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Service and Maintenance Manual

Model

E400A/AJP

E400A/AJPnarrow

M400A/AJP

M400A/AJPnarrow

P/N - 3121827

March 20, 2014

Summary of content (258 pages)

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Service and Maintenance Manual Model E400A/AJP E400A/AJPnarrow M400A/AJP M400A/AJPnarrow P/N - 3121827 March 20, 2014
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised A-2 - August 15, 2000 - October 1, 2001 - December 18, 2001 - April 11, 2002 - May 24, 2004 - September 17, 2007 - January 21, 2008 - January 27, 2009 - January 7, 2013 - April 26, 2013 - October 24, 2013 - March 20, 2014 – JLG Lift – 3121827
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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. 2.4 2.5 2.6 TITLE PAGE NO. Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.8 3.9 3.10 3.12 3.13 3121827 TITLE PAGE NO. Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 3.14 TITLE PAGE NO. Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Alternator Output Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 RBS Engine/Generator Controller . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 4.12 4.13 TITLE PAGE NO. Helac Rotary actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Tools Required for Assembly/Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Disassembly. . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM 6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Using the Analyzer. . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 2-1. 3-3. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 3121827 TITLE PAGE NO. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 4-9. 4-10. 4-11. 4-12. 4-13. 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. 6-1. 6-2. 6-3. 6-4. 6-5. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. viii TITLE PAGE NO. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 3121827 TITLE PAGE NO. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 DT/DTP Contact Installation . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 2-1 2-2 2-3 3-1 3-2 3-3 3-11 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 4-1 4-1 5-1 5-2 5-3 5-4 5-5 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 7-1 7-2 7-3 7-4 7-5 7-6 x TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 1.5 OPERATING SPECIFICATIONS Table 1-1. Operating Specifications Maximum Work Load (Capacity) Unrestricted: Table 1-5. Hydraulic Pump/Electric Motor Assembly 500 lb. (230 kg) 30% Maximum Travel Grade (Gradeablility 5° Maximum Travel Grade (Side Slope) Machine Weight (GVW) E400Anarrow M400Anarrow E400AJP M400AJP E400AJPnarrow M400AJPnarrow 13100 lbs. (5942 kg) 13300 lbs. (6033 kg) 13700 lbs. (6214 kg) 13930 lbs. (6318 kg) 14900 lbs.
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SECTION 1 - SPECIFICATIONS 1.8 DIMENSIONAL DATA 1.9 FUNCTION SPEEDS Table 1-9. Function Speeds Table 1-8. Dimensional Data Machine Height (stowed) E/M400AJP E/M400AJPnarrow E/M 400A E/M 400Anarrow Machine Width E/M 400A E/M 400Anarrow E/M400AJP E/M400AJPnarrow Function 6 ft. 7 in. (2.0 m) 6 ft. 5.75 in. (1.31m) 6 ft. 7 in. (2.0 m) 6 ft. 5.75 in. (1.97 m) 5 ft. 9 in. (1.75 m) 4 ft. 11 in. (1.50 m) 5 ft. 9 in. (1.75 m.) 4 ft. 11 in. (1.49 m.
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SECTION 1 - SPECIFICATIONS Machine Orientation When Doing Function Tests 8. LOWER LIFT: Upper boom horizontal, telescoped in. Lower lift up, record time. Lower lift down, record time. 1. LIFT: Boom retracted, telescope retracted. Lift up, record time. Lift down, record time. 2. SWING: Boom at full elevation, telescope retracted. Swing the turntable to the end stop. Swing the opposite direction. Record time. Swing the other direction, record time. 9. JIB SWING: Platform level and centered with the boom.
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SECTION 1 - SPECIFICATIONS 1.11 CYLINDER SPECIFICATIONS 1.12 MAJOR COMPONENT WEIGHTS NOTE: All dimensions are given in inches (in.), with the metric equivalent, millimeters (mm), given in parentheses. Table 1-11. Cylinder Specifications Cylinder Table 1-12.Major Component Weights Component LB. KG. Platform and Support 215 97.5 Upper Boom Complete 810 367 Mid Boom Complete 550 249 Lower Boom Complete 550 249 Bore Stroke Rod Dia. 3.00 (76.2) 28.3125 (719.1) 1.50 (38.
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SECTION 1 - SPECIFICATIONS 1.13 CRITICAL STABILITY WEIGHTS Table 1-15. Pressure Settings - S/N 0300062642 to Present Table 1-13.
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SECTION 1 - SPECIFICATIONS 1.15 SERIAL NUMBER LOCATIONS Lubrication Specifications 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.
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SECTION 1 - SPECIFICATIONS Figure 1-2.
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SECTION 1 - SPECIFICATIONS 1.17 OPERATOR MAINTENANCE & LUBRICATION NOTE: 2. Swing Bearing/Worm Gear Teeth The following numbers correspond to those in Figure 1-2., Operator Maintenance & Lubrication Diagram. Table 1-19. Lubrication Specifications. KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).
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SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 6. Wheel Bearings Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - Under certain conditions, it may be necessary to replace the hydraulic filter on a more frequent basis. A common symptom of a dirty filter is sluggishness experienced in hydraulic functions. 7.
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SECTION 1 - SPECIFICATIONS 9. Engine Lube Point(s) - Fill Cap Capacity - Refer to Engine Manual Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
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SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
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SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121827
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
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SECTION 2 - GENERAL fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles. 3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil. 4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
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SECTION 2 - GENERAL 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES 2.6 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. Bearings that have moved or spun in their housing. d.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE SAE 20 ENGINE SPECIFICATIONS SAE 30 SAE 10W-30 NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) 60 F(16 C) 50 F(10 C) 40 SAE 10 30 ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121827
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.
