Service and Maintenance Manual

Service and Maintenance Manual
Service and Maintenance Manual
Models
600SC
660SJC
S/N 74785
to Present
P/N - 3121157
November 14, 2005
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.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
B
HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
3121157
– JLG Lift –
A-1
INTRODUCTION
REVISON LOG
Original Issue
Revised
A-2
- December 4, 2003
- November 14, 2005
– JLG Lift –
3121157
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A
B
C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Operator Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SECTION 2 - GENERAL
2.1
2.2
2.3
3121157
Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
– JLG Lift –
i
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT - SECTION, PARAGRAPH
2.4
2.5
2.6
2.7
2.8
2.9
PAGE NO.
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6
Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .2-6
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 2-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SECTION 3 - UNDERCARRIAGE
3.1
3.2
3.3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Track tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Rubber Track Pad Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
SECTION 4 - TURNTABLE
4.1
4.2
4.3
4.4
4.5
Swing Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Swing Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Deutz EMR 2 (S/N 85110 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
SECTION 5 - BOOM & PLATFORM
5.1
5.2
5.3
5.4
ii
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Three Month Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Seven Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
– JLG Lift –
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TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT - SECTION, PARAGRAPH
5.5
5.6
5.7
5.8
5.9
PAGE NO.
Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Disassembly of Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
SECTION 6 - HYDRAULICS
6.1
6.2
6.3
6.4
6.5
6.6
6.7
3121157
Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Solenoid Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Cylinders Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Main Relief, Steer, Swing and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Articulating Jib Boom (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Inspect Parts For Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
– JLG Lift –
iii
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT - SECTION, PARAGRAPH
6.8
6.9
6.10
PAGE NO.
Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
Ports and Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Removal and Installation of FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Removal and Installation of FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Charge Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Hydraulic Pump W/hayes Pump Drive Coupling Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
Hydraulic Component Start-Up Procedures and recommendations . . . . . . . . . . . . . . . . . . . . . . .6-32
SECTION 7 - JLG CONTROL SYSTEM
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43
SECTION 8 - SCHEMATICS
8.1
8.2
8.3
iv
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
– JLG Lift –
3121157
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
2-14.
2-15.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
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.
4-14.
4-15.
4-16.
4-17.
4-18.
4-19.
4-20.
4-21.
4-22.
5-1.
3121157
TITLE
PAGE NO.
Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Torque Chart - (N, m) - (For Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Connector Assembly Figure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Connector Assembly Figure 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Connector Assembly Figure 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Connector Assembly Figure 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Engine Operating Temperature Specifications - Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Chassis Service Notes - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Chassis Service Notes - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Bottom Track Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Carrier Track Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Hose Routing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Hose Routing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Track Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Spring & Shock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Swing Torque Hub Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Swing Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Deutz Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Deutz Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Caterpillar Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Caterpillar Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
– JLG Lift –
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TABLE OF CONTENTS (Continued)
LIST OF FIGURES (continued)
FIGURE NO.
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.
5-20.
5-21.
5-22.
5-23.
5-19.
5-24.
5-25.
5-26.
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
TITLE
PAGE NO.
Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Boom Assembly Cutaway - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Boom Assembly Cutaway - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Boom Assembly Cutaway - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Location of Components - Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Removing Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Articulating Jib Boom Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Main Control Valve Pressure Adjustments - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Main Control Valve Pressure Adjustments - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Location of Components - Main Control Valve (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Location of Components - Main Control Valve (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Main Control Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Platform Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Platform Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Plugs/Fittings Size & Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
– JLG Lift –
3121157
TABLE OF CONTENTS
LIST OF FIGURES (continued)
FIGURE NO.
6-30.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
8-11.
8-12.
8-13.
8-14.
3121157
TITLE
PAGE NO.
Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
ADE Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .7-11
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . .8-4
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . .8-5
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . .8-6
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . .8-7
Electrical Schematic - Deutz EMR2 - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Electrical Schematic - Deutz EMR2 - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Electrical Schematic - Deutz EMR2 - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
Electrical Schematic - Deutz EMR2 - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Hydraulic Schematic - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
Hydraulic Schematic - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Hydraulic Schematic - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Hydraulic Schematic - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15
– JLG Lift –
vii
TABLE OF CONTENTS (Continued)
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.
2-1
2-2
2-3
6-1
6-2
6-3
6-4
7-1
7-2
7-3
7-4
7-5
7-6
viii
TITLE
PAGE NO.
