRAULIC PUMP/ELECTRIC MOTOR ASSEMBLY 1.3 BATTERY CHARGER Table 1-5. Battery Charger Input Table 1-9. Hydraulic Pump/Electric Motor 110 VAC,60 HZ Output 48 VDC (23 Amps) Batteries (8) 6 Volt, 370 AmpHour (20 hour rate) Motor 48 VDC, 2.14 H.P. @ 2700 rpm Displacement 0.19 cu. in./rev. (3.12 cm3/rev.) Output 2.71 gpm (10,25 lpm) @ 2000 psi (137.9 Bar) 1.4 DRIVE SYSTEM 1.8 DIMENSIONAL DATA Table 1-6. Drive System Table 1-10.
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SECTION 1 - SPECIFICATIONS 1.9 FUNCTION SPEEDS 1.10 TORQUE SPECIFICATIONS Table 1-11. Function Speeds Function Travel Speed (Forward & Reverse) High drive Travel Speed (Forward & Reverse) boom above Horizontal Table 1-12. Torque Requirements Speed in seconds (unless otherwise noted) 0.62 mph (1 kmh) (55-68 sec / 50ft.) 24-27 Upper Lift Down 20-23 17-20 12-15 Lower Lift Up 17 - 20 Lower Lift Down 17 - 20 Swing - 360 Degrees 79 - 86 Platform Rotate, Left and Right* *Max.
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SECTION 1 - SPECIFICATIONS Table 1-14. Pressure Settings - S/N 0300063313 to Present Circuit PSI 1.13 MAJOR COMPONENT WEIGHTS Bar SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF SAFELY SUPPORTING WEIGHT Main Control Valve Upper Lift Down Relief 550 38 Lower Lift Down Relief 1700 117 Telescope Relief (A/AJ) 2150 148 Telescope Relief (AJP) 3000 207 Platform Level Up Relief 3000 Platform Level Down Relief 1200 Table 1-16. Major Component Weights COMPONENT LBS. KG.
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SECTION 1 - SPECIFICATIONS Critical Stability Weights 1.15 HYDRAULIC OIL Table 1-18. Hydraulic Oil Hydraulic System Operating Temperature Range DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Table 1-17. Critical Stability Weights Components LBS. KG. Counterweight 5300 2404.1 Tire and Wheel 120 54.4 Tire and Wheel (CSA) 262 119 Platform 135 61.
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SECTION 1 - SPECIFICATIONS Table 1-21. Mobil EAL 224H Specs Table 1-19. Mobil DTE 11M Specs ISO Viscosity Grade #15 Type Synthetic Biodegradable Gravity API 31.9 ISO Viscosity Grade 32/46 Pour Point, Max -40°F (-40°C) Specific Gravity .922 Flash Point, Min. 330°F (166°C) Pour Point, Max -25°F (-32°C) Flash Point, Min. 428°F (220°C) 15 cSt Operating Temp. 0 to 180°F (-17 to 162°C) at 100° C 4.1 cSt Weight at 100° F 80 SUS 7.64 lb. per gal. (0.
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SECTION 1 - SPECIFICATIONS 8 8 8 8 3 4 7 1,2 5 6 Figure 1-1. Operator Maintenance & Lubrication Diagram 1.16 LUBRICATION NOTE: NOTE: It is recommended as a good practice to replace all filters at the same time. The following numbers correspond to those in Figure 1-1., Operator Maintenance & Lubrication Diagram. Table 1-22. Lubrication Specifications. KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F.
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SECTION 1 - SPECIFICATIONS 2. Swing Bearing/Worm Gear Teeth 5. Wheel Drive Hub Lube Point(s) - 2 Grease Fittings Capacity - Spray On Lube - Mobiltac375NC Interval - A/R Comments - If necessary install grease fittings into worm gear housing and grease bearings. Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation 6. Wheel Bearings DO NOT OVERGREASE BEARINGS.
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3120772 – JLG Lift – 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 40 48 32 40 32 36 24 32 20 28 1.5000 1.3750 1.2500 1.1250 1.0000 0.8750 0.7500 0.6250 0.5625 0.5000 0.4375 0.3750 0.3125 IN 0.2500 0.1900 0.1640 0.1380 0.1120 IN BOLT DIA. 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 SQ. IN. 0.00604 0.00661 0.00909 0.