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SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence: 5. Check the unit for end play by moving the hub up & down parallel along the centerline of the spindle. If you can feel excessive end play (over the 0.010" [0.25 mm] specification), recheck the nut to see what is causing the excessive end play. Keep in mind that there can be some movement and still be within the 0.010" (0.25 mm) maximum specification.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dust Cap Cotter Pin Spindle Nut Spindle Washer Stud Nut Bearing Cone Hub Bearing Cone Seal Spindle Figure 3-3.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB (PART NO. 2780236) 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. A shaft seal protects the unit against contamination.
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SECTION 3 - CHASSIS & TURNTABLE Disassembly 1. Loosen and remove hex head bolts (53) to remove cover (51). Assembly of first stage planetary assembly (7) 1. Pre-freeze planet pins (5) and install into planet carrier (7). 2. Remove shaft rod (56) and “o” ring (54). 2. Install planet carrier (7) together with planet pins (5) on sun gear (3), and install snap ring (16). 3. Remove sleeve (52). Disassembly of the first stage planetary assembly (7) 3.
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SECTION 3 - CHASSIS & TURNTABLE Final Assembly Maintenance Daily: - Check for oil leakage 1. Install thrust washer (29) in spindle (60). 2. Install “o” ring (19) into groove of support ring (6). 3. Install planet gears (1) onto planet pins which are part of spindle (60). Weekly: - Check oil level Monthly: - Check mounting bolt torque Oil Change Interval-Gear Drive 4. Install snap rings (15) on planet pins of spindle (60) in order to fix the planet gears (1). 1.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Planet Gear Planet Gear Sun Gear Shaft Nut Planet Bolt Support Ring Planet Carrier Cover (Not Used) Roller Bearing Roller Bearing Tapered Roller Bearing (Not Used) Retaining Ring 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 29. 30. Retaining Ring Retaining Ring Support Disc (Not Used) O Ring Ring Seal Screw Plug Seal Ring Bolt Ball Expander thru 28. (Not Used) Washer Ring Gear 31. 33. 34. 35. 43. 44. 45. 49. 50. 51. 52.
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SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover (21). Disassembly 1. Remove pressure plate (3) from cover (21) by removing the capscrews (1) and washers (2). NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. This should be five red springs evenly spaced. 5. Install dowel pins (20), spring retainer (16) and springs (5) in cover plate (21).
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SECTION 3 - CHASSIS & TURNTABLE 23 22 NOTE: The speed sensor port in the cover (21) should be 180° from the brake release port in the pressure plate (3). 19 21 18 17 16 20 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 23 1. 2. 3. 4. 5. 6. Capscrew Washer Pressure Plate Case Seal O-ring Backup Ring 7. 8. 9. 10. 11. 12. Piston O-ring Backup Ring Shaft Stator Disc Sensor Ring 13. 14. 15. 16. 17. 18. Rotor Disc Plate Spring Spring Retainer Retaining Ring Bearing 19. 20. 21. 22. 23.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive Brake Diagnosis Problem Brake slips Brake drags or runs hot Brake will not release 3-10 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 Adjustment Procedure 1. Back off the locking nut and o-ring. 2. Thread the sensor in until it bottoms out (don’t use excessive force). 3. Back-off 1-2 turns and align the notch with the axis of the brake. Refer to Figure 3-3., Speed Sensor Orientation. 4. Use a 1/2” wrench to hold the sensor and a 11/16” wrench to snug the lock nut to the brake. For proper drive operation, the speed sensors must be properly installed and adjusted.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-3.
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Figure 3-4.
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Figure 3-5.
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3121827 The drive system should show 48 volts with the main contactor closed and 35 volts with the main contactor open. These voltage checks should be performed with the machine powered up and the main contactor open. Figure 3-6. Voltage Checks Should read 0-7 Volts. Anything over 7 volts should flash Error Code 7-7, Open Pump Circuit. If the voltage is high, check for corrosion, a dirty pump motor, or bad brushes.
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SECTION 3 - CHASSIS & TURNTABLE Speed Sensor Installation Verification 3. Power up the machine in platform mode and plug in the Analyzer in the platform. The motor controller averages the readings from the right and left speed sensors and therefor, it can be difficult to detect if the speed sensors are adjusted properly. When the positrac keeps coming in and out while on level surfaces, this is a sure indication that one of the speed sensors is not adjusted properly.
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SECTION 3 - CHASSIS & TURNTABLE 18. While watching the analyzer display, select drive forward. Be ready to remove your foot from the foot switch if the machine lunges forward. 19. The analyzer display should read the following if the left speed sensor is adjusted properly: “SPEED 20% FWD”. 20. If the left speed sensor is adjusted improperly, the analyzer will display “SPEED 20% REV”, and the machine will lunge forward. 21.
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Figure 3-7.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Drive Components 3.6 POSITRAC/TILT MODULE 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 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. 5. Use the right arrow key to curse over to “LEVEL VEHICLE”.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-9.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING MOTOR - S/N 0300135649 TO PRESENT Figure 3-10. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Swing Motor Troubleshooting Trouble Oil Leakage Significant loss of speed under load Cause 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit. 3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion.
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SECTION 3 - CHASSIS & TURNTABLE 20 18 8 25 16 8C 8E 15 14 19 14 8B 13 4 8A 8D 17 12 4 10 9 4 8 4 7 5 4 3 6 4 2 1 1. 2. 3. 4. 5. Bolt End Cover Seal Ring Seal Ring Commutator 6. Commutator Ring 7. Manifold 8. Rotor Set 8A. Rotor 8B. Stator Half 8C. Stator Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 11. Thrust Bearing 12. 13. 14. 15. 16. Coupling Shaft Inner Bushing Thrust Washer Thrust Bearing Seal 17. 18. 19. 20. 21.
