B S E N I S O 90 01 C er tificat e N o. 6 917 CORPORATE OFFICE EUROPEAN OFFICE AUSTRALIAN OFFICE JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417 JLG INDUSTRIES (EUROPE) Kilmartin Place, Tannochside Park, Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Fax: 01698 811055 JLG INDUSTRIES (AUSTRALIA) P.0. Box 972 11 Bolwarra Road Port MacQuarie N.S.W.
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.
INTRODUCTION REVISON LOG August 5, 1999 2-40 1-1 and 1-2 2-50 2-52 thru 2-54 1-1 3-1 3-5 3-16 A-2 - Original Issue - Updated 8-30-99 - Updated 10-7-99 - Updated 10-7-99 - Updated 10-7-99 - Updated 2-15-00 - Updated 2-15-00 - Updated 2-15-00 - Updated 2-15-00 – JLG Lift – 3120884
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-14. 2-15. 2-16. 2-17. 2-18. 2-19. 2-20. 2-21. 2-22. 2-23. 2-24. 2-25. 2-26. 2-27. 2-28. 2-29. 2-30. 2-32. 2-31. 2-33. 2-34. 2-35. 2-36. 2-37. 2-38. 2-39. 2-40. 2-41. 2-42. 2-43. 2-44. 2-45. 2-46. 2-47. 2-48. 2-49. ii TITLE PAGE NO. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES (continued) FIGURE NO. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. TITLE PAGE NO. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Platform Electrical Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS This Page Left Blank Intentionally.
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES 1.3 PERFORMANCE DATA Hydraulic Oil Tank Travel Speed 19 liters (5 gallons) 5.2 kph (3.2 mph) Generator Fuel Tank Gradeability 15.1 liters (4 gallons) 30% (16.7 degrees) Drive Axle Turning Radius (Inside) Torque Hubs - 0.5 liters (19 oz.) 0.61 m (2ft. 0 in.) Turning Radius (Curb to Curb) 1.2 COMPONENT DATA 3.15 m (10 ft. 4 in.
SECTION 1 - SPECIFICATIONS Ground Bearing Pressure 1.4 M45A, E45A - 6.2 Bar (95 psi) M45AJ, E45AJ - 7.6 Bar (110 psi) FUNCTION SPEEDS (M45A/E45A) Lift Up - 30-24 seconds Lift Down - 29-23 seconds Machine Height (stowed) Tower Lift Up - 33-27 seconds M45A, E45A - 1.99 m (6 ft. 6.25 in.) M45AJ, E45AJ - 2.0 m (6ft. 7 in.) Tower Lift Down - 26-22 seconds Telescope Out - 18-14 seconds Machine Length (stowed) Telescope In - 28-23 seconds M45A, E45A - 5.69 m (18 ft. 8.0 in.) M45AJ, E45AJ - 6.
SECTION 1 - SPECIFICATIONS 1.6 Lubrication Specifications TORQUE SPECIFICATIONS Table 1-3.Lubrication Specifications. Table 1-1.Torque Requirements Description Torque Value Interval Hours KEY SPECIFICATIONS Wheel Lugs 170 ft. lbs. (230 Nm) 150 MPG Swing Bearing (Dry) 220 ft. lbs. (298 Nm) 50/600* 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).
SECTION 1 - SPECIFICATIONS 1.8 PRESSURE SETTINGS 1.10 MAJOR COMPONENT WEIGHTS Table 1-6.Major Component Weights Main Valve Component LB. KG. Platform and Support 215 97.
SECTION 1 - SPECIFICATIONS 1.12 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to the left rear of frame, in front of left rear wheel. If the serial number plate is damaged or missing, the machine serial number is stamped on the top left side of the frame and the top left side of the turntable. In addition, the serial number is stamped on top of the end of the upper boom, mid boom, and lower boom at the left rear of the booms. Figure 1-1.
SECTION 1 - SPECIFICATIONS Figure 1-2.