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1-10 – JLG Lift – 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 40 48 32 40 32 36 24 32 20 28 SQ. IN. 1.5000 1.3750 1.2500 1.1250 1.0000 0.8750 0.7500 0.6250 0.5625 0.5000 0.4375 0.3750 0.3125 IN 0.2500 0.1900 0.1640 0.1380 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 SQ. IN. 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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SECTION 1 - SPECIFICATIONS VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY CLASS 8.8 METRIC BOLTS & CLASS 8 METRIC NUTS SIZE PITCH CLASS 10.9 METRIC BOLTS & CLASS 10 METRIC NUTS TORQUE TENSILE STRESS AREA CLAMP LOAD sq. mm TORQUE DRY OR LOCTITE 263 LUB LOCTITE 262 LOCTITE 242 OR 271 KN N, m N, m N, m N, m CLAMP LOAD DRY OR LOCTITE 263 LUB LOCTITE 262 LOCTITE 242 OR 271 KN N, m N, m N, m N, m 3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1 3.5 .6 6.
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SECTION 1 - SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3120772
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly 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 2.3 LUBRICATION AND INFORMATION Changing Hydraulic Oil 1. Filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils.
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SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Maximum acceptable cylinder drift is to be measured using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift 1. Pinned joints should be disassembled inspected if the following occurs: Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off.
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SECTION 2 - GENERAL 2.6 WELDING ON JLG EQUIPMENT NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external structure, or component, • Ground on frame and weld on any other area than the chassis. • Ground on turntable and weld on any other area than the turntable. Do the Following When Welding on JLG Equipment • Ground on the platform/support and weld on any other area than the platform/support. • Disconnect the battery.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3120772
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS 2. Tighten nuts in the following sequence. Tire Wear and Damage Inspect tires periodically 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. Wheel and Tire Replacement Replacement wheels must have the same diameter and profile as the original.
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SECTION 3 - CHASSIS & TURNTABLE 3.2 DRIVE HUB PART NO. 2780236 changing the sun gear shaft (43) along with this set of planets. The final drive consists of two planetary stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load distribution. All torque transmitting components are made of forged quenched and tempered highalloy steels. External gears are carburized. Precision roller bearings support the sprocket or wheel loads.
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SECTION 3 - CHASSIS & TURNTABLE Assembly of end cover unit (8) Initial Start-up And After Repairs Before operating the machine, make sure that the drive is filled with clean oil, approximately 0.2 US gallons(.8 L). An accurate oil level is determined by the oil level plug, which should be removed before oil fill. 1. Press sleeve (52) into cover (8). 2. Install “o” ring (54) into groove of cover (8). 3. Install shift rod (56) into cover (8).
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-1.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB (S/N 115723 TO PRESENT) 5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts. 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.
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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 3-3.
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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). 1F 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). Output Carrier Thrust Washer Needle Bearing Thrust Spacer Planet Gear Figure 3-5.
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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. 2. Remove Retaining Ring (1J) with appropriate tool. 3. Remove Spacer (1N). 7. Remove Seal (1B) from Hub (1G). NOTE: The Seal (1B) should NOT be reused when reassembling the unit. 4. Remove "A" position Bearing Cone (1C) from Bearing Cup (1D) in Hub (1G). 8. Remove "B" position Bearing Cone (1E) from Hub (1G).
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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 3-6., Input Carrier) (Refer to Figure 3-5., 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 3-7., Hub Spindle) (Refer to Figure 3-4., 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 Cover Subassembly Main Assembly (Refer to Figure 3-8., Cover Assembly) (Refer to Figure 3-2., Main Disassembly Drawing 1 and Figure 3-3., Main Disassembly Drawing 2) 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. NOTE: All components should receive a generous amount of lubricant oil as they are being assembled. 1.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-9.
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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 Figure 3-11. Cup Pressing Tool Figure 3-12.
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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. 5. Install dowel pins (20), spring retainer (16) and springs (5) in cover plate (21). 6. Position plate (14) on springs (15).
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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 3120772 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 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. 1. Place the machine on a flat, level surface. Check for level by placing a bubble level on the frame in both directions. 2.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-14. Speed Sensor Orientation.
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SECTION 3 - CHASSIS & TURNTABLE Fuse Box U/L Machines Only JLG P/N 1600292 MOTOR A MOTOR B 1704246-D Figure 3-15.