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SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its components read this entire section. It provides important information on parts and procedures you will need to know to service the motor. 1. Place the motor in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port ORings if applicable.
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SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. 3. Remove the special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.
PAGE 68
SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set. 8. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling.
PAGE 69
SECTION 3 - CHASSIS & TURNTABLE 9. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane to stator contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor and wearplate.
PAGE 70
SECTION 3 - CHASSIS & TURNTABLE 12. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. keyway. Replace coupling shaft if any of these conditions exist. 13. Remove coupling shaft (12), by pushing on the output end of shaft.
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SECTION 3 - CHASSIS & TURNTABLE 15. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 18. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly. 16.
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SECTION 3 - CHASSIS & TURNTABLE replaced. If the housing has passed this inspection the disassembly of the motor is completed. NOTE: The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings. 20.
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SECTION 3 - CHASSIS & TURNTABLE SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.
PAGE 74
SECTION 3 - CHASSIS & TURNTABLE 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the motor. 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. NOTE: The motor requires one thrust washer (14) with thrust bearing (15).
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SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15). THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE.
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SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link. NOTE: If necessary, go to the appropriate, "Rotor Set Component Assembly Procedure.
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SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. 18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 17.
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SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 25-30 ft. lbs. (34-41 N m). NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.
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SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the following procedures. 1. Place stator onto wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure the seal ring is in place.
PAGE 80
SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction 8. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures. 9.
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SECTION 3 - CHASSIS & TURNTABLE 3.8 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 1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Mid/Lower Boom stowed, (See Figure 3-13.), using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. (See Figure 3-14. Figure 3-13. Swing Bearing Tolerance Boom Placement 2.
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SECTION 3 - CHASSIS & TURNTABLE f. Carefully place the turntable on a suitably supported trestle. g. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use suitable lifting equipment to remove the bearing and rotation box assembly from the frame; move to a clean, suitably supported work area. h.
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SECTION 3 - CHASSIS & TURNTABLE IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE. g. Following the torque sequence diagram shown in Figure 3-15., tighten the bolts to an initial torque of 130 ft. lbs. (175 Nm). Then following the same sequence, tighten to a final torque of 190 ft. lbs. (260 Nm). h. Remove lifting equipment from bearing. Figure 3-15.
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SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Adjusting End Play Install bolts with Loctite - 190 ft. lbs. (260 Nm). 1. Remove end plate. Checking Worm Gear End Play 2. Measure and record total thickness of existing shim pack. NOTE: JLG Industries requires that a annual inspection be performed on the worm gear end play. 3. Determine thickness of shim pack required to obtain 0.001" - 0.005" end play. 1.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-16.
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SECTION 3 - CHASSIS & TURNTABLE 3.9 BATTERY MAINTENANCE AND CHARGING Charging Sequence of Remote LED Card 1. Plug in charger. Battery Maintenance, Quarterly 2. All three LED’s (light emitting diode) flash three times. 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. WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-18.
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SECTION 3 - CHASSIS & TURNTABLE Battery Charging (On Board Charger) 1. For maximum battery life: a. Avoid completely discharging the batteries. b. Fully charge the batteries each day the machine is used. c. Charge the batteries at available times between charging. d. Be sure the battery fluid covers the battery plates before charging, but to avoid overflow, do not top off the fluid level until charging.
PAGE 90
Figure 3-20.
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SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY CHARGER (S/N 0300059350 TO PRESENT) 4. If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. Maintenance Instructions 1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.
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SECTION 3 - CHASSIS & TURNTABLE 1 2 4 3 1. AC Voltage - Input Cable 2. Charger Interlock Cable 3. DC Power Cable to Batteries 4. LED Indicator Cable Figure 3-21.
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SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger. 1. Check the connections to AC power. Check for AC voltage between 90 and 260 VAC at the charger. 2. If the AC voltage is verified to be correct at the connection to the charger, and the charger still displays no lights at all, return the charger for service.
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SECTION 3 - CHASSIS & TURNTABLE [5 Flashes] - Over Temperature This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge time will be extended significantly. 1. This fault indication will not clear automatically, but the charger will restart charging automatically when the temperature drops. The fault indicaiton must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.
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SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger Algorithm 3. Remove the AC power from the charger and reconnect the charger’s positive connector to the battery. It is recommended to check a newly changed algorithm by repeating the above steps 1 and 3. The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Algorithms. NOTE: Contact JLG if your specific battery model is not listed. Table 3-4.
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SECTION 3 - CHASSIS & TURNTABLE 3.12 GENERATOR (PRIOR TO S/N 88539) 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. Alternator The alternator is a brushless, DC output alternator.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-22.
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SECTION 3 - CHASSIS & TURNTABLE 2. Time Delay Pre-Heat (TDPH) 6. Time Delay Bypass (TDBP) TDPH, if enabled, occurs after TDES has elapsed and the engine temperature is below the factory set engine preheat temperature setting. The engine preheater will be energized for the factory set preheat delay period. Once the engine starts, TDBP must elapse before low oil pressure and underspeed shutdowns are activated.
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SECTION 3 - CHASSIS & TURNTABLE To Connect the JLG Control System Analyzer to the Generator 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.
PAGE 100
Figure 3-23.
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SECTION 3 - CHASSIS & TURNTABLE • Over Speed • Loss Of Voltage Sense 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.