SECTION 1 - SPECIFICATIONS Table 1-8. Lubrication Chart Components Number/Type Lube Points Interval Hours Capacity Lube 1 Grease Fitting or by brush A/R MPG X More frequent lubrication intervals may be required X More frequent lubrication intervals may be required.
Figure 1-3.
SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter. GENERAL This section provides information necessary to perform maintenance on the aerial platform.
SECTION 2 - PROCEDURES Bearings Hydraulic Lines and Electrical Wiring 1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing. 2. Discard bearings if the races and balls (or rollers) are pitted, scored or burned. Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit.
SECTION 2 - PROCEDURES 2.3 sesses the same antiwear and rust protection characteristics as mineral oils, but will not adversely affect ground water or the environment when spilled or leaked in small amounts. Mobil EAL224H has a viscosity of 34 cST at 40° C and a viscosity index of 213. The operating range of this oil is -18° C to +83° C. LUBRICATION INFORMATION Hydraulic System 1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.
SECTION 2 - PROCEDURES Lubrication Specifications 3. Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or ammonia) and wire brush. Replace cables and/or cable clamp bolts as required. Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose requirements.
Figure 2-1.
SECTION 2 - PROCEDURES NOTE: The engine will automatically shut down under the following conditions: 2. To charge the batteries, connect the charger to a 115 volt source with a 15 amp minimum capacity. 3. The Charger will shut off automatically when the batteries are fully charged. High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage Batteries fully charged 4. The charge cycle is complete when the ammeter reads 0 amps.
SECTION 2 - PROCEDURES Holding valves are used in the Lift circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or leak develop between the cylinder and its related control valve. 2.6 CYLINDER CHECKING PROCEDURES NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system operation is suspected. WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 2.
SECTION 2 - PROCEDURES 2. When working on the platform slave cylinder, stroke platform slave level cylinder forward until platform sits at a 45 degree angle. source. Adequately support the cylinder rod, if applicable. 3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings. 3. After completing the above, shut down hydraulic system and allow machine to sit for 10-15 minutes. This is done to relieve pressure in the hydraulic lines.
SECTION 2 - PROCEDURES 12. Remove the bushing from the piston. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 2-6. Tapered Bushing Removal 13. Screw the piston CCW, by hand, and remove the piston from cylinder rod.
SECTION 2 - PROCEDURES 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. 10. Inspect threaded portion of head for damage. Dress threads as necessary. 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. 11. Inspect seal and o-ring grooves in head for burrs and sharp edges.
SECTION 2 - PROCEDURES 3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head. 7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the solid seal.) NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal.(See magnified insert in Figure 2-11.
SECTION 2 - PROCEDURES 11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and into the tapped holes in the piston. b. Tap each space once; this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews. Figure 2-13. Seating the Tapered Bearing Figure 2-12. Tapered Bushing Installation 12. Tighten the capscrews evenly and progressively in rotation to the specified torque value.
SECTION 2 - PROCEDURES 17. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. Table 2-1.Cylinder Head and Tapered Bushing Torque Specifications Description Head Torque Value (Wet) Tapered Bushing Torque Value (Wet) E.A.R. Cylinder 30 ft. lbs (41 Nm) 5 ft. lbs. (7 Nm) Level Cylinder (M45AJ) 30 ft.
SECTION 2 - PROCEDURES 2.8 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. CYLINDER REMOVAL AND INSTALLATION 4. With function speed switch at its slowest setting, extend the cylinder rod until attach pin hole aligns with those in boom. Using a suitable drift, drive the cylinder rod attach pin #1 through the aligned holes. Secure the pin in place with pin retaining hardware. Upper (Main) Boom Lift Cylinder Removal 1.
SECTION 2 - PROCEDURES Mid Boom Lift Cylinder Installation. 4. Tag, disconnect and cap the lift cylinder hydraulic lines and ports. NOTE: Coat I.D. of bushings with specified lubricant prior to installing pins. 5. Remove the hardware securing the barrel end attach pin #6 to the boom. Using an appropriate brass drift, drive out the cylinder barrel pin #6. 1. With the booms positioned and supported, place cylinder in position and secure in place using slings. 2.