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SECTION 3 - CHASSIS & TURNTABLE 6 1 2 7 3 12 5 4 13 11 14 19 18 21 9 20 24 26 22 14 15 23 11 25 27 30 17 8 10 16 29 28 1. 2. 3. 4. 5. 6. Bolt Keeper Pin Flatwasher Steer Cylinder Shoulder Bolt 7. 8. 9. 10. 11. 12. Hub/Spindle Assembly Tie Rod Shoulder Bolt Locknut Bearing King Pin 13. 14. 15. 16. 17. 18. Thrust Bearing Bushing Castle Nut Flatwasher Cotter Pin Spindle 19. 20. 21. 22. 23. 24. Seal Bearing Cone Bearing Cup Hub Bearing Cup Bearing Cone 25. 26. 27. 28. 29. 30.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-17.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING BEARING 2. Check the turntable to bearing. Attach bolts as follows: Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
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SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance Replacement of Swing Bearing 1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Tower Boom raised half way (approx 37°)See Figure 2-22, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. (See Figure 2-20) 2.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Swing Bearing Tolerance Boom Placement.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-21.
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SECTION 3 - CHASSIS & TURNTABLE 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. b. Line up high spot (blue) of bearing with center tooth of worm gear. Set backlash to 0.008 0.010 inch (0.20 - 0.25 mm). Tighten cap screws as shown in Figure 2-24. c. Spray Mobiltac 375NC open gear spray onto gear teeth. d. Apply Tribol Molub-Alloy 936 Open Gear Compound to bearing. e.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Swing Bearing Torquing Sequence Swing Bearing Torque Value Install bolts with Loctite - 240 ft. lbs. (326 Nm).
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SECTION 3 - CHASSIS & TURNTABLE Checking Worm Gear End Play . Fig 2 Adjusting End Play. JLG Industries requires that a annual inspection be performed on the worm gear end play. 1. Using a dial indicator, measure end play of worm gear, by applying side to side movement by hand to platform. 2. If tolerance exceeds.010”, reduce end play to less than.005”. Refer to Adjusting End Play. SHIMS END PLATE 3.8 SWING MOTOR Removal Allowable Tolerance (.001 to .005) 1.
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SECTION 3 - CHASSIS & TURNTABLE 3. Install the shaft seal down onto the shaft making sure the lip on the seal faces down. Refer to Figure 3-23., Seal Orientation. 8. Gently tap the shaft upward through the housing and remove through the rear of the housing. Turn the shaft over and remove the cooling plug. 9. Remove the housing from the vise and turn over. Pry the dust seal from the housing. 10. Push the seal carrier, thrust washer, and thrust bearing down and remove from the rear of the housing.
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SECTION 3 - CHASSIS & TURNTABLE 3. Lower the drive link into the shaft making sure that the timing mark end of the drive link faces up and the timing mark on the end of the drive link is aligned with one of the through holes in the shaft. 11. Lower the rotor onto the drive link making sure the timing mark on the drive link is aligned with a peak on the rotor as shown in Figure 3-25., Timing Mark. TIMING MARK 4.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. Dust Seal Retainer Ring Backup Shim Housing Seal Body Seal 6. Shaft Seal 7. Thrust Washer 8. Thrust Bearing 9. Wear Plate 10. End Cover 11. 12. 13. 14. 15. Ball Cooling Plug Housing Drive Link Rotor Set 16. 17. 18. 19. Drive Link Pin Bolt Shaft Key Figure 3-26.
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SECTION 3 - CHASSIS & TURNTABLE 11 7 201 103 104 102 SWING3 MOTOR SWING ROTATION BOX 105 4 1 101 SWING BEARING Figure 3-27.
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SECTION 3 - CHASSIS & TURNTABLE 3.9 HELAC ROTARY ACTUATOR 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 3 - CHASSIS & TURNTABLE 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap 109. Lock Pin 113. Cap Screw 200. 202. 204. 205. 207. 302. T-Seal T-Seal O-Ring Cup Seal Back-Up Wear Guide 304. Thrust Washer 304.1. Wiper Seal 400. Stop Tube (Optional) 401. Counterbalance Valve Figure 3-28.
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SECTION 3 - CHASSIS & TURNTABLE 1. Housing 2. Shaft 3. Piston Sleeve 4. End Cap 109. Lock Pin 113. Cap Screw 200. 202. 204. 205. 207. 302. T-Seal T-Seal O-Ring Cup Seal Back-Up Wear Guide 304. Thrust Washer 304.1. Wiper Seal 400. Stop Tube (Optional) 401. Counterbalance Valve Figure 3-29.