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Deutz F4M1011F/F4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Caterpillar 3044C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
Adjustments - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43
Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46
– JLG Lift –
3121157
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS
1.3 ENGINE DATA
Table 1-3. Deutz F4M1011F/F4M2011 Specifications
Table 1-1. Operating Specifications
Fuel
Maximum Work Load (Capacity)
Unrestricted:
Restricted - 600SC
Restricted - 660SJC
500 lb. (230 kg)
1000 lb. (450 kg)
500 lb. (230 kg)
Maximum Travel Grade (Gradeability)*
55%
Maximum Travel Grade (Side Slope)*
5°
Max.Vertical Platform Height:
600SC
660SJC
60 ft. 3 in. (18.36 m)
66 ft. 8 in. (20.32 m)
Oil Capacity
Cooling System
Crankcase
Total Capacity
49 ft. 6 in. (15.09 m)
56 ft. 9 in. (17.3 m)
Turning Radius - Inside
0
Turning Radius - Outside
8 ft. (2.4 m)
Low RPM
1800
High RPM
2800
Alternator
Horsepower
6.5 psi (0.457 kg/cm2)
1.6 mph (2.6 kph)
65 @ 3000 RPM, full load
Type
Cylinders
Maximum Wind Speed
28 mph (12.5 m/s)
Bore
Maximum Manual Force
101 lb. (450 N)
Electrical System Voltage
12 Volts
Stroke
Aspiration
Four Stroke Cycle
4 in-line
3.70 inch (94 mm)
4.72 inch (120 mm)
turbocharged
Compression ratio
22,500 lb. (10,205 kg)
27,100 lb. (12,292 kg)
Displacement
Firing Order
* With boom in stowed position.
1.2 CAPACITIES
Table 1-2. Capacities
Fuel Tank
39 US. Gallons (147.6 L)
Hydraulic Oil Tank
31 U.S. Gallons (117.3 L)
3121157
1.90 GPH (7.19 lph)
2.50 GPH (9.46 lph)
Table 1-4. Caterpillar 3044C
4500 psi (310 Bar)
Engine Crankcase
Deutz w/Filter
Caterpillar (w/filter)
60 Amp, belt drive
1000 Cold Cranking Amps, 210
Minutes Reserve Capacity, 12 VDC
Fuel Consumption
Low RPM
High RPM
Max. Hydraulic System Pressure
Hydraulic System (Including Tank)
1000
5.45 psi (0.383 kg/cm2)
Maximum Drive Speed:
Gross Machine Weight (Platform Empty)
600SC
660SJC
5 Quarts (4.5 L)
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L)
Idle RPM
Battery
Max.Horizontal Platform Reach:
600SC
660SJC
Maximum Ground Bearing Pressure
600SC
660SJC
Diesel
37.2 U.S. Gallons (140.8 L)
19:1
3 (3.33 L)
203 in
1-3-4-2
Rotation (viewed from flywheel)
Counterclockwise
Oil Capacity (w/filter)
10.6 quarts (10 L)
Cooling System (Engine Only)
5.8 quarts (5.5 L)
Idle RPM
1000
Low RPM
1800
High RPM
2800
Alternator
60 Amp, belt drive
Battery
11 quarts (10.5 L)
10.6 quarts (10 L)
– JLG Lift –
930 Cold Cranking Amps, 205
Minutes Reserve Capacity, 12 VDC
1-1
SECTION 1 - SPECIFICATIONS
1.4 COMPONENT DATA
1.5 PERFORMANCE DATA
Swing System
Function Speeds
Table 1-5. Swing System
Swing Motor Displacement
Swing Brake
Table 1-8. Function Speeds
4.62 cu. in. (75 cm3)
Automatic spring applied hydraulically released disc brakes.
Swing Hub Ratio - 50:1
Main Boom Speed - Telescope
Main Boom Speed - Lift
Up 46 - 60 Seconds
Down 33 - 43 Seconds
Swing Speed 360°
Note 1
Left 79 - 101 Seconds
Right 79 - 101 Seconds
Swing Hub Ratio - 50:1
Gear Pump @ 1800 rpm
7.9 GPM (29.90 lpm)
Pump Displacement
1.02 cu. in. (16 cm3)
Rotation
Clockwise
Auxiliary Power Pump
Table 1-6. Auxiliary Power Pump
Output
2.6 GPM (9.8 lpm) @
1200 PSI (82.7 BAR)
Pump Displacement
0.244 cu. in. (14 cm3)
Motor Type
DC
Rotation
Clockwise
Out 50 - 67 Seconds
In 22 - 33 Seconds
Drive (Horizontal)
Note 2
Forward & Reverse 85-90
Drive (Out of Transport)
Note 3
Forward & Reverse 80-85
Rotator Speed
Note 4
Left 16-25 Seconds
Right 16-25 Seconds
Jib Boom Speed - Lift
Up 22 - 34 Seconds
Down 16 - 26 Seconds
Note 1: No more than 10% difference between swing left and right.