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SECTION 3 - CHASSIS & TURNTABLE Priming the Fuel Line 5. Clean up any spilled fuel and try to start the generator engine. The following procedure is for re-priming the fuel line on the generator engine in the event fuel system components have been replaced or the unit has been run dry of fuel. 6. If the engine still doesn’t start, remove the steel line from the fuel injector pump. 7. Once fuel starts to flow, re-connect the fuel line to the fuel injector pump. 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.13 GENERATOR (S/N 88539 TO PRESENT) Dynamo and Dynamo Voltage Regulator NOTE: Throughout the Generator section, the abbreviation RBS is used. RBS stands for Rotary Battery System, which is the generator system. The engine-driven generator is designed to produce a DC output directly without the need of a separate rectifier. Included in the RBS unit is the engine, generator, engine/ generator controller, harness and related components.
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SECTION 3 - CHASSIS & TURNTABLE 7 13 10 12 11 7 8 9 1. 2. 3. 4. 5. 6. 7. Glow Plug Relay Fuel Control Relay Start Control Relay Fuel Solenoid Fuel Pump Low Oil Pressure Switch Glow Plug 8. 9. 10. 11. 12. 13. 14. Temperature Sensor Voltage Regulator Alternator Starter Starter Solenoid Oil Filter Fuel Filter 11 12 10 14 13 3 5 4 1 2 6 Figure 3-24.
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SECTION 3 - CHASSIS & TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead-acid start battery (not supplied with the system), which provides starting power and power for the RBS controls. This battery is charged by the engine dynamo and dynamo regulator when the engine is running. Engine Starter The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid.
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SECTION 3 - CHASSIS & TURNTABLE Fuel Control Relay Glow Plug Control Relay The fuel control relay energizes the hold coil of the fuel solenoid. The glow plug control relay energizes the glow plug. It is energized by the engine/generator controller, pin J2-27. The fuel control relay is energized by the engine/ generator controller from pin J2-3. The glow plug control relay is located on the fuel solenoid bracket on the right side of the engine.
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SECTION 3 - CHASSIS & TURNTABLE Fuel Pump Engine Low Oil Pressure Switch The fuel pump runs in parallel with the fuel solenoid hold coil which is run by the fuel control relay. The pump runs whenever the engine runs, and keeps the fuel filter filled. Excess fuel flows through the return line back to the fuel tank. The fuel pump is located on the right side of the engine. Fuel Solenoid Engine Oil Temperature Sensor The fuel solenoid actuates the run/stop lever of the engine.
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SECTION 3 - CHASSIS & TURNTABLE engine. The signal is also used in determining if the air glow plug should be energized. The engine oil temperature sensor is connected to the engine/generator controller at pins J2-8 and J2-19. The engine oil temperature sensor is located on the left side of the engine. RBS Engine/Generator Controller The control system enclosure houses the RBS engine/ generator controller, which performs all control tasks associated with the RBS.
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SECTION 3 - CHASSIS & TURNTABLE Warnings and Safety Precautions System Settings CALL TO START SETTINGS THE RBS MAY START WITHOUT WARNING. MORE THAN ONE LIVE CIRCUIT IS USED INSIDE THE RBS CONTROL PANEL. EXERCISE CAUTION WHEN THE CONTROL PANEL IS OPEN, EVEN WHEN THE RBS IS NOT RUNNING. System Controls Low battery voltage call to start level 48.0 VDC Low battery voltage remove call to start level 54.
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SECTION 3 - CHASSIS & TURNTABLE RBS Start Call to start RBS shutdown Manual 48V DC applied to the input Call to start removed Automatic 1 Low battery voltage (below 48VDC) 2 Low engine temperature (below 5°C) RBS waits to verify that call to start is valid (not a transient condition). Preheat delay - if engine temperature is below 32°F (0°C) Crank time (Rest time) RBS will crank and rest until engine starts, or Overcrank fault is indicated after 3 failed crank cycles.
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SECTION 3 - CHASSIS & TURNTABLE RBS Alarms and Flash Codes In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. Table 3-10. RBS Alarms and Flash Codes Flash Code Problem RBS Condition 1-1 Low Oil Pressure 1 Below 7psi Shutdown 1-2 High Engine Temp.
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SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-11. Troubleshooting Flash Code - Problem Solution Unit Off / Disabled (engine will not Check position of selector switch. crank) Verify that the inhibit run is released. Check the warning LED. Remedy fault if present and restart the RBS. Check the start battery voltage. Check control fuse. Check for loose wiring or connection. 1-1 Low Oil Pressure Check oil level. Check oil supply lines. Refer to Kubota Workshop manual WSM OC60/80/95.
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SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Troubleshooting Flash Code 2-2 Problem Engine Starting System fault Solution Check engine start battery charging system for current output. Check for failed engine start battery. 2-4 Loss Of Voltage Sense APU Engine Start Battery Boosting Always connect the POSITIVE (+) of the booster battery to the POSITIVE (+) of the APU start battery, and the NEGATIVE (-) of the booster battery to the ground of the engine block.
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SECTION 3 - CHASSIS & TURNTABLE 3.14 SUPPLEMENTARY FUSE FOR APU The purpose of this section is to describe the procedure to add a supplementary fuse for the Engine Generator Controller for the APU. 2. Find where the harness attaches to the rear cover of the generator and the connection point for the new inline fuse.
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SECTION 3 - CHASSIS & TURNTABLE conductors of the harness. 6. Re-install the harness with the new fuse in place. 7. Reconnect the lift and APU start battery. The APU is now ready for use. 5. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the conductors that lead to the new inline fuse holder. Use insulated butt splice connectors for these conductors.