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SECTION 3 - CHASSIS & TURNTABLE Tools Required for Assembly/Disassembly Disassembly Upon assembly and disassembly of the actuator there are basic tools required. The tools and their intended functions are as follows: 1. Flashlight- helps examine timing marks, component failure and overall condition. 2. Felt Marker- match mark the timing marks and outline troubled areas. 3. Allen wrench- removal of port plugs and setscrews. 4. Box knife- removal of seals. 5.
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SECTION 3 - CHASSIS & TURNTABLE 4. Install the end cap (4) removal tools provided with the Helac seal kit. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. 5. Using a metal bar, or something similar, un-screw the end cap (4) by turning it counter clock-wise. 8. Every actuator has timing marks for proper engagement. 6. Remove the end cap (4) and set aside for later inspection.
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SECTION 3 - CHASSIS & TURNTABLE 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. 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).
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SECTION 3 - CHASSIS & TURNTABLE 15. Remove the wear guides (302) 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). 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). 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 20. Remove the piston I.D. seal (200).
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SECTION 3 - CHASSIS & TURNTABLE Inspection Assembly 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. 1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal orientations. 2.
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SECTION 3 - CHASSIS & TURNTABLE 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. 7. 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). 5. Install the wear guide (302) on the end cap (4) and shaft (2). 8.
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SECTION 3 - CHASSIS & TURNTABLE 10. 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. Install the shaft (2) into the piston (3). Be careful not to damage the seals. Do not engage the piston gear teeth yet. 13. Install 2 bolts in the threaded holes in the flange.
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SECTION 3 - CHASSIS & TURNTABLE 16. Install the O-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4). 17. Thread the end cap (4) onto the shaft (2) end. Make sure the wear guide stays in place on the end cap as it is threaded into the housing (1). 19. 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. 20. Insert the set screws (113) over the lock pins.
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SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY MAINTENANCE AND CHARGING Charging Sequence of Remote LED Card 1. Plug in charger. 2. All three LED’s (light emitting diode) flash three times. Battery Maintenance, Quarterly 1. Open battery compartment cover to allow access to battery terminals and vent caps. 3. In sequence. a. Green LED flashes once. b. Yellow LED flashes once. c. Red LED flashes once. WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES.
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SECTION 3 - CHASSIS & TURNTABLE 3 4 10 13 5 7 11 11 15* 2 11 10 11 2 11 11 11 2 11 6 7 9 12 8 14 NOTE: Apply Item #10 to contacts of Anderson connectors only. NOTE: Apply Item #11 to Battery Terminal connections only. * Torque to 70 ft.lbs. (95 Nm) 1. 2. 3. 4. Battery Cable Cover Cover 5. 6. 7. 8. Hold Down Insulation Grommet Loctite #242 Wear Pad 9. 10. 11. 12. Shim Dielectric Grease Battery Terminal Grease Battery Box 13. Battery Box 14. Battery Box Liner 15.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-32.
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SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-52 – JLG Lift – 3120772
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE f. Remove hardware securing the lower boom pivot pin. Using a suitable brass drift and hammer, remove pin from the turntable. IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A LIFTING DEVICE TO LIFT THE BOOMS UNLESSTHE HOLDING VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILL RESULT IN SEVERE DAMAGE TO THE BOOM. g.
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SECTION 4 - BOOM & PLATFORM 4 1 5 2 3 12 6 7 8 10 11 9 1. 2. 3. 4. Master Cylinder Boom Lift Level Cylinder Base Boom 5. 6. 7. 8. Fly Boom Mid Link Mid Boom Lower Link 9. 10. 11. 12. Lower Boom Tower Lift Cylinder Lower Upright Upper Upright Figure 4-1.
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SECTION 4 - BOOM & PLATFORM 11 1 3 1 3 16 3 6 3 1 4 3 7 1 1 3 3 3 1 13 14 15 8 10 3 3 1 14 1 3 1 3 3 9 1 6 14 4 7 3 12 1. 2. 3. 4. 5. Loctite #242 Bumper Composite Bearing Channel Tower Lift Cylinder 6. 7. 8. 9. 10. Mid Link Mid Boom Lower Link Lower Boom Timing Link 11. 12. 13. 14. Upper Upright Boom Rest Lower Upright Composite Bearing Figure 4-2.
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SECTION 4 - BOOM & PLATFORM 6. Using a suitable lifting device, remove telescope cylinder from boom sections. 6. Using suitable lifting equipment, slide fly boom section out to gain access to telescope cylinder attach pin hole. 7. Using a piece of tape, mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly. 7. Measure the distance between the telescope cylinder port block attach point on base boom section and the attach point on fly boom section. 8.
