Service Manual Manual

ManualsBrandsJLG ManualsSpecial machineryM4069

Service & Maintenance Manual

Models

3369LE

4069LE

M3369

M4069

S/N-0200230092 to

Present

3121639

June 10, 2014

Summary of content (138 pages)

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Service & Maintenance Manual Models 3369LE 4069LE M3369 M4069 S/N-0200230092 to Present 3121639 June 10, 2014
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH SECTION A B C PAGE NO. - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 2.4 2.5 2.6 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 4.15 4.16 4.17 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 Main Relief at Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Lift Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Steer Relief. . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 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. 3-23. 3-24. 3-25. 3-26. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-16. 4-17. 4-18. 4-19. 5-1. 5-2. 5-2. 5-3. 5-4. 3121639 TITLE PAGE NO. Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. 6-18. 6-19. 6-20. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. vi Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Continuity Measurement . . . . . . . . . . . . .
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TABLE OF CONTENTS 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 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 4-1 4-2 4-3 4-4 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 3121639 TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS NOTES: viii – JLG Lift – 3121639
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS Table 1-1. Operating Specifications Description 3369LE/M3369 ANSI 4069LE/M4069 CE/AUS Max. Number of Persons CSA ANSI CE/AUS 2 Max. Workload (Capacity) Extension Only: ANSI/CSA/Brazil: CE/AUS: ANSI/CSA/Brazil: CE/AUS: Max. Platform Height Max. Gradeability Max. Slope (Left - Right) Max. Slope (Front - Back) Max. Slope (Left - Right) (optional for CE machines with 37 mph (16.7 m/s) windspeed rating only) Max.
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SECTION 1 - SPECIFICATIONS Table 1-1. Operating Specifications Description 3369LE/M3369 ANSI 4069LE/M4069 CE AUS ANSI CE Drive Speed - (reduced) 16 - 24 sec/50 ft (15 m) 16 - 24 sec/50 ft (15 m) Drive Speed - (high) 10.6 - 12 sec/50 ft (15 m) 10.6 - 12 sec/50 ft (15 m) Drive Speed - (creep) (AUS Full drive height model) NA 142 -146 sec/25 ft (7.
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SECTION 1 - SPECIFICATIONS Tires Table 1-3. Tire Specifications Size 240/55 D17.5 R4 Tread (Fill tire with high durometer polyurethane at 90 psi) IN240/55-17.5 FF 27.2/10.5-15 FF Turf IN240/55-17.
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SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES 1.6 CYLINDER SPECIFICATIONS Table 1-6. Capacities Description Hydraulic Tank Hydraulic System Fuel Tank - (M Models only) 3369LE/M3369 Table 1-9. Cylinder Specifications 4069LE/M4069 DESCRIPTION BORE STROKE ROD DIA. 8.25 gal (31.2 liters) 5.4 gal (20.4 liters) @ full mark Lift Cylinder (M3369/3369LE) 4.00 in (10.16 cm) 63.69 in (161.77 cm) 2.75 in (6.98 cm) approx. 8.5 gal (32.1 liters) Upper Lift Cylinder (M4069/4069LE) 3.00 in (7.62 cm) 58.
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SECTION 1 - SPECIFICATIONS 1.9 LUBRICATION NOTE: Refer to Lubrication Chart - Table 1-15 for specific lubrication procedures. Table 1-12. Hydraulic Oil Table 1-14.
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SECTION 1 - SPECIFICATIONS Note: 500 Hrs. = 3 months 1000 Hrs. = 6 months 2000 Hrs. = 1 year 4000 Hrs. = 2 years Figure 1-1. Lubrication Chart Table 1-15.
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SECTION 1 - SPECIFICATIONS 1.10 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to the left front of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left front of the machine frame. Figure 1-2.
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SECTION 1 - SPECIFICATIONS 1.11 TORQUE CHARTS Figure 1-3.
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SECTION 1 - SPECIFICATIONS Figure 1-4.
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SECTION 1 - SPECIFICATIONS Figure 1-5.
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SECTION 1 - SPECIFICATIONS Figure 1-6.
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SECTION 1 - SPECIFICATIONS Figure 1-7.