PAGE 116
SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-74 – JLG Lift – 3121827
PAGE 117
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE e. Remove hardware securing the master cylinder pin #2. Using a suitable brass drift and hammer, remove pin #2 from the base boom. Removal f. Remove hardware securing the base boom pin #3. Using a suitable brass drift and hammer, remove pin #3 from the upright. 1. Remove the platform/support as follows: a. Disconnect electrical cable from control console. g.
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SECTION 4 - BOOM & PLATFORM 4. Remove hardware securing telescope cylinder #1 to the fly boom section, then remove pin from fly. Inspection 1. Inspect boom pivot pin for wear, scoring or other damage, and for tapering or ovality. Replace pin as necessary. 5. Remove hardware securing telescope cylinder to the 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.
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SECTION 4 - BOOM & PLATFORM 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.
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SECTION 4 - BOOM & PLATFORM 4.2 UPPER (MAIN) BOOM LIFT CYLINDER 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. Removal 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. 1. Place the machine on a flat and level surface.
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SECTION 4 - BOOM & PLATFORM Installation 3. Remove the hardware securing the cylinder rod attach pin #5 to the boom. Using an appropriate brass drift, drive out the cylinder rod attach pin #5. NOTE: Coat I.D. of bushings with specified lubricant prior to installing pins. 1. With the booms positioned and supported, place cylinder in position and secure in place using slings. 2. Install the cylinder barrel pin #4, being sure to align the hole in the cylinder barrel pin with the retaining pin screw hole.
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SECTION 4 - BOOM & PLATFORM 4.5 UPPER BOOM TELESCOPE CYLINDER 6. Remove the four (4) bolts securing the telescope cylinder barrel end to the base boom. 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. NOTE: Care should be taken when removing the telescope cylinder, do not leave cylinder rest on power track which could cause damage to power track. 7.
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SECTION 4 - BOOM & PLATFORM 6. Carefully install the telescope cylinder barrel end to base, securing cylinder to the base boom with four (4) bolts and hardware. 7. Remove applicable hydraulic line and port caps and correctly connect the hydraulic lines to the telescope cylinder. Ensure all hoses are correctly routed. 4.7 WEAR PADS 1. Shim up wear pads until snug to adjacent surface. 2. Replace wear pads when worn to thickness shown below . 8. Remove boom prop and overhead crane.
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SECTION 4 - BOOM & PLATFORM 4.8 BOOM SYNCHRONIZING PROCEDURE Disassembly 1. Remove mounting hardware from articulating jib boom pivot pins #3 and #4. Using a suitable brass drift and hammer, remove the pins from articulating jib boom pivot weldment. NOTE: If the Lower Boom assembly does not fully lower: 1. Remove all personnel from the platform. 2. Pull the red knob located under the main control valve. 2. Remove mounting hardware from rotator support and jib lift cylinder pins #5 and #6.
PAGE 125
SECTION 4 - BOOM & PLATFORM Figure 4-8.
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SECTION 4 - BOOM & PLATFORM Assembly 5. Align articulating jib boom pivot weldment with attach holes in fly boom assembly. Using a soft head mallet, install pivot pin #2 into fly boom assembly and secure with mounting hardware. NOTE: For location of components See Section 4-7., Location of Components - Articulating Jib Boom. 6. Align the slave leveling cylinder with attach holes in articulating jib boom pivot weldment.
PAGE 127
SECTION 4 - BOOM & PLATFORM Figure 4-10.
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SECTION 4 - BOOM & PLATFORM 4.12 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 4 - BOOM & PLATFORM 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 4-11.
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SECTION 4 - BOOM & PLATFORM 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 4-12.
PAGE 131
SECTION 4 - BOOM & PLATFORM 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. Remove the cap screws (113) over end cap lock pins (109). 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.
PAGE 132
SECTION 4 - BOOM & PLATFORM 4. Install the end cap (4) removal tools provided with the Helac seal kit. 5. Using a metal bar, or something similar, un-screw the end cap (4) by turning it counter clock-wise. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. 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 4 - BOOM & PLATFORM 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 4 - BOOM & PLATFORM 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). 20. Remove the piston I.D. seal (200). You may now proceed to the inspection process. 17.
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SECTION 4 - BOOM & PLATFORM 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. Install the thrust washer (304) onto shaft (2) and end cap (4).
PAGE 136
SECTION 4 - BOOM & PLATFORM 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 4 - BOOM & PLATFORM 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. 12.
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SECTION 4 - BOOM & PLATFORM 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 4 - BOOM & PLATFORM Installing Counterbalance Valve Testing the Actuator Refer to Figure 4-13., Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old Loctite. 2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing. 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve.
PAGE 140
SECTION 4 - BOOM & PLATFORM Figure 4-13.
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SECTION 4 - BOOM & PLATFORM Installation and Bleeding After installation of the actuator on the equipment, it is important that all safety devices such as tie rods or safety cables are properly reattached. To purge air from the hydraulic lines, connect them together to create a closed loop and pump hydraulic fluid through them. Review the hydraulic schematic to determine which hydraulic lines to connect.
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SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem 1. Shaft rotates slowly or not at all Cause Solution a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator. b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic lines for restrictions and leaks. c. Control or counterbalance valve has internal leak c.
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SECTION 4 - BOOM & PLATFORM 4.13 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the powertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be different. 1. Clamp the bar and poly roller tightly so they do not spin when removing the screw. With a small ¼” ratchet and a t-20 torx bit, remove the 8-32 x 0.500 screw from one side.
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SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together must be removed. Use a right-angle pneumatic die grinder with a ¼” ball double cut bur attachment. 4. insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled over part of the rivet falls off. Repeat this step for all the rivets that must be removed. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
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SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet out by using a center punch with a hammer. 6. Using a flat head screwdriver between the links, twist the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.