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SECTION 4 - BOOM & PLATFORM Installation of the Boom Assembly 4.2 WEAR PADS 1. Using suitable lifting equipment, position boom assembly on turntable so that boom pivot holes in both boom and turntable are aligned. 1. Shim up wear pads until snug to adjacent surface. 2. Install boom pivot pin, ensuring that location of the hole in pivot pin aligns with attach point on upright. 3. Replace wear pads when worn to thickness of 9/16”. 2. Bolt into threaded insert of wear pad. 3.
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SECTION 4 - BOOM & PLATFORM 4.3 ARTICULATING JIB (AJ/AJP) 4.4 TILT INDICATOR SWITCH LEVELING Removal 1. Place the Jib in a horizontal position and support the complete assembly with adequate blocking. PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH. 2. Remove the Platform as follows: 1.
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SECTION 4 - BOOM & PLATFORM Figure 4-4. Jib - E300AJ Figure 4-5.
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SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A,B,D C,D A B C D Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque 250-270 ft. lbs. (339-366 Nm) Check torque every 150 hours of operation Figure 4-6.
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SECTION 4 - BOOM & PLATFORM DETAIL A 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 SEE DETAIL A Figure 4-7.
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SECTION 4 - BOOM & PLATFORM NOTES: 4-10 – JLG Lift – 3120772
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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 CYLINDERS - THEORY OF OPERATION 6. Activate hydraulic system and activate cylinder retract function. Check extend port for leakage. Systems Incorporating Double Acting Cylinders 7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made.
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SECTION 5 - HYDRAULICS Cylinders With Dual Counterbalance Valve (Lower Lift, Telescope, and Slave Cylinders) OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system. WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. REFER TO FIG. 2-1.
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SECTION 5 - HYDRAULICS Figure 5-1. Boom Positioning and Support, Cylinder Repair 5.4 CYLINDER REPAIR NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. 2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source.
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SECTION 5 - HYDRAULICS Figure 5-2. Cylinder Barrel Support Figure 5-4. Cylinder Rod Support 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer cap screws, and remove cap screws from cylinder barrel. 9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 10. Loosen and remove the cap screw(s), if applicable, which attach the tapered bushing to the piston.
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SECTION 5 - HYDRAULICS Cleaning and Inspection 1. Clean all parts thoroughly in an approved cleaning solvent. 13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary. a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary. b.
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SECTION 5 - HYDRAULICS 7 7 27 13 13 10 6 18 19 25 19 18 5 14 16 20 22 17 9 21 23 3*,4*,24 12 1,3,26 11 8 8 *Prior to S/N 0300106517 1. 2. 3. 4. 5. 6. 5-8 Loctite #242 Not Used Primer #7471 Loctite RC 609 Bolt Tapered Bushing 7. 8. 9. 10. 11. 12. Composite Bearing 13. O-ring Plug Composite Bearing 14. Piston Cylinder Head 15. Not Used Barrel 16. Backup Ring Rod 17. Backup Ring Washer Ring Figure 5-7. Jib Cylinder – JLG Lift – 18. 19. 20. 21. 22.
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SECTION 5 - HYDRAULICS 5 21 3 1 22 8 4 12 20 10 20 12 14 15 14 13 16 19 6 18 9 17 1 23 2 7 5 1. Loctite #242 2. Primer #7471 3. Bolt 4. Tapered Bushing 5. Composite Bushing 6. 7. 8. 9. 10. Head Rod Barrel Ring Washer Piston 11. 12. 13. 14. 15. Not Used Lock Ring Wear Ring Backup Ring O-ring 16. 17. 18. 19. 20. O-ring Wiper Seal Backup Ring Seal 21. Counterbalance Valve 22. Counterbalance Valve 23. Bolt Figure 5-8.