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
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SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION This will allow start up at temperatures down to -20° F (-29° C). However, use of this oil will give poor performance at temperatures above 120°F (49°C). Systems using DTE 13 oil should not be operated at temperatures above 200°F (94°C) under any condition. Hydraulic System 1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.
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SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods. 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift Measure the drift of the platform to the ground. Fully elevate the platform. Maximum allowable drift is 2 in. (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following. 1. Pinned joints should be disassembled inspected if the following occurs: and a.
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SECTION 2 - GENERAL 2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The inspection and maintenance code numbers for Table 2-3, Preventive Maintenance and Inspection Schedule, are as follows: The preventive maintenance and inspection checks are listed and defined in Table 2-3, Preventive Maintenance and Inspection Schedule. This table is divided into two basic parts, the “AREA” to be inspected, and the “INTERVAL” at which the inspection is to take place.
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SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Inspection Schedule AREA PLATFORM INTERVAL 10 HOURS DAILY 1. Controller 1, 11 2. Switches 1, 11 3. Placards and Decals 1, 2 4. Control Tags 1, 2 5. Hoses and Cables 1 50 HOURS WEEKLY 200 HOURS MONTHLY 1000 HOURS 6 MONTHS 5, 8 6. Wear Pads 7. Handrail and Chains 500 HOURS 3 MONTHS 8 1, 4 CHASSIS 1. Batteries 3 5 2. Battery Charger 1 3. Hydraulic Pump/Motor 1 5 4. Valves 1 5 5. Hydraulic Filter* (1) 5, 14 6.
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SECTION 2 - GENERAL NOTES: 2-8 – JLG Lift– 3121639
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SECTION 3 - CHASSIS & SCISSOR ARMS SECTION 3. CHASSIS & SCISSOR ARMS 3.1 CALIBRATIONS Tilt Sensor Calibration: Elevation Sensor Calibration Using the Analyzer, in Access Level 1, go to MENU: CALIBRATION: 1. SET STOW ELEV; a. Completely lower platform to stowed position. b. Enter YES on the Analyzer. c. COMPLETE will show on the analyzer when calibrated. 2. SET 25FT ELEV (3369LE) or SET 30FT ELEV (4069LE); a.
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SECTION 3 - CHASSIS & SCISSOR ARMS c. Reassemble and test. If fault persists, replace tilt sensor. 2 2. If the Analyzer displays angles other than +20.0°, attempt to calibrate. If machine will not calibrate, note the reason displayed on Analyzer: a. SENSOR FAILURE – tilt sensor internal frequency is out of range (replace sensor). b. NOT LEVEL - tilt sensor has either developed an offset or it is to unlevel as mounted on the machine.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.2 TILT SENSOR Tilt Sensor, JLG P/N 4000021: 2 6 7 2 1 1 5 4 3 1. Ground Control Box 2. Tilt Sensor Assembly (JLG P/N 1810140) Figure 3-3. Tilt Sensor Location 1. Tilt Sensor (JLG P/N 4000021) 2. Sensor Mount NOTE: Refer to Figure 3-4., Tilt Sensor Removal for numbers in parenthesis. 3. Screw, 6-32 x 1 1. Disconnect the batteries. 4. Lockwasher 2. Open the Ground Control Box to gain access to the Tilt Sensor Assembly. 5. Standoff Insulator 6. Washer, 0.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.3 BATTERY MAINTENANCE AND CHARGING ammonia) and wire brush. Replace cables and/or cable clamp bolts as required. 4. Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly. IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH AT LEAST 52 KG (115 LB). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH. 5.
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SECTION 3 - CHASSIS & SCISSOR ARMS 2. To charge the batteries, connect the charger to a 230 volt source with a 15 amp minimum capacity. 3. The charge cycle is complete when the 100% LED is lit. Any other reading indicates the charge cycle is not complete. Battery Charger (Delta-Q) The battery charger is located on a tray behind the hinged JLG cover at the front of the machine, or on the sliding engine tray on the (M) model machines. 4.
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SECTION 3 - CHASSIS & SCISSOR ARMS Battery Charger Maintenance Table 3-2. Delta-Q - Battery Charger Specs BATTERY CHARGER SPECIFICATION OUTPUT Nominal DC Output Voltage USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE. 48V Maximum DC Output Voltage 52V Maximum DC Output Current 20A Maximum Interlock Current LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION.