SECTION 2 - PROCEDURES 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. 9. Using another lifting device, support the rod end of the cylinder and remove the cylinder from the boom assembly. 10. Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area. Upper Boom Telescope Cylinder Installation 1.
SECTION 2 - PROCEDURES 2.9 WEAR PADS 2.10 BOOM MAINTENANCE 1. Shim up wear pads until snug to adjacent surface. Removal 2. Replace wear pads when worn to thickness shown below. 1. Remove the platform/support as follows: a. Disconnect electrical cable from control console. b. Using an overhead crane or suitable lifting device, strap support the platform/support. c. Remove hardware from pin #1. Using a suitable brass drift and hammer, remove pin #1 from the platform support. d.
SECTION 2 - PROCEDURES Figure 2-21.
SECTION 2 - PROCEDURES d. Remove hardware securing the lift cylinder pin #1. Using a suitable brass drift and hammer, remove pin #1 from the base boom. Disassembly Boom Sections 1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments. e. Remove hardware securing the master cylinder pin #2. Using a suitable brass drift and hammer, remove pin #2 from the base boom. 2. Using a portable power source, attach hose to telescope cylinder port block.
SECTION 2 - PROCEDURES 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. Inspection 1. Inspect boom pivot pin for wear, scoring or other damage, and for tapering or ovality. Replace pin as necessary. 8. Remove hardware securing the front cover on base boom section. 2. Inspect lift and master cylinder pins for wear, scoring or other damage, and for tapering or ovality. Ensure pin surfaces are protected prior to installation.
SECTION 2 - PROCEDURES 6. Using suitable lifting equipment, slide fly boom section out to gain access to telescope cylinder attach pin hole. Installation 1. Using suitable lifting equipment, position boom assembly on upright so that boom pivot holes in both boom and upright are aligned. 7. Measure the distance between the telescope cylinder port block attach point on base boom section and the attach point on fly boom section. 2.
SECTION 2 - PROCEDURES Figure 2-23.
SECTION 2 - PROCEDURES 4. Place two (2) 3/8"x16NC bolts in threaded holes in bottom of the actuator. Using a suitable bar, unscrew the end cap (5). Remove the end cap from the actuator housing (1). 6. Remove piston sleeve (3) from housing (1). Figure 2-26. Removing Sleeve from Housing 7. Remove all seals and bearings from grooves. Discard seals. Figure 2-24. Removing End Cap 5. Remove the shaft (2) from piston sleeve (3) and the actuator housing (1). Inspection 1. Clean all parts thoroughly. 2.
SECTION 2 - PROCEDURES Assembly 5. Install the shaft (2) into housing (1) by aligning the proper punched timing marks. NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. 1. Install new seal (7 and 6) on the piston sleeve (3). NOTE: Apply a coat of grease to the thrust ring before sliding onto the shaft. 2. Install new seal (13), thrust washer (16) and bearing (15) on shaft (2). NOTE: Apply a coat of grease to the thrust washer before sliding onto the end cap. 3.
SECTION 2 - PROCEDURES Figure 2-28.
SECTION 2 - PROCEDURES 2. Inspect articulating fly boom pivot attach points for scoring, tapering and ovality, or other damage. Replace pins as necessary. 2.13 ARTICULATING JIB BOOM Removal 3. Inspect inner diameter of articulating fly boom pivot bearings for scoring, distortion, wear, or other damage. Replace bearings as necessary. (See Section 2.7, Cylinder Repair For Bearing Replacement). 1. For platform/support removal see platform/support removal diagram. See Section 2.10, Boom Maintenance. 4.
SECTION 2 - PROCEDURES 7. Align the slave leveling cylinder with attach holes in articulating jib boom pivot weldment. Using a soft head mallet, install slave leveling cylinder pin #1 into articulating jib boom pivot weldment and secure with mounting hardware. head and hardened washer at the arrow indicated position. 2.14 SWING BEARING Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service.