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SECTION 5 - HYDRAULICS 4 4 7 1 2 23 17 18 22 17 8 3 12 21 10 14 11 5 19 1 20 23 13 16 15 6 4 4 1. 2. 3. 4. 5. 5-10 Loctite #242 Bolt Tapered Bushing Composite Bushing Head 6. 7. 8. 9. 10. Rod 11. Backup Ring 16. Seal Barrel 12. Backup Ring 17. Wear Ring Piston 13. O-ring 18. Cap Not Used 14. O-ring 19. Ring Washer Wear Ring 15. Wiper 20. Bolt Figure 5-9. Main Boom Lift Cylinder – JLG Lift – 21. Tube Spacer 22. Counterbalance Valve 23.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 3120772 O-ring O-ring Backup Ring Seal Wiper 6. 7. 8. 9. 10. O-ring 11. Setscrew 16. Valve Cartridge Seal 12. Setscrew 17. Bushing Wear Ring 13. Nylon Plug 18. Barrel Wear Ring 14. Plug 19. Rod Not Used 15. Plug 20. Piston Figure 5-10. Tower Boom Lift Cylinder – JLG Lift – 21. Head 22.
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SECTION 5 - HYDRAULICS 5 9 5 3 1 2 4 12 20 6 20 12 14 15 14 16 19 13 8 18 7 17 1 2 21 10 5 5 1. 2. 3. 4. 5. 6. Loctite #242 Locking Primer Bolt Tapered Bushing Composite Bushing Piston 7. 8. 9. 10. 11. Ring Washer Head Barrel Rod Not Used 12. 13. 14. 15. 16. Lock Ring Wear Ring Backup Ring O-ring O-ring 17. 18. 19. 20. 21. Wiper Seal Backup Ring Seal Bolt Figure 5-11.
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SECTION 5 - HYDRAULICS 5 5A 1 2 7 11 14 3 8 9 10 13 12 6 4 1. 2. 3. 4. 3120772 Locknut Piston Piston Seal O-ring 5. Barrel 6. Rod 7. Guide 8. O-ring Figure 5-12. 9. Backup Ring 10. Retaining Ring 11. Seal 12. Nut Steer Cylinder – JLG Lift – 13. Wiper 14.
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SECTION 5 - HYDRAULICS 29 28 27 12 6 30 10 31 22 7 16 25 13 31 5 16 15 18 19 18 14 26 21 20 32 17 9 24 23 8 11 1. 2. 3. 4. 5. 6. 7. Loctite #242 Not Used Locking Primer Loctite Bolt Bolt Tapered Bushing 8. 9. 10. 11. 12. 13. 14. Cap Head Barrel Rod O-ring Locknut Pad 15. 16. 17. 18. 19. 20. Piston Wear Ring Wear Ring Backup Ring O-ring O-ring 21. 22. 23. 24. 25. 26. Setscrew Bolt Wiper Seal Teflon Seal Tube Spacer 27. 28. 29. 30. 31. 32.
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SECTION 5 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove. Figure 5-15. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head. 4.
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SECTION 5 - HYDRAULICS Figure 5-18. Tapered Bushing Installation 12. Tighten the capscrews evenly and progressively in rotation to the specified torque value. (See Table 5-1, Cylinder Head and Tapered Bushing Torque Specifications.) 13. After the screws have been torqued, tap the bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4” in dia.) as follows; Figure 5-17. Piston Seal Kit Installation a. Place the brass shaft against the tapered bushing on the spaces between the capscrews. 8.
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SECTION 5 - HYDRAULICS IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD. Table 5-1. Cylinder Head and Tapered Bushing Torque Specifications Figure 5-20. Poly-Pak Piston Seal Installation Head Torque Value (Wet) Tapered Bushing Torque Value (Wet) Upper Lift Cylinder 44 ft.
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SECTION 5 - HYDRAULICS 5.5 CYLINDER REMOVAL AND INSTALLATION Upper (Main) Boom Lift Cylinder Installation NOTE: Coat I.D. of bushings with specified lubricant prior to installing pins. Upper (Main) Boom Lift Cylinder Removal 1. Install Lift Cylinder in place using suitable slings or supports, aligning attach pin mounting holes on upright. 1. Place the machine on a flat and level surface. Place the Upper Boom in a horizontal position. Place Tower halfway (approx. 37 degrees).
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SECTION 5 - HYDRAULICS 5. Remove boom prop and overhead crane. Take the lift cylinder through one complete cycle to assure correct functioning. Place boom in stowed position. Check hydraulic fluid and adjust accordingly. Upper Boom Telescope Cylinder Removal 1. Place machine on flat and level surface, with Upper Boom in the horizontal position. Extend Upper Boom until fly attach pin #1 is accessible on fly. 2. Support Upper Boom basket end with a prop. Support Upper Upright end with an overhead crane.