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SECTION 3 - CHASSIS & SCISSOR ARMS Battery Charger Troubleshooting 4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service. No Lights at all 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.
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SECTION 3 - CHASSIS & SCISSOR ARMS [5 Flashes] - Over Temperature This fault indicates the charger has become too hot during operation. Though not damaging 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 indication must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.
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SECTION 3 - CHASSIS & SCISSOR ARMS Checking - Changing the Battery Charger Algorithm Table 3-3. Battery Algorithms The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-3, Battery Algorithms on Page 3-9. Contact JLG if your specific battery model is not listed. Each time AC power is applied with the battery pack not connected, the charger enters an algorithm select/display mode for approximately 11 seconds.
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SECTION 3 - CHASSIS & SCISSOR ARMS Removing the Battery Box Figure 3-8. Batteries and Battery Charger To remove the battery box, perform the following steps. 1. Pull the handle on the battery disconnect to disconnect the batteries. 2. Remove the two attachment bolts that secure the battery box to the frame. 3. Using a forklift, lift the battery box up enough to clear the brackets on the back of the battery box and remove the battery box from the machine.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.4 GENERATOR • Start Control Relay 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.
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SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-9.
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SECTION 3 - CHASSIS & SCISSOR ARMS Timing Sequences Table 3-5. RBS Startup Sequence 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. • RBS Pre start Sequence 1.
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Figure 3-10.
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SECTION 3 - CHASSIS & SCISSOR ARMS 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: Alarms and Fault Flash Codes In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. NOTE: Alarms must be reset once the fault has been corrected. Table 3-7.
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SECTION 3 - CHASSIS & SCISSOR ARMS • Overcrank If the engine fails to start after a set number of start attempts, the RBS will cease attempts to restart and an engine overcrank alarm will be indicated. • No Speed Signal In the event of a loss of speed signal, the RBS will shutdown and an engine no speed signal alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault was not momentary. voltage CTS.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.5 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 & SCISSOR ARMS 4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. 5. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the conductors that lead to the new in-line fuse holder. Use insulated butt splice connectors for these conductors. 6. Re-install the harness with the new fuse in place. 7.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 JOYSTICK CONTROLLER Figure 3-11. Joystick Controller - (JLG P/N 1600403) Table 3-8. Joystick Specifications Input Voltage Table 3-9. Joystick Plug Loading Chart 5V Terminal Color Function Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right Reverse Voltage 4.60V to 4.80V 2 Green Steer Left Forward Voltage 0.40V to 0.
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SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-12.
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SECTION 3 - CHASSIS & SCISSOR ARMS Power Controller 3.7 TOWING Disengaging for Towing PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT, I.E. VIA TOW BAR TO PULLING VEHICLE. THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY. ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL. THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE.
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SECTION 3 - CHASSIS & SCISSOR ARMS Engaging after Towing is Complete PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT, I.E. VIA TOW BAR TO PULLING VEHICLE. THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY. ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STAND STILL. THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE.
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SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-14.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.8 DRIVE HUB The final drive consists of two stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load of distribution. All torque transmitting components are made of forged, quenched and tempered high-alloy steels. External gears are carborized. Precision roller bearings are used exclusively. Two large, tapered roller bearings support the sprocket or wheel loads.
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SECTION 3 - CHASSIS & SCISSOR ARMS 1. Retaining Screws 9. Back-up Ring 17. Retaining Ring 2. Washers 10. Shaft 18. Bearing 3. Pressure Plate 11. Stator Disc 19. Retaining Ring 4. Case Seal 12. Sensor Ring 20. Dowel Pins 5. O-ring 13. Rotor Disc 21. Cover 6. Back-up Ring 14. Plate 22. Rotary Oil Seal 7. Piston 15. Springs 23. Brake to Hub Gasket 8. O-ring 16. Spring Retainer 24. Brake to Motor Gasket Figure 3-15.
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.9 DRIVE BRAKE - MICO 3. Install new bearing (18) and retaining ring (19) on shaft (10). Disassembly 4. Install shaft assembly and retaining ring (17) in cover (21). 1. After removing the brake from its installation, place brake on a clean dry work bench with mounting plate uppermost. 2. Remove pressure plate (3) from cover (21) by removing cap screws (1) and washers (2). PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 680 KG (1500 LB).