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SECTION 4 - BOOM & PLATFORM 7. Remove the link from the other section of the powertrack using a screwdriver. Installing a New Link 1. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section.
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SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new link and slide the peanut end of the track section into it. a screwdriver may be necessary to do this. 3121827 – JLG Lift – 3. After the new link is installed in the powertrack the round half-shears will not fit properly in the peanut cut-outs yet.
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SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the new connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs. 6. Push pin thru center hole then slide washer on pin. 5. The parts shown below will be used to connect the new link to the powertrack.
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SECTION 4 - BOOM & PLATFORM 7. Install the snap ring in the groove on the pin. Repeat the pin installation steps for all center holes that have the rivets removed. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY 8. Hold new aluminum round bar tightly, then install new 8-32 x 0.500 self-threading torx head screw into one end.
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SECTION 4 - BOOM & PLATFORM 9. Pull up on the other end of the round bar and slide the new poly roller onto the bar. NOTE: Maximum tightening torque is 18-20 in-lbs.
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SECTION 4 - BOOM & PLATFORM 10. Install a new 8-32 x 0.500 self threading screw on the other side. Replacing Fixed End Brackets 1. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. NOTE: When tightening screws make sure screw head is seated against link with no space in between the link and underside of screw head.
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SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING 3. Take the new bracket and install bracket center pin and snap ring. Repeat on the other bracket if replacing it as well.
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SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. 1. Remove existing pins and center rivet. Remove the rivet the same way as shown in the link removal instructions. Repeat on other bracket if replacing it as well. 2. Take new bracket and install center pin with snap ring. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
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SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and install snap rings. Repeat with other moving end if replacing as well. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY 4. When complete make sure that both brackets rotate correctly.
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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 check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made. Double Acting Cylinder (Upper Boom Lift, Mid Boom Lift, Lower Boom Lift, Telescope, Slave, Master, Rotator, and Steer) Cylinders With Single Counterbalance Valve A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions.
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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 26 11 8 8 *Prior to S/N 0300106518 1. 2. 3. 4. 5. 6. Loctite #242 Loctite #222 Primer #7471 Loctite RC 609 Bolt Tapered Bushing 1683779-E 7. 8. 9. 10. 11. 12. Bearing Bushing Cylinder Head Barrel Cylinder Rod Washer Ring 13. 14. 15. 16. 17. 18. O-ring Plug Piston Not Used Backup Ring Backup Ring Seal Ring 19. 20. 21. 22. 23. 24. Wear Ring Wear Ring O-ring O-ring Seal Wiper 25. Seal 26.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Cylinder Rod Retainer Piston Cylinder Head Hex Nut 7. 8. 9. 10. 11. 12. Tube Spacer Holding Valve Setscrew Pipe Plug T-Seal Wear Ring 13. 14. 15. 16. 17. 18. O-ring O-ring Wear Ring Rod Seal Wiper Locking Primer 19. 20. 21. 22. 23. Loctite #242 Loctite #222 Pipe Sealant Holding Valve Plug Figure 5-2.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Loctite #242 Primer #7471 Socket Head Bolt Tapered Bushing Bushing Cylinder Head 7. 8. 9. 10. 11. 12. Cylinder Rod Barrel Washer Ring Piston Not Used Lock Ring 13. 14. 15. 16. 17. 18. Wear Ring Backup Ring O-ring O-ring Wiper Seal 19. 20. 21. 22. 23. Backup Ring Seal Valve Cartridge Valve Cartridge Bolt Figure 5-3.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Cylinder Rod Retainer Piston Cylinder Head Hex Nut 7. 8. 9. 10. 11. 12. Tube Spacer Holding Valve Holding Valve Pipe Plug Setscrew Piston Seal 13. 14. 15. 16. 17. 18. Wear Ring O-ring Wear Ring O-ring Rod Seal Wiper 19. 20. 21. 22. 23. Not Used Loctite #242 Loctite #222 Locking Primer Bushing Figure 5-4.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Cylinder Rod Retainer Piston Cylinder Head 6. 7. 8. 9. 10. Hex Nut Washer Spacer Holding Valve Holding Valve 11. 12. 13. 14. 15. Plug Setscrew Lock Ring Piston Seal Not Used 16. 17. 18. 19. 20. Not Used O-ring Backup Ring Rod Seal Rod Wiper 21. 22. 23. 24. 25. Loctite #242 Loctite #222 Locking Primer Not Used Bushing Figure 5-5.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Cylinder Rod End Cap Piston Cylinder Head 6. 7. 8. 9. 10. Hex Nut Tube Spacer Not Used Holding Valve O-ring Plug 11. 12. 13. 14. 15. Setscrew Setscrew Wear Ring Seal O-ring 16. 17. 18. 19. 20. Wear Ring O-ring Seal Wiper Loctite #242 21. Locking Primer 22. Loctite #222 23. Bushing Figure 5-6.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Barrel Cylinder Rod Retainer Piston Cylinder Head 6. 7. 8. 9. 10. Hex Nut Tube Spacer Setscrew T-Seal Wear Ring 11. 12. 13. 14. 15. O-ring O-ring Wear Ring Rod Seal Rod Wiper 16. Locking Primer 17. Loctite #242 18. Loctite #222 Figure 5-7.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Loctite #242 Locking Primer Bolt Tapered Bushing Bushing 6. 7. 8. 9. 10. Piston Washer Head Barrel Cylinder Rod 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. Bolt Figure 5-8.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Wiper Spanner Nut Retaining Ring Lip Seal Wear Ring 6. 7. 8. 9. 10. Backup Ring O-ring Guide Barrel Tube 11. 12. 13. 14. 15. Piston Wear Ring Seal O-ring O-ring 16. Rod 17. Rod Figure 5-9.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. Barrel Rod Piston Head Spacer Counterbalance Valve 7. 8. 9. 10. 11. 12. Bolt Plug Setscrew Locknut Retaining Ring Wear Ring 13. 14. 15. 16. 17. 18. Cap Seal O-Ring Wear Ring O-ring Rod Seal Wiper 19. 20. 21. 22. 23. 24. Loctite #242 Not Used Fitting Cap O-Ring Plug Bolt 25. Fitting 26. Cap 27. Lockwasher * Torque to 150 foot-pounds (203 Nm) Figure 5-10.