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SECTION 5 - HYDRAULICS Upper Boom Telescope Cylinder Installation 1. Attach a hydraulic power supply to the telescope cylinder ports. Using suitable supports or lifting devices at each end of the cylinder, extend the rod so that the cylinder pin attach holes are the same distance apart as the boom pin attach holes. 5.6 LOWER LIFT CYLINDER BLEEDING PROCEDURE NOTE: Bleeding procedure should only be necessary if rebuilding or replacing lift cylinder. 1.
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SECTION 5 - HYDRAULICS 5.7 PRESSURE SETTINGS Platform Level Up Relief Cold temperatures have a significant impact on pressure readings.JLG Industries Inc. recommends operating the machine until hydraulic system has warmed to normal operating temperatures prior to checking pressures. We also recommend using a calibrated gauge. Pressure readings are acceptable if within +/- 5% of specified pressures. Main Relief at Pump 1.
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SECTION 5 - HYDRAULICS Platform Level Down Relief Steer Relief 1. On machines prior to S/N 0300063313, install the pressure gauge at the “G” port on Main Control valve, activate and bottom out Platform Level Down. 1. With pressure gauge at “G” port on Steer/Brake valve, activate and bottom out Steer Left or Right. 2. Adjust Steer Relief to value in the pressure settings table.
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SECTION 5 - HYDRAULICS Table 5-4.
PAGE 120
SECTION 5 - HYDRAULICS STEER/BRAKE VALVE JIB VALVE OR JIB VALVE MANUAL DESCENT HANDLE MAIN CONTROL VALVE Figure 5-26.
PAGE 121
SECTION 5 - HYDRAULICS Figure 5-27.
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SECTION 5 - HYDRAULICS 20 11 2 19 3 16 12 4 24 8 18 1 17 10 13 14 5 15 21 9 1. 2. 3. 4. 5. 6. 7. Proportional Flow Regulator Bypass Unloading Lower Lift Upper Lift Swing Swing Restrictor Telescope Out 8. 9. 10. 11. 12. 13. 14. 7 Telescope In Platform Level Rotator Lower Lift Down Upper Lift Down Telescope Platform Level Back 6 15. 16. 17. 18. 19. 20. 21. Platform Level Forward Telescope Shuttle P.O. Check - Platform Level Piston Side P.O.
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SECTION 5 - HYDRAULICS Figure 5-29.
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SECTION 5 - HYDRAULICS NOTES: 5-28 – JLG Lift – 3120772
PAGE 125
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 ELECTRI- CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
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Figure 6-2.
PAGE 127
SECTION 6 - JLG CONTROL SYSTEM The upper lift, swing, and drive are controlled by individual joysticks, with steering being controlled by a rocker switch built into the top the drive joystick. To activate Drive, Lift, and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired. The motor controller will control current output, as programmed for smooth operation and maximum cycle time.
PAGE 128
SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: menu. In some cases, such as DRIVE, the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC. key.
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SECTION 6 - JLG CONTROL SYSTEM Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly: Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: MENU: ACCESS LEVEL 1 PERSONALITIES: DRIVE ACCEL 1.
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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 Machine Configuration Programming Information Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number NOTE: When configuring the E450, E400, or the E300 machine, the machine configuration must be completed before any personality settings can be changed.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit 5 (JIB) Number Description 0 No JIB installed. 1 JIB installed which has up and down movements only. Option 2 JIB installed which has up and down movements and side to side movements. Option 0 No ground alarm installed. 1 Travel alarm- Sounds when the drive function is active. Option 2 Descent Alarm- Sounds when either lift down is active.
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SECTION 6 - JLG CONTROL SYSTEM Machine Personality Settings NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-3. Personality Ranges/Defaults FUNCTION DRIVE LOWER LIFT UPPER LIFT 3120772 PERSONALITY RANGE DEFAULTS ACCELeration 0.5s to 5.0s 1.5 DECELeration 0.1s to 2.0s 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults FUNCTION SWING TELEscope BASKET LEVEL BASKET ROTATE 6-10 PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0s 2.0 DECELeration 0.0 to 3.0s 1.5 MINimum LEFT speed 0 to 10% 6 MAXimum LEFT speed 0 to 60% 33 CREEP maximum LEFT speed 0 to 35% 12 MINimum RIGHT speed 0 to 10% 6 MAXimum RIGHT speed 0 to 60% 33 CREEP maximum RIGHT speed 0 to 35% 12 ACCELeration 0.5 to 5.0 1.0 DECELeration 0.1 to 3.0 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults FUNCTION JIB JIB SWING STEER GROUND MODE PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0 1.5 DECELeration 0.5 to 3.0 0.