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SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 TORQUE HUB 1. Spindle 12. Thrust Washer 23. Needle Bearing 34. O-ring 2. Lip Seal 13. Spacer 24. Thrust Spacer 35. Retaining Ring, Int. 3. Tapered Bearing Cone 14. Seal Boot 25. Planet Shaft 36. Coupling 4. Tapered Bearing Cup 15. Thrust Spacer 26. Planet Gear 37. Input Shaft 5. Tapered Bearing cone 16. Input Carrier 27. Roll Pin 38. Input Sun Gear 6. Ring Gear 17. Thrust Washer 28. Thrust Washer 39. Output Sun Gear 7.
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SECTION 3 - CHASSIS & SCISSOR ARMS Roll Test The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others.
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SECTION 3 - CHASSIS & SCISSOR ARMS Main Disassembly 1. Coupling 7. Input Shaft 13. Housing 2. Retaining Ring 8. Carrier Subassembly 14. O-Ring 3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring 4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining Ring, Ext. 5. Washer 11. Flat Head Bolts 17. Retaining Ring, Ext. 6. First Stage Sun Gear 12. Ring Gear 18. ID Plate Figure 3-18.
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SECTION 3 - CHASSIS & SCISSOR ARMS Disassembly Instructions: 1. Perform the Roll Check and Leak Check, if applicable prior to disassembling the unit. NOTE: On units with ratios greater than 36:1 numerically, there will not be a separate First Stage Sun Gear (6), as the gear teeth will be integral to the Input Shaft (7). 2. Drain oil from the unit. 7. Remove the Input Carrier Subassembly (8). 3. Remove the Coupling (1) from Spindle End first. 8. Remove the Second Stage Sun Gear (9). 4.
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SECTION 3 - CHASSIS & SCISSOR ARMS Output Carrier Disassembly 1. Roll Pin 5. Thrust Washers 2. Planet Shaft 6. Thrust Spacer 3. Carrier 7. Planet Gears 4. Needle Bearings 8. Thrust Washer Figure 3-19. Output Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (1) into the Planet Shaft (2) until it bottoms against the Carrier (refer to Figure 3-16.). 4.
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SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Disassembly 1. Roll Pin 4. Planet Gears 2. Planet Shaft 5. Thrust Spacer 3. Carrier 6. Needle Bearings Figure 3-20. Input Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (1) into the Planet Shaft (2) until it bottoms against the Carrier (3). 2. Using a soft face hammer, tap the Planet Shaft (2) out of the Carrier (3). 3. Using a 1/8" diameter punch, drive the Roll Pin (1) out of the Planet Shaft (2). 4.
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SECTION 3 - CHASSIS & SCISSOR ARMS Hub-Spindle Disassembly 1. Spindle 4. Bearing Cone 7. Boot Seal 2. Retaining Ring 5. Bearing Cup 8. Studs 3. Spacer 6. Hub 9. Bearing Cone Figure 3-21. Hub-Spindle Disassembly 1. Place unit on bench with Spindle (1) end down. 7. Remove Seal from Hub. 2. Remove Retaining Ring (2) with appropriate tool. NOTE: The Seal should NOT be reused when reassembling the unit. 3. Remove Spacer (3). 4. Remove "A" position Bearing Cone (4) from Bearing Cup (5) in Hub (6).
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SECTION 3 - CHASSIS & SCISSOR ARMS Cover Disassembly 1. O-Ring 4. Hex Head Bolts 7. O-ring 2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs 3. Thrust Washer 6. Disengage Rod Figure 3-22. Cover Disassembly 1. Remove O-ring (1) from the groove in the Cover (2). 4. Pull Disengage Rod (6) out of the Cover. 2. Remove the Thrust Washer (3) from Cover pockets. 5. Use an appropriate tool to remove the O-ring (7) from the internal groove in the Cover. 3.
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SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Sub-Assembly 1. Roll Pin 2. Planet Shaft 3. Carrier 4. Planet Gears 5. Thrust Spacer 6. Needle Bearings Figure 3-23. Input Carrier Sub-Assembly 1. Apply a liberal coat of grease to the bore of one Input Planet Gear (4). 7. Following the Planet Gear, place one more Thrust Washer onto the Planet Shaft. Align the Thrust Washer in the same manner described in Step 5. 2. Line the inside of the Planet Gear with 14 Needle Bearings (6).