SECTION 2 - PROCEDURES Figure 2-31. Swing Bearing Tolerance Boom Placement 4. If a difference less than 1.40 mm (0.057 in.) is determined, and any of the following conditions exist, the bearing should be removed. a. Metal particles in the grease. b. Increased drive power. c. Noise. d. Rough rotation. 5. If bearing inspection shows no defects, reassemble bearing and return to service. c. Attach suitable overhead lifting equipment to the base of turntable weldment. d.
SECTION 2 - PROCEDURES attach the outer race of the bearing to the frame. Discard the bolts. Use suitable lifting equipment to remove the bearing and rotation box assembly from the frame; move to a clean, suitably supported work area. g. Following the torque sequence diagram shown in Figure 2-33., tighten the bolts to an initial torque of 175 ft. lbs. (237 Nm). Then following the same sequence, tighten to a final torque of 240 ft. lbs. (326 Nm). h.
SECTION 2 - PROCEDURES 2. If tolerance exceeds .010", reduce end play to less than .005". Refer to Adjusting End Play. thicker shims and replacing with thinner shims, included in kit. 5. Replace end plate and torque bolts to 90 ft. lbs. (122 Nm). 6. Recheck end play. Fig 2 Adjusting End Play. Allowable Tolerance (.001 to .005) Adjusting End Play SHIMS 1. Remove end plate. END PLATE 2. Measure and record total thickness of existing shim pack. 3. Determine thickness of shim pack required to obtain .
SECTION 2 - PROCEDURES Figure 2-34.
SECTION 2 - PROCEDURES 2.15 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE 2.16 BOOM SYNCHRONIZING PROCEDURE NOTE: If the Lower Boom assembly does not fully lower: NOTE: Bleeding procedure should only be necessary if rebuilding or replacing lift cylinder. 1. Remove all personnel from the platform. 2. Pull the red knob located under the main control valve. 1. Check oil level in the hydraulic oil tank (all booms must be retracted). 3.
SECTION 2 - PROCEDURES Figure 2-35.
SECTION 2 - PROCEDURES NOTE: Disc (13 &11) and plate (14) must remain dry during installation. No oil residue must be allowed to contaminate disc surfaces. 2.18 DRIVE BRAKE - MICO Disassembly 7. Place a new friction disc (13) on shaft (10) until it contacts plate (14). Install stator disc (11). 1. Remove pressure plate (3) from cover (21) by removing cap screws (1) and washers (2). 8. Install new o-ring (5), new back-up ring (6), new oring (8) and new back-up ring (9) on piston (7).
SECTION 2 - PROCEDURES Figure 2-36.
SECTION 2 - PROCEDURES 2.19 PINS AND GAR-MAX BEARING REPAIR GUIDELINES 2.20 SPEED SENSOR ADJUSTMENT Filament wound bearings. 1. Pinned joints should be disassembled inspected if the following occurs: and a. Excessive sloppiness in joints. b. Noise originating from the joint during operation. 2. Filament wound bearings should be replaced if any of the following is observed: a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing. c.
SECTION 2 - PROCEDURES Figure 2-37.
SECTION 2 - PROCEDURES 2-38 – JLG Lift – 3120884 Figure 2-38.
3120884 – JLG Lift – 2-39 SECTION 2 - PROCEDURES Figure 2-39.
SECTION 2 - PROCEDURES Figure 2-40. Drive Components 2.21 FOOTSWITCH ADJUSTMENT 2.22 POSITRAC/TILT MODULE Adjust switch so that functions will operate when pedal is at center of travel. If switch operates within last 1/4 inch (6.35 mm) of travel, top or bottom, it should be adjusted. When installing a new positrac/tilt module, always ensure that it is calibrated using the JLG Control System analyzer before operating the machine. Refer to Section 2.24, JLG Control System Analyzer Kit Instructions.