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SECTION 5 - HYDRAULICS Cylinders With Dual Counterbalance Valve (Lower Lift, Mid Lift, Telescope, and Slave Cylinders) 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. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system.
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SECTION 5 - HYDRAULICS 5. 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. 11.
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SECTION 5 - HYDRAULICS 6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary. 7. Inspect threaded portion of piston for damage. Dress threads as necessary. 8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary. 16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary. 17.
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SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove. Figure 5-17. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head. Figure 5-19. Piston Seal Kit Installation 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible. 9.
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SECTION 5 - HYDRAULICS NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER, OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY. 11. Assemble the tapered bushing loosely into the piston and insert JLG cap screws (not vendor cap screws) through the drilled holes in the bushing and into the tapped holes in the piston. Figure 5-21. Seating the Tapered Bearing 14.
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SECTION 5 - HYDRAULICS 19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder. Table 5-2. Cylinder Piston Nut Torque Specifications) Description 20. Secure the cylinder head gland using the washer ring and socket head bolts. Nut Torque Valve (Wet) Setscrew Torque Value (Dry) Upper Lift Cylinder 200 ft. lbs. (270Nm) 100 in. lbs. (11 Nm) Mid Lift Cylinder 400 ft. lbs. (542 Nm) 100 in. lbs. (11 Nm) Mid Lift Cylinder E400An 200 ft.lbs.
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SECTION 5 - HYDRAULICS 5.5 PRESSURE SETTING PROCEDURES 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 1.
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SECTION 5 - HYDRAULICS Platform Level Down Relief Steer Relief 1. On machines prior to S/N 0300062642, 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 given in Table 5-4, Pressure Settings - Prior to S/N 0300062642 or Table 5-5, Pressure Settings - S/N 0300062642 to Present.
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SECTION 5 - HYDRAULICS Table 5-4. Pressure Settings - Prior to S/N 0300062642 Circuit PSI Table 5-5.
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SECTION 5 - HYDRAULICS MAIN RELIEF STEER RELIEF CHECK CARTRIDGE PRESSURE SWITCH GAUGE PORT BRAKE RELEASE CARTRIDGE STEER CARTRIDGE SHUTTLE CARTRIDGE PROPORTIONAL (FLOW CONTROL) CARTRIDGE HYDRAULIC FILTER Figure 5-25.
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SECTION 5 - HYDRAULICS Figure 5-26.
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SECTION 5 - HYDRAULICS Figure 5-27.
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SECTION 5 - HYDRAULICS EMERGENCY DESCENT VALVE EMERGENCY DESCENT HAND PUMP UPPER LIFT DOWN RELIEF LOWER LIFT DOWN RELIEF GAUGE PORT TELESCOPE RELIEF RELEVELING VALVE PLATFORM LEVEL RELIEF (BACKWARD) RELEVELING RELIEF PLATFORM LEVEL RELIEF (FORWARD) Figure 5-28.
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SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Introduction WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS. IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
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SECTION 6 - JLG CONTROL SYSTEM The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubleshooting. Optional equipment includes an hour meter, beacon light, function cutout, and ground alarm. These options may be added later but must be programmed into the motor controller when installed. The Control System may be accessed in one of two ways: Utilizing a custom designed, hand held analyzer (Analyzer, JLG part no.
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SECTION 6 - JLG CONTROL SYSTEM Using the Analyzer With the machine power on and the analyzer connected properly, the analyzer will display the following: If ENTER is pressed again, the display moves to the following display: LOGGED HELP 1: STARTUP ( 2/ 1) HELP: PRESS ENTER LOGGED HELP 1: STARTUP (2/1) HELP: PRESS ENTER At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER.
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SECTION 6 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly: When the analyzer is first connected, you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered.
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SECTION 6 - JLG CONTROL SYSTEM 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: Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2=DRIVE PERSONALITIES: DRIVE ACCEL 1.0s GROUND ALARM: 2 = DRIVE PERSONALITIES: DRIVE ACCEL 1.
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SECTION 6 - JLG CONTROL SYSTEM The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving. There are certain settings allowed to install optional features or select the machine model. When selection the machine model to match the size of the machine, the personality settings will all default to the factory recommended setting.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION DRIVE LOWER LIFT UPPER LIFT SWING 3121827 PERSONALITY RANGE DEFAULTS ACCELeration 0.5s to 5.0s 1.0 DECELeration 0.1s to 2.0s 0.5 MINimum speed 0 to 25% 3 MAXimum speed 0 to 100% 100 ELEVATED MAXimum speed 0 to 25% 20 CREEP MAXimum speed 0 to 45% 30 POSITRAC time 0 to 60s 10 POSITRAC current 50-250 A 170A ACCELeration 0.5 to 5.0s 1.0 DECELeration 0.0 to 3.0s 0.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION TELEscope BASKET LEVEL BASKET ROTATE JIB STEER 6-8 PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0 1.0 DECELeration 0.1 to 3.0 0.5 MINimum IN speed 0 to 20 8 MAXimum IN speed 0 to 100 60 MINimum OUT speed 0 to 20 5 MAXimum OUT speed 0 to 100 70 ACCELeration 0.5 to 5.0 1.0 DECELeration 0.1 to 3.0 1.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1.