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SECTION 3 - CHASSIS & SCISSOR ARMS Output Carrier Sub-Assembly 1. Roll Pin 2. Planet Shaft 3. Carrier 4. Needle Bearings 5. Thrust Washers 6. Thrust Spacer 7. Planet Gears 8. Thrust Washer Figure 3-23. Output Carrier Sub-Assembly 1. Apply a liberal coat of grease to the bore of one Output Planet Gear (7). 8. Place the Planet Gear Sub-assembly into the Carrier. Visually align the planet gear bore with one of the planet shaft holes on the Carrier. 2.
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SECTION 3 - CHASSIS & SCISSOR ARMS Hub-Spindle Sub-Assembly 1. Spindle 2. Retaining Ring 3. Spacer 4. Bearing Cone 5. Bearing Cup 6. Hub 7. Boot Seal 8. Studs 9. Bearing Cone Figure 3-24. Hub-Spindle Sub-Assembly 7. Install Bearing Cone (4) into Bearing Cup, position "A". NOTE: Apply a light coat of oil on all component parts during assembly. 1. Place the Hub (6) into a pressing base. Press 9 Studs (8) into the Hub. NOTE: Use enough pressure to press in studs.
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SECTION 3 - CHASSIS & SCISSOR ARMS Cover Sub-Assembly 1. O-Ring 4. Hex Head Bolts 7. O-ring 2. Cover 5. Disengage Cap 8. O-ring Pipe Plugs 3. Thrust Washer 6. Disengage Rod Figure 3-25. Cover Sub-Assembly 1. Grease O-Ring (7) and insert groove in Cover (2). 2. Assemble Disengage Cap (5) onto Cover using two Hex Head Bolts (4). Torque bolts to 70-80 in-lbs. 3. Insert Disengage Rod (6) into hole in Cover until it touches the inside of the Disengage Cap. 4.
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SECTION 3 - CHASSIS & SCISSOR ARMS Main Assembly 1 3 8 15 6 4 2 18 5 13 14 12 16 7 9 17 11 1. Coupling 7. Input Shaft 13. Housing 2. Retaining Ring 8. Carrier Subassembly 14. O-Ring 3. Ring Gear 9. Second Stage Sun Gear 15. O-Ring 4. Cover Subassembly 10. Output Stage Carrier Subassembly 16. Retaining ring Ext. 5. Washer 11. Flat Head Bolts 17. Retaining Ring Rxt. 6. First Stage Sun Gear 12. Ring Gear 18. ID Plate Figure 3-26.
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SECTION 3 - CHASSIS & SCISSOR ARMS 8. Place the Input Shaft spline end into mesh with the Internal Coupling (1) splines. NOTE: All components should receive a generous amount of lubricant oil as they are being assembled. 1. Place Hub-Spindle Sub-Assembly on a bench. 9. With the modified spline end facing up, place the Output Sun Gear into mesh with the Output Planet Gears. 2. Grease O-Ring (14) and place it into the groove of the Housing (13). 3. Place the Ring Gear (12) onto the Hub.
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SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 SERVICING AND MAINTENANCE GUIDELINES 3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc. have been removed and that no adjacent parts are interfering. General Component Disassembly and Reassembly The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.
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SECTION 4 - HYDRAULICS 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat treated bolts, studs and steel nuts, in accordance with recommended shop practices. 4.2 LUBRICATION INFORMATION Hydraulic System 1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.; inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc.
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SECTION 4 - HYDRAULICS basis. However, filter elements must be changed after the first 50 hours of operation and every 250 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils.
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SECTION 4 - HYDRAULICS 4.7 MOTOR CONTROLLER - MODES OF OPERATION 4.8 FEATURES Traction Mode Traction Motor (Drive) Drive in either forward or reverse will start only if the following conditions are satisfied: 1. Function switches off. 2. No procedure or diagnostic faults present. 3. Depress drive select. Lights indicating drive at the platform control will flash. The controller must be moved within 3 seconds after the drive select illuminates. NOTE: The lift up and drive functions are proportional.
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SECTION 4 - HYDRAULICS 7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made. 3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block. 4.
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SECTION 4 - HYDRAULICS Lift Cylinder Installation 1. Install lift cylinder in place using a suitable slings, aligning barrel end attaching pin mounting holes on lower arm assembly. 2. Using a suitable drift, drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly. Secure in place with bolt, locknut and keeper shaft. 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. 4.