SECTION 2 - PROCEDURES 4. Use Up/Down arrow keys to enter the following password "33271". Depress Enter. 5. Use the right arrow key to curse over to "LEVEL VEHICLE". Depress Enter. Depress Enter again. 2.23 PRESSURE SETTING PROCEDURES Main Relief 1. Install pressure gauge at port “G” on Steer/Brake valve. 6. Verify that the tilt reading is now "0.0; 0.0". TO ASSURE PROPER OPERATION, THE MACHINE MUST BE LEVEL WHEN INSTALLING AND CALIBRATING A NEW POSITRAC/TILT MODULE. 2.
SECTION 2 - PROCEDURES Platform Level Up Relief Table 2-4.Pressure Settings 1. With pressure gauge at “G” port on main valve, activate and bottom out Platform Level Up. Function PSI Bar Upper Lift Down Relief 550 38 Mid/Lower Lift Down Relief 1700 117 Telescope In Relief 2150 148 Platform Level Up Relief 2500 172 Platform Level Down Relief 1200 83 2. Adjust Platform Level Up Relief to value in the Pressure Settings chart. Platform Level Down Relief 1.
SECTION 2 - PROCEDURES Figure 2-43.
SECTION 2 - PROCEDURES Figure 2-44.
SECTION 2 - PROCEDURES 2.24 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Figure 2-45. Control Module Location MINIMUM DISTANCE OF 30.5 CM (12 INCHES) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. 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.
SECTION 2 - PROCEDURES 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.
SECTION 2 - PROCEDURES The top level menus are as follows: Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected 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.
SECTION 2 - PROCEDURES 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 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.
SECTION 2 - PROCEDURES Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE. ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
SECTION 2 - PROCEDURES NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Machine Personality Settings Table 2-5. Personality Ranges/Defaults FUNCTION DRIVE PERSONALITY RANGE DEFAULTS ACCELeration 0.5s to 5.0s 1.0 DECELeration 0.1s to 2.0s 0.
SECTION 2 - PROCEDURES Table 2-5. Personality Ranges/Defaults FUNCTION SWING TELEscope BASKET LEVEL BASKET ROTATE 3120884 PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0s 2.7 DECELeration 0.0 to 3.0s 1.8 MINimum LEFT speed 0 to 10% 1 MAXimum LEFT speed 0 to 60% 25 CREEP maximum LEFT speed 0 to 35% 15 MINimum RIGHT speed 0 to 10% 1 MAXimum RIGHT speed 0 to 60% 25 CREEP maximum RIGHT speed 0 to 35% 15 ACCELeration 0.5 to 5.0 1.0 DECELeration 0.1 to 3.0 0.
SECTION 2 - PROCEDURES Table 2-5. Personality Ranges/Defaults FUNCTION JIB STEER GROUND MODE PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0 1.5 DECELeration 0.5 to 3.0 0.
SECTION 2 - PROCEDURES 2. TILT SENSOR Table 2-6. Machine Setup Descriptions MODEL NUMBER... When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting Displays/adjusts machine model NOTE: all personalities reset to default when model number is altered TILT... Displays/adjusts tilt sensor function DRIVE CUTOUT... Displays/adjusts drive cutout switch presence/ function FUNCTION CUTOUT... Displays/adjusts function cutout switch presence/function JIB. . .
SECTION 2 - PROCEDURES 3= Motion Alarm - Sounds when any function is active (Option) Help Descriptions and Fault Flash Codes 7. PLATFORM ALARM Table 2-7. JLG Control System Flash Codes 0= Sounds continuously when above elevation and tilted only. 1= Sounds continuously when above elevation and tilted, and in conjunction with fault code flashes (Option) Code 8.
SECTION 2 - PROCEDURES Table 2-8. 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.
SECTION 2 - PROCEDURES Table 2-8. 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.
SECTION 2 - PROCEDURES Table 2-8. 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.
SECTION 2 - PROCEDURES Table 2-8. Help Descriptions and Fault Flash Codes 3/3 Flash code 3/3 indicates that a contactor coil is short-circuited. OVERLOADED VALVE SUPPLY-CHECK WIRING. There is a high current draw from the valve supply when no valve is energized; this is probably due to a wiring error at the ground module. SHORT-CIRCUIT FORWARD CONTACTOR COIL The forward contactor was not energized when required, due to coil overcurrent protection.