PAGE 136
SECTION 6 - JLG CONTROL SYSTEM Level Vehicle Description Help Descriptions and Fault Flash Codes Table 6-4. JLG Control System Flash Codes DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected.
PAGE 138
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes 2/2 Flash code 2/2 indicates problems with drive & steer selection. DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range, or the wiper is wire-off. DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FWS Drive was selected before and during footswitch closure. FWS INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected.
PAGE 139
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes 2/5 Flash code 2/5 indicates that a function is prevented due to a cutout. BOOM PREVENTED - DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive & boom operation. BOOM PREVENTED - FUNCTION CUTOUT ACTIVE A boom function is selected while function cutout is active and configured to cutout boom functions.
PAGE 140
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes 3/5 Flash code 3/5 indicates that there is a brake pressure problem. BRAKES DID NOT LOCK Brake pressure did not clear when the brake valve was deenergized. BRAKES DID NOT RELEASE No brake pressure was detected when running the pump motor and energizing the brake valve 4/2 Flash code 4/2 indicates that the controller is over temperature.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes 6/6 Flash code 6/6 indicates problems with the CANbus. 48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data, and the protection circuit which supplies the platform and ground modules has tripped. This is probably due to wiring problems at the platform or ground module.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Descriptions and Fault Flash Codes 9/9 Flash code 9/9 indicates problems with the controller. POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off. POWER MODULE FAILURE: HWFS CODE 2 The hardware fail-safe tests did not complete because traction point A is not safe, or the hardware fail-safe is permanently tripped.
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Figure 6-3.
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Figure 6-4.
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SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item is selected by pressing ENTER; pressing ESC steps back to the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow keys alter a value if allowed Table 6-6. Diagnostics - Menu Descriptions DRIVE DRIVE... Displays drive joystick direction & demand SPEED... Displays vehicle direction & speed POSITRAC...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostics - Menu Descriptions TILT... Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direction (pitch) The second value indicates tilt in the left/ right direction (roll) DATALOG MAX.TEMP... Displays maximum measured heat sink temp. MIN.TEMP... Displays minimum measured heat sink temp. MAX. BATTERY. Displays maximum measured battery voltage ON... Displays total controller on (EMS) time DRIVE...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Descriptions ACTIVATE TESTS YES:ENTER, NO:ESC RUN SYSTEM TEST 3120772 Not available once tests are activated ENTER activates system tests NOTE: cannot be done while controller is in use (footswitch closed) and for a short time afterwards ENTER starts system test Not available until tests are activated Displays messages while system test runs Some messages are prompts, requiring user intervention.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. System Test Messages RUNNING 6-24 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. Check all power wiring.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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. In platform mode, inputs are tested in the order: UL U, UL D, UL JOY., SWING L, SWING R, SWING JOY., LEVEL U, LEVEL D, PUMP POT.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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 6 - JLG CONTROL SYSTEM NOTES: 6-28 – JLG Lift – 3120772
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 7.
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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 the inside of the connector prior to assembly. This is most easily achieved by using a syringe. NOTE: Over a period of time, oxidation increases electrical resistance at the connection, eventually causing circuit failure. 2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11.
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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 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A B C C Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MAIN VALVE PLATFORM CONSOLE J1 J2 J4 J3 J5 J7 J8 J6 JIB VALVE J11 STEER / BRAKE VALVE JIB VALVE TO ANALYZER FOOT SWITCH PLATFORM WORK LIGHTS RECEPTACLE AT PLATFORM Figure 7-18.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS POSI-TRACK/ SPEED TILT MODULE SENSOR (LEFT BRAKE) SPEED SENSOR (RIGHT BRAKE) BATTERY CHARGER HORN TO GROUND CONTROL BOX COVER POWER MODULE (SHOWN HERE FOR CLARITY) CONTROL MODULE (SHOWN HERE FOR CLARITY) BEACON LIGHT GROUND CONTROL BOX TO BATT. B– TO BATTERY CHARGER CONTACTOR PLATE PUMP/ MOTOR BOOM LIMIT SWITCHES Figure 7-19.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870225 A Figure 7-21.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792521 B Figure 7-23.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-24.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792522 B 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 2792523 B Figure 7-27.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-20 – JLG Lift – 3120772
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3120772 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 +55 19 3295 1025 +55 19 3295 0407 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.