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SECTION 4 - HYDRAULICS 7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 9. If applicable, loosen and remove the nut which attaches the piston to the rod, then remove the piston from the rod. 10.
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SECTION 4 - HYDRAULICS 1. Using a special tool, pictured in the following illustration, install a new rod seal into the applicable cylinder head gland groove. Refer to the following illustration for the proper tool size. Figure 4-7. Installation of Head Seal Kit (Typical) 7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. Figure 4-5. Rod Seal Installation 8.
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SECTION 4 - HYDRAULICS 10. Install the bolts into the bushing using Loctite #242. Refer to Cylinder Component Torque Specifications Table for proper bolt torque values. 11. Remove the cylinder rod from the holding fixture. 12. Place new guidelock and hydrolock seals in the applicable outside diameter grooves of both the piston and the cylinder head. 13. Position the cylinder barrel in a suitable holding fixture. 16. Secure the cylinder head gland using the washer ring and socket head bolts. 17.
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SECTION 4 - HYDRAULICS 21. Position the cylinder barrel in a suitable holding fixture. 5. Remove the nut and bolt from the rod end of the cylinder from out at the spindle. 6. Remove cylinder from machine. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 4.13 OSCILLATION CYLINDER BLEEDING Bleeding Procedure 1. Run one side wheel onto a ramp or block of wood.
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SECTION 4 - HYDRAULICS Oscillating Axle Lockout Test (If Equipped) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure platform is fully lowered prior to beginning lockout cylinder test. 1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left rear wheel. 2. From platform control station, select LOW drive speed. 3.
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SECTION 4 - HYDRAULICS 4.14 CYLINDER ASSEMBLIES 18 20 19 21 22 3 23 24 25 1 4 17 7 8 5 6 9 12 13 11 14 10 15 2 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
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SECTION 4 - HYDRAULICS 18 20 19 21 22 26 LOWER LIFT CYLINDER 3 23 24 OR 25 UPPER LIFT CYLINDER 17 1 4 7 8 5 6 9 12 13 11 14 10 15 16 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
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SECTION 4 - HYDRAULICS 8 20 19 10 11 9 19 12 11 13 15 4 21 14 16 17 18 1 5 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Cylinder Barrel Jack Pad Special Screw, 1/2" - 13NC x 1-1/4 Cylinder Rod Retaining Ring Plate End Cap Locknut Piston Flatwasher, 1-1/4" Wear Ring Piston Seal O-Ring Head Wear Ring O-Ring Polyseal Wiper Seal Plug Counter Balance Valve (see note) Check Valve (see note) 6 5 3 3 2 3 Figure 4-13.
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SECTION 4 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1 Barrel Rod Guide Locknut Piston Piston Seal O-Ring Back-Up Ring Seal Wiper Retainer Ring O-Ring 4 6 5 7 8 9 3 10 11 12 2 Figure 4-16.
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SECTION 4 - HYDRAULICS 6 7 8 9 1 1. Barrel 2. Rod 3. Wiper 4. Wear Ring 4 5. Rod Seal 6. Plug 5 7. Piston Pilot 8. Check Valve 9. Bleeder Valve 4 NOTE: Torque item #8 to 25-27 lb-ft (34-37 Nm) 3 2 THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF THE BLEEDER VALVE IS LOOSENED. Figure 4-17.
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SECTION 4 - HYDRAULICS 4.15 PRESSURE SETTING PROCEDURES NOTE: On the back of the control valve is a flow control valve. This valve is used to adjust the lift down speed. Main Relief at Pump Table 4-4. Valve Component Torque Values 1. Install pressure gauge at port “MP” on control valve. 2. Remove the plug from the lift coil. COMPONENT 3. Activate and bottom out Lift Up. Adjust Main Relief to 3000 psi (207 bar). 4. Replace the plug on the lift coil. Lift Relief 1.
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SECTION 4 - HYDRAULICS Figure 4-18. Control Valve 4.16 DRIVE TORQUE HUB the output shaft. The lip seal will be automatically removed during this procedure. Disassembly NOTE: If bearing replacement is necessary, the bearing cups can be removed with a slide hammer puller or driven out with a punch. 1. Loosen all cover bolts and drain oil from unit. 2. Remove the cover bolts and lift off input cover. Remove and discard o-ring from counterbore of input cover. 3. Remove sun gear and thrust washer. 4.