SECTION 2 - PROCEDURES Table 2-8. 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.
SECTION 2 - PROCEDURES Table 2-8. 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 failsafe tests did not complete because traction point A is not safe, or the hardware failsafe is permanently tripped.
3120884 – JLG Lift – 2-61 SECTION 2 - PROCEDURES Figure 2-46.
SECTION 2 - PROCEDURES 2-62 – JLG Lift – 3120884 Figure 2-47.
SECTION 2 - PROCEDURES 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 2-9. DIAGNOSTICS - Menu Descriptions DRIVE DRIVE . . . Displays drive joystick direction & demand SPEED . . . Displays vehicle direction & speed POSITRAC . . .
SECTION 2 - PROCEDURES Table 2-9. 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 heatsink temp. MIN.TEMP . . . Displays minimum measured heatsink temp. MAX . BATTERY . . Displays maximum measured battery voltage ON . . . Displays total controller on (EMS) time DRIVE . . .
SECTION 2 - PROCEDURES System Self Test up switch has been closed, it will move on to the next input, lower lift down LLD. 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. The system self test is utilized to locate typical problems.
SECTION 2 - PROCEDURES Table 2-11. System Test Messages RUNNING 2-66 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.
SECTION 2 - PROCEDURES Table 2-11. 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: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L, SWING R, SWING REST, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, TELE I, TELE O, BYPASS, STEER L, STEER R, STEER PROP, BRAKE NOTE: in platform mode, the footswitch must be closed.
SECTION 2 - PROCEDURES Table 2-11. 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.
SECTION 2 - PROCEDURES Table 2-11. 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.
SECTION 2 - PROCEDURES • Start Control Relay 2.25 GENERATOR NOTE: Throughout the Generator section, the abbreviations RBS and CTS are used. RBS stands for Rotary Battery System, which is the generator system. CTS stands for Call To Start, which is the electronic inputs which signal the generator to start and charge the batteries. The generator consists of a drive engine, controller, and related components.
SECTION 2 - PROCEDURES Figure 2-48.
SECTION 2 - PROCEDURES Timing Sequences 4. Time Delay Bypass (TDBP) • RBS Prestart Sequence Once the engine starts, TDBP must elapse before low oil pressure and underspeed shutdowns are activated. This allows the engine to come up to normal operating conditions before enabling these shutdowns are monitored. 1. Time Delay Engine Start (TDES) TDES is the period which the RBS waits to verify that the CTS is valid rather than a transient condition. 2. Time Delay Pre-Heat (TDPH) Table 2-13.
SECTION 2 - PROCEDURES To Connect the JLG Control System Analyzer to the Generator Alarms and Fault Flash Codes The JLG Control System Analyzer can be used to monitor generator settings and conditions. Connect the analyzer as follows: 1. Connect the four pin end of the cable supplied with the analyzer, to the connector behind the ground control module located on the left side of the machine next to the ground control station and connect the remaining end of the cable to the analyzer.
SECTION 2 - PROCEDURES 2-74 – JLG Lift – 3120884 Figure 2-49.
SECTION 2 - PROCEDURES Output Current and Voltage Settings • Overspeed If the engine speed exceeds the overspeed limit, the engine will stop immediately and an overspeed alarm will be indicated. • Underspeed Enabled once TDBP (time delay bypass) period has elapsed after engine startup. If the engine speed drops below the underspeed limit, the engine will stop immediately and an engine underspeed alarm will be indicated.
SECTION 2 - PROCEDURES The inspection and maintenance code numbers are as follows: 2.26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 1. Check for proper and secure installation. The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the "AREA" to be inspected, and the "INTERVAL" at which the inspection is to take place.