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SECTION 6 - JLG CONTROL SYSTEM 1. TILT SWITCH Table 6-2. 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...
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SECTION 6 - JLG CONTROL SYSTEM 3= Motion Alarm - Sounds when any function is active (Option) 6. PLATFORM ALARM 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) Not available at password level 2 ENTER confirms that vehicle is currently level, and zeroes the tilt sensor measurements Help Descriptions and Fault Flash Codes Table 6-3. JLG Control System Flash Codes Code 7.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. 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.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. 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 6-4. 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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6-18 – JLG Lift – (001) DATALOG: RENTAL XXXhXXm DATALOG: ERASE RENTAL SYSTEM: DRIVE CUTOUT OP SYSTEM: ELEV. CUTOUT OP SYSTEM: DOS OFF SYSTEM: BRAKES LOW PRES. BOOM: SWING 0% BOOM: LEVEL 0% BOOM: TELE 0% BOOM: ROTATE 0% BOOM: JIB (U/D) 0% BOOM: JIB (L/R) 0% BOOM: PUMP POT 0% BOOM: CREEP ACTIVE DRIVE: POSITRAC OFF DRIVE: STEER 0% DRIVE: BRAKES LOCKED DRIVE: CREEP ACTIVE DRIVE: DOS LIM SW OP DRIVE: DOS O//R SW OP 0% 1 VERSIONS: ANALYZER vX.X VERSIONS: POSITILT vX.X VERSIONS: GROUND vX.
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3121827 – JLG Lift – 2 DRIVE: POSITRAC 170 A MAIN LIFT : CREEP DOWN 55% MAIN LIFT : MAX DOWN 63% MAIN LIFT : MIN DOWN 30% MAIN LIFT : CREEP UP 30% MAIN LIFT : MAX UP 80% MAIN LIFT : MIN UP 18% MAIN LIFT : DECEL 0. 3s MAIN LIFT : ACCEL 1. 0s LIFT : MAIN LIFT 2 2 2 2 2 2 2 2 2 22% TELE: MAX OUT 40% TELE: MIN OUT 16% TELE: MAX IN 50% TELE: MIN IN TELE: DECEL 0. 5s TELE: ACCEL 1.
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6-20 1 1 MACHINE CALS: FLOW@0% 30% MACHINE CALS: FLOW@100% 50% MACHINE CALS: TLIFT@0% 30% MACHINE CALS: TLIFT@100% 50% MACHINE CALS: MLIFT@0% 30% CONTROLLER CALS: 1 TRACTION I 1.28 CONTROLLER CALS: 1 PUMP I 1.26 CONTROLLER CALS: 1 TILTdelayIN 62! CONTROLLER CALS: 1 TILTdelayOUT 6! – JLG Lift – 1 1 MACHINE CALS: SWINGcalSw OFF MACHINE CALS: SWINGL@0% 43% 1 1 1 1 MACHINE CALS: SPEEDprop2 16 MACHINE CALS: SPEEDint 0.
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SECTION 6 - JLG CONTROL SYSTEM 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 6-5. 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 6-5. 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 6-6. System Test Descriptions ACTIVATE TESTS YES:ENTER, NO:ESC RUN SYSTEM TEST 3121827 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 6-7. 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 6-7. 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 6-7. 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 6-7. 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 Non Table 6-8. Diagnostic Fault Codes DTC Flash Code 001 00 Fault Message Description EVERYTHING OK The "normal" help message in platform mode 002 00 GROUND MODE OK The "normal" help message in ground mode 0010 00 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" while the vehicle is out of transport position. 0011 00 FSW OPEN A drive or boom function has been selected but footswitch is open.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes DTC Flash Code 2514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configured to not allow simultaneous drive & boom operation. 2516 25 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while Boom functions are selected AND is configured to not allow simultaneous drive & boom operation.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes DTC Flash Code 33364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized. This maybe due to an open circuit traction motor or power wiring error 33369 33 REVERSE CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when reverse contactor was energized.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8.
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SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-34 – JLG Lift – 3121827
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS SECTION 7. BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.1 GENERAL This section contains basic troubleshooting information and basic electrical information to be used for locating and correcting most of the operating problems which may develop.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-1. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE 3121827 PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered. Check wiring/Run System Test. Personalities not set correctly Check settings.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-2. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction. 7-8 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-3. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-4. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-5. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function sluggish during operation. (System pressure too low.) 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS . Table 7-6. 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.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-6. 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 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.3 MULTIMETER BASICS nal and the lead on the other port goes to the positive side of the signal. A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. This section shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the meter operator’s manual for more information.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Resistance Measurement • Use firm contact with meter leads Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Current Measurement b. Change the switch position. c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short. 5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will be connected. The test is similar to testing a switch with two terminals. a.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Automatic Switches • LSS Modules connections, • Deutz EMR 2 ECM connection. If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.6 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.
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SECTION 7 - BASIC TROUBLESHOOTING, 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 TROUBLESHOOTING, 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 TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-11.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.7 DEUTSCH CONNECTORS NOTE: The receptacle is shown - use the same procedure for plug. DT/DTP Series Assembly A DT/DTP Series Disassembly B A B C D Figure 7-12. DT/DTP Contact Installation C 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.
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SECTION 7 - BASIC TROUBLESHOOTING, 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. 2.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-18.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-19.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-20.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-21.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-22.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-23.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-24.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-25.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-26.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-27.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-28.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-29.
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SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-30.
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3121827 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 813058 JLG Deutschland GmbH Max-Planck-Str.