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SECTION 4 - HYDRAULICS Assembly 8. Sun gear is installed, meshing with the teeth of the large diameter cluster gear. The counterbore on the sun gear locates on the shoulder of the input spacer. This is to be a slip fit and should operate freely. 1. With the hub shaft sub-assembly resting on the shaft install internal gear. The spline of the internal gear. bore will mesh with the spline of the output shaft. 2. Thrust washer is installed on the face of the output shaft.
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SECTION 4 - HYDRAULICS 4.17 DRIVE ASSIST VALVE 2L 1R T1 PR T PL 2R MPR 1L MPL 1L MPL 2L PL 2R 1R PR MPR T1 T VALVE SCHEMATIC Figure 4-19.
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SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER men u: HELP:PRESS ENTER Analyzer Display Escape Key Enter Key To return home or access previous menu Stores and selects Top Level, Sub Level, and item menus Left & Right Arrow Keys Up & Down Arrow Keys Used to move between Top Level, Sub Level, and item menus Value Selector Figure 5-1. Hand Held Analyzer To Connect the Hand Held Analyzer: 1.
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SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: With the machine power on and the analyzer connected properly, the analyzer will display the following: In platform mode: HELP: EVERYTHING OK, In ground mode: HELP: GROUND MODE OK If ENTER is pressed again, the display moves to the following display: MENU: HELP:PRESS ENTER log: 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 5 - JLG CONTROL SYSTEM while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key. Changing the Access Level of the Hand Held Analyzer: Once the correct password is displayed, press ENTER.
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SECTION 5 - 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: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION. PERSONALITIES: DRIVE ACCEL 1.
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SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to Table 5-3, Machine Model Adjustment, and Table 5-4, Machine Configuration Programming Information for the default settings. 5.2 PC BOARDS PCB - JLG P/N 1001099428 Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings. CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
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SECTION 5 - JLG CONTROL SYSTEM 5.3 FLASH CODES/DTC’S AND DESCRIPTIONS NOTE: Machines with software prior to P1.0 will display the Flash Code on the JLG Analyzer as shown below. The 2 digit Flash Code is scrolled at the end of the Help Message. Refer to "Flash Code" column of Table 5-1. hel p: n g chan ge ( 2/ 2) . NOTE: Diagnostic Trouble Codes (DTC’s) will only show for machines with software P1.0 and above.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 2-1 210 POWER UP 211 POWER CYCLE A new system power up has occurred since the last help message. 212 KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously. 220 PLATFORM CONTROLS 221 FUNCTION PROBLEM - HORN PERMANENTLY SELECTED Horn switch in platform control box closed at start up. Release switch to clear fault.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 2-5 250 FUNCTION PREVENTED 251 ELEV ANGLE SESOR FAULTY - VOLTAGE OUT OF RANGE The sensor signal input voltage is outside acceptable range. This could be a short to IGN, short to B+, short to ground, or sensor not properly mounted. 2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE Platform elevated for 5 sec. and elevation voltage change not detected. Fault sensor, wire harness, or ground module.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Flash Codes/DTC’s FLASH CODE DTC 4-4 440 BATTERY SUPPLY 441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Recharge batteries or check for damaged batteries. 442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Disconnect battery charger. Check that the correct voltage batteries are being used. N/A BATTERY CHARGE TOO LOW - SYSTEM SHUTDOWN 660 COMMUNICATION 661 CANBUS FAILURE: POWER MODULE Lost communication to power module.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-2.
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3121639 – JLG Lift – *(Outrigger Option Only) Figure 5-2. Analyzer Flow Chart - Software P1.
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5-12 – JLG Lift– ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. Figure 5-3. Analyzer Flow Chart - Software P1.