SECTION 2 - PROCEDURES Table 2-16.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY BOOM 1. Platform 1,4 2. Platform Gate 1,4 3. Platform Rotator 4. Footswitch 5. Controllers 1,11 6. Switches 1,11 7 Lift Up/Platform Down Disable Switch* 7. Placards and Decals 1,2 8. Control Tags 1,2 9. Valves 1,11 5,6 10. Carrier (Hoses and Cables) 1 4,8 11. Lockout Cylinders (If equipped) 1 5 12. Pins 8 13.
SECTION 2 - PROCEDURES Table 2-16.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY MONTHLY WEEKLY 3 MONTH 6 MONTH YEARLY TURNTABLE 1. Engine Oil (see mfg. manual) 3 5 2. Battery 3 5 3. Radiator 3 5 4. Air Cleaner 1 14 5. Exhaust System 1 1,5 6. Spark Arrester 1 1,5 7. Engine Mount 8. Ground Controls 1,2,11 9. Main Hydraulic Pump 1 5 10. Auxiliary Power Pump 1 5 11. Valves 1,11 5 12. Hydraulic Filters 14 5 13. Hydraulic Hoses 1 5 14.
SECTION 2 - PROCEDURES Table 2-16.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY MONTHLY WEEKLY 3 MONTH 6 MONTH YEARLY CHASSIS 1. Wheel and Tire Assembly 2. Drive Motors 1,5,6 3. Drive Torque Hubs** 1,5,6 4. Drive Brakes 1,5,6 5. Steer Cylinders 1 1,5,6,13 6. Steer Components 1 4,6 8 7. Lockout Cylinders (if equipped)* 1 5,13 8 8. Hydraulic Hoses 1 9. Placards and Decals 1,2 10. Wheel Bearings 11.
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SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information 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. 3.2 TROUBLESHOOTING.
SECTION 3 - TROUBLESHOOTING . Table 3-1.Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Automatic leveling inoperative. Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on slave cylinder or main lift cylinder. Clean, repair, or replace line or fitting. Worn seal(s) in slave level or main lift cylinder. Replace seal(s).
SECTION 3 - TROUBLESHOOTING Table 3-1.Platform Assembly - Troubleshooting TROUBLE 3120884 PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered. Check wiring/Run System Test. Personalities not set correctly Check settings.
SECTION 3 - TROUBLESHOOTING . Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature buildup. Flush system and change oil using recommended viscosity Moisture in oil. Flush system and change oil using recommended viscosity Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting. Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Restricted or broken supply line on valve bank or hydraulic pump. Clean or replace line. Directional valve not functioning properly. Repair or replace valve. Lift cylinder not functioning properly. Repair or replace cylinder Lift function not activated within 7 seconds after footswitch was depressed. Recycle footswitch. Load capacity exceeded (personnel or equipment on platform). Reduce load.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function Speed and Drive Speed does not operate below horizontal. Damaged wiring on level limit switch. Repair or replace wiring/Run System Test Creep Switch Open. Replace switch/Run System Test Machine Tilted Level machine. Speed Sensor Failure. Replace Sensor. LOWER LIFT FUNCTION. If the boom assembly does not fully lower. The Mid and Lower Booms are out of synchronization.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom extends and retracts erratically. Hydraulic system oil low. Replenish oil as necessary. Wear pads worn. Replace pads as required. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Directional valve not functioning properly. Repair or replace valve. Worn seals in telescope cylinder. Replace seals. Cylinder not functioning properly.
SECTION 3 - TROUBLESHOOTING Table 3-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction. 3-8 Hydraulic system oil low. Replenish oil as necessary. Lack of lubricant on swing gear or speed reducer pinion. Lubricate as required. (See Lubrication Chart.) Swing motor not functioning properly. Repair or replace swing control switch. Worn or broken teeth on swing gear or swing motor pinion. Replace gear(s) as required.
SECTION 3 - TROUBLESHOOTING . Table 3-3.Turntable Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVE. Valve Spool Sticking. Dirt in oil causing excessive temperature builtup. Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting.Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary. Return spring weak or broken.
SECTION 3 - TROUBLESHOOTING . Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY GENERATOR. Engine will not start. Enable switch is open. Actuate switch. Fuses open. Determine and correct cause; replace fuse. Ground EMS is open. Pull out EMS to activate. Defective starter motor. Replace starter motor. Damaged wiring in ignition circuit (broken wire on starter). Repair, replace wiring. Manual start switch not functioning properly. Replace switch/check wiring.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY FRONT FRAME AXLE AREA. One or both wheels will not steer. Steering link or tie rod broken or attaching hardware missing. Replace steering link, tie rod or hardware as necessary. Wheel hub or bearings damaged or not lubricated. Replace hub or bearings as necessary and repack bearings with approved grease. One or both front wheels will not rotate or rotate erratically. REAR FRAME AXLE AREA.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Joystick not functioning properly. Replace joystick/Run System Test. Charger plugged in. Check help message. Drive prevented. Check help message. Brake(s) not releasing. Determine cause and repair or replace. Hydraulic system oil low. Replenish oil as necessary. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Cutback - Tilted Check help message.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Valve not functioning properly. Repair or replace valve. Hydraulic pump not functioning properly. Repair or replace pump. Personality Settings Incorrect. Adjust settings. Steer cylinder not functioning properly. Repair or replace cylinder. Damaged wiring on control switch or solenoid valve. See proper wiring diagram/Run System Test. Solenoid valve not functioning properly.
SECTION 3 - TROUBLESHOOTING Table 3-4.Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Brake Drags or runs hot. Low actuation pressure. Place pressure gauge in bleed port & check pressure with system on. Bearing failure. Replace bearing. Stuck or clogged valve. Place pressure gauge in bleed port - check for adequate pressure. Replace defective line or component. Bad o-rings. Replace o-rings. Discs frozen. Replace disc stack. Brake will not release.
SECTION 3 - TROUBLESHOOTING . Table 3-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEMS - GENERAL. Hydraulic pump noisy. Air entering system through broken line or fitting. (Suction Side.) Repair or replace line or fitting. Air bubbles in oil. (Reservoir oil too low. Replenish oil as required. Suction hose squeezed shut. Determine cause and repair. Oil filter dirty. Replace hydraulic filter. Wrong type of hydraulic oil. Replace hydraulic oil.
SECTION 3 - TROUBLESHOOTING Table 3-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function sluggish during operation. Main relief valve set too low. Reset valve as required. Pump section not delivering sufficient oil. Repair or replace pump section or pump. Main relief valve stuck in open position. Clean, repair, or replace valve. (Check system oil for contamination.) Oil viscosity too low. Drain system and replace with recommended oil. (Refer to Hydraulic Oils.
SECTION 3 - TROUBLESHOOTING . Table 3-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS. No power to platform controls. 15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary. Contact block in footswitch malfunctioning. Repair, replace or adjust contact block as required. Faulty power circuit wiring. Check wiring continuity.
SECTION 3 - TROUBLESHOOTING Table 3-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hourmeter inoperative. Damaged wiring in hourmeter circuit. Repair or replace wiring. Inoperative hourmeter. Replace hourmeter. Platform alarm inoperative. Check platform alarm/Run System Test. Defective bulb in tilt light. Replace bulb. Platform alarm circuit.
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SECTION 3 - TROUBLESHOOTING Figure 3-1.
SECTION 3 - TROUBLESHOOTING Figure 3-2.
SECTION 3 - TROUBLESHOOTING Figure 3-3.
SECTION 3 - TROUBLESHOOTING 1870072D Figure 3-4.
SECTION 3 - TROUBLESHOOTING 1870072D Figure 3-5.
SECTION 3 - TROUBLESHOOTING 1870072D Figure 3-6.
SECTION 3 - TROUBLESHOOTING 1870072D Figure 3-7.
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SECTION 3 - TROUBLESHOOTING Figure 3-8.
SECTION 3 - TROUBLESHOOTING 2792337C Figure 3-9.
SECTION 3 - TROUBLESHOOTING 2792337A Figure 3-10.
SECTION 3 - TROUBLESHOOTING 2792337C Figure 3-11.
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Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