Note 2: 200 ft. (61 m) course
Note 3: 50 ft. (15.2 m) course
Note 4: No more that 15% difference between rotator left and right.
Dimensions
Hydraulic Filters
Table 1-9. Dimensions
Table 1-7. Hydraulic Filters
Hydraulic Filter Location
In-line
Return Filter Type
Bypass Type
Return Filter Rating
10 Microns Absolute
Charge Filter Rating
10 Microns Absolute
Strainer Rating (In Tank)
30 Microns
Boom Elevation - 600SC
+60 ft. 2 13/16 in. (18.36 m)
-6 ft. 1 11/16 in. (1.87 m)
Boom Elevation - 600SCJ
+60 ft. 5 3/4 in. (18.43 m)
-9 ft. 9 3/16 in. (2.98 m)
Boom Elevation - 660SCJ
+66 ft. 7 5/8 in. (20.31 m)
-11 ft. 5 1/4 in. (3.49 m)
Machine Height (Stowed)
Steel Track - 8’4" (2.54 m)
Rubber Track - 8’6" (2.59 m)
Machine Length (Stowed)
35’ 6" (10.8 m)
Machine Width
1-2
– JLG Lift –
8 ft. (2.4 m)
3121157
SECTION 1 - SPECIFICATIONS
1.6 TORQUE REQUIREMENTS
1.8 CYLINDER SPECIFICATIONS
Table 1-10. Torque Requirements
Torque Value
(Dry)
Description
Table 1-12. Cylinder Specifications
BORE
Interval
Hours
Bearing To Chassis
See Note
50/600*
Bearing To Turntable
See Note
50/600*
Wire Rope
15 ft.lbs.
(20 Nm)
150
M16 Travel Motor
mounting bolts
175 ±30 ft.lbs.
(240±40 Nm)
As
required
M20 Final Drive
mounting bolts
390 ±50 ft.lbs.
(530±70 Nm)
As
required
M20 Track Roller
mounting bolts
340 ±44 ft.lbs.
(460±60 Nm)
As
required
M24 Carrier Roller
mounting bolts
600 ±70 ft.lbs.
(800±100 Nm)
As
required
STROKE
ROD DIA.
660SJ
600S
660SJ
600S
660SJ
600S
Lift
6.00
(152.4)
6.00
(152.4)
44.6875
(1135.1)
44.6875
(1135.1)
3
(76.2)
3
(76.2)
Telescope
3.5
(88.9)
3.5
(88.9)
168.437 177.75
(4278.3) (4514.9)
2.5
(63.5)
2.5
(63.5)
Master
3.5
(88.9)
3
(76.2)
13.0625
(331.8)
8.5
(215.9)
1.5
(38.1)
1.5
(38.1)
Slave Level
3.5
(88.9)
3
(76.2)
13.0625
(331.8)
8.5
(215.9)
1.5
(38.1)
1.5
(38.1)
Lift (Jib Boom)
3
(76.2)
N/A
25.5
(647.7)
N/A
1.5
(38.1)
N/A
1.9 MAJOR COMPONENT WEIGHTS
Table 1-13. Major Component Weights
660SJ
*Check swing bearing bolts for security after first 50 hours
of operation and every 600 hours thereafter. (See paragraph on Swing Bearing in Section 2.)
NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart to
determine proper torque value.
1.7 PRESSURE SETTINGS
600S
LB.
KG.
LB.
KG.
Platform Control Console
250
113
250
113
Platform Level Cylinder
60
27
46
21
Main Boom (Includes Lift Cyl., Rotator,
and Support)
3783
1716
3527
1600
Turntable Complete (including engine)
9065
4112
7315
3318
Table 1-11. Dimensions
Main Relief
Upper Boom Lift Down
Swing
3000 PSI (206.85 Bar)
1500 PSI (103.4 Bar)
1700 PSI (117.2 Bar)
Platform Level - Forward
2800 PSI (193.06 Bar)
Platform Level - Backward
1800 PSI (124.11 Bar)
Jib Boom - Up
1500 PSI (103 Bar)
Jib Boom - Down
1200 PSI (82.7 Bar)
3121157
– JLG Lift –
1-3
SECTION 1 - SPECIFICATIONS
1.10 SERIAL NUMBER LOCATIONS
the machine serial number is stamped on the left side of
the frame.
A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing,
SERIAL NUMBER
PLATE
SERIAL NUMBER
(STAMPED ON FRAME)
Figure 1-1. Serial Number Locations
1-4
– JLG Lift –
3121157
SECTION 1 - SPECIFICATIONS
1.11 HYDRAULIC OIL
Table 1-16. Mobil DTE 13M Specs
Table 1-14. Hydraulic Oil
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
SAE VISCOSITY GRADE
+0° to +180° F (-18° C to +83° C)
10W
+0° F to +210° F (-18° C to +99° C)
10W-20, 10W-30
+50° F to +210° F (+10° C to +210° C)
20W-20
ISO Viscosity Grade
#32
Specific Gravity
0.877
Pour Point, Max
-40°F (-40°C)
Flash Point, Min.
330°F (166°C)
Viscosity
at 40° C
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152.
33cSt
at 100° C
6.6 cSt
at 100° F
169 SUS
at 210° F
48 SUS
cp at -20° F
6,200
Viscosity Index
140
NOTE: When temperatures remain below 20° F (-7 degrees
C), JLG Industries recommends the use of Mobil
DTE 13M.
Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommendations.
Table 1-15. Mobilfluid 424 Specs
SAE Grade
10W30
Gravity, API
29.0
Density, Lb/Gal. 60°F
7.35
Pour Point, Max
-46°F (-43°C)
Flash Point, Min.
442°F (228°C)
Viscosity
Brookfield, cP at -18°C
2700
at 40° C
55 cSt
at 100° C
9.3 cSt
Viscosity Index
152
3121157
– JLG Lift –
1-5
SECTION 1 - SPECIFICATIONS
Figure 1-2. Operator Maintenance and Lubrication Diagram
1.12 OPERATOR MAINTENANCE AND
LUBRICATION
NOTE: The following numbers correspond to those in Figure
1-2., Operator Maintenance and Lubrication Diagram.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN
MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE
ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.
Table 1-17. Lubrication Specifications
1. Swing Bearing
KEY
SPECIFICATIONS
MPG
Multipurpose Grease having a minimum dripping point of 350° F
(177° C). Excellent water resistance and adhesive qualities, and
being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105
HO
Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid
424.
EO
Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104.
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access
1-6
– JLG Lift –
3121157
SECTION 1 - SPECIFICATIONS
2. Swing Drive Hub
5. Hydraulic Charge Filter
Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation
Interval - Change after first 50 hrs. and every 6
months or 300 hrs. thereafter or as indicated by
Condition Indicator.
6. Hydraulic Tank
3. Final Drive Hub
Lube Point(s) - Level/Fill Plug
Capacity - 2.1 gal.(7.9 L); 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation
NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION
4. Hydraulic Return Filter
Lube Point(s) - Fill Cap
Capacity - 30.6 gal. Tank; 32.7 gal. System
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
Interval - Change after first 50 hrs. and every 6
months or 300 hrs. thereafter or as indicated by
Condition Indicator.
3121157
– JLG Lift –
1-7
SECTION 1 - SPECIFICATIONS
7. Suction Strainers (in tank)
10. Fuel Filter - Deutz
REMOVE FILL CAP PLATE FROM
TANK TO GAIN ACCESS TO
STRAINERS
Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
11. Fuel Filter - Caterpillar
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.
Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
12. Air Filter
8. Oil Change w/Filter - Deutz
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts Crankcase; 5 Quarts Cooler
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accordance with engine manual.
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator
9. Oil Change w/Filter - Caterpillar
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 10.6 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with engine manual.
1-8
– JLG Lift –
3121157
3121157
– JLG Lift –
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.1120
IN
BOLT
DIA.
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
SQ. IN.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
FT-LB
8
9
16
18
30
31
43
49
96
120
IN-LB
263
TENSILE
CLAMP DRY OR
STRESS
LOAD