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3121639 – JLG Lift – - Item to be Viewed or Changed - Sub Level Menu - Top Level Menu ) YOU CAN SCROLL THROUGH THE TOP LEVEL MENUS. Figure 5-4. Analyzer Flow Chart - Software P1.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Model Adjustment Adjustment Adjustment Range Default Values - 3369LE Default Values - 4069LE ACCEL 1.0 - 5.0 (sec) 3.5 3.5 DRIVE DECEL 0.1 - 5.0 s(sec) 0.1 0.1 MINIMUM 1 - 6% 4 4 MAXIMUM 30 - 100% 100 100 ELEVATED 1 - 15% 10 10 LOW MAX 35 - 65% 50 50 BRAKE FLOW 15 - 100% 75 75 OSC AXLE 15 - 100% 50 50 OSC AXLE 0.1 - 5.0 (sec) 1.0 1.0 4WA MAX 35 - 65% 40 40 ACCEL 1.0 - 5.0 (sec) 2.0 2.0. DECEL 0.1 - 5.
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SECTION 5 - JLG CONTROL SYSTEM NOTE: When configuring an LE scissors machine, the machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default. Table 5-4.
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SECTION 5 - JLG CONTROL SYSTEM 5.4 GROUND CONTROL CIRCUIT BOARD Software Version P1.X Table 5-5.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-6.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-6. J2 Connector PIN TAGNAME FUNCTION TYPE 38 4AWR 4 Wheel Assist Reverse Solenoid Valve DIGITAL OUTPUT 39 OSAX Oscillating Axle Solenoid Valves DIGITAL OUTPUT 40 DO22 Spare High-Side Digital Otput 22 (12V, 5A) DIGITAL OUTPUT Table 5-7.
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SECTION 5 - JLG CONTROL SYSTEM Table 5-8. J4 Connector PIN TAGNAME FUNCTION TYPE 1 12V 12V Sensor Supply POWER OUTPUT 2 TILTX X-Axis Tilt Input (PWM) ANALOG INPUT 3 TILTY Y-Axis Tilt Input (PWM) ANALOG INPUT 4 GND Ground POWER OUTPUT Table 5-9.
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SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-20 – JLG Lift– 3121639
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL Backprobing This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances 1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution. When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector Assembly (2 of 4)). 2. Pull back on the contact wire with a force of 1 or 2 lbs.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 2. Pry open the wedge lock to the open position. 1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 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. Figure 6-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS HD30/HDP20 Series Assembly DT/DTP Series Assembly Figure 6-14. HD/HDP Contact Installation Figure 6-12. DT/DTP Contact Installation 1. Grasp contact about 25mm behind the contact crimp barrel. 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 2. Hold connector with rear grommet facing you. 3.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal 1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 2. Slide tool along into the insert cavity until it engages contact and resistance is felt. 3. Pull contact-wire assembly out of connector. Figure 6-17. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PUMP/MOTOR DRIVE CONTACTOR TO BATTERIES RIGHT DRIVE MOTOR DRIVE CONTROLLER F2 LEFT DRIVE MOTOR MAIN VALVE PLATFORM CONSOLE BOX BATTERY CHARGER TO GROUND CONTROL BOX TERMINAL J1 LIFT CYLINDER PRESSURE TRANSDUCER OR OVERLOAD CUT-OUT Figure 6-18.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO MOTOR/ GENERATOR GENERATOR MODULE J2 TO ANALYZER PROXIMITY SENSOR SWITCH (USA BUILT MACHINES S/N 0200138293 TO PRESENT) 4WD LEFT SIDE MOTOR OSCILLATING AXLE CYLINDERS PROXIMITY SENSOR SWITCH (USA BUILT MACHINES PRIOR TO S/N 0200138293 & ALL BELGIUM BUILT MACHINES) ROTARY ANGLE SENSOR SWITCH HORN TO BEACON LIGHT HARNESS GROUND CONTROL BOX TO ANALYZER PC BOARD CONTROLLER TO ANALYZER Figure 6-19.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS LEVEL JACK SWITCHES TO GENERATOR MODULE (M3369 & M4069) LEVEL JACK VALVES ALARM TO PLATFORM BEACON LIGHT VALVE HARNESS GROUND CONTROL BOX Figure 6-20.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DRIVE CONTROLLER DRIVE CONTACTOR CIRCUIT BREAKER RECEPTACLE AT PLATFORM PLATFORM CONSOLE BOX PLATFORM WORKLIGHTS Figure 6-21.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-23.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-24.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-25.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-26.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-27.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-28.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-29.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 6-24 – JLG Lift – 3121639
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3121639 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +55 19 3295 1025 +55 19 3295 0407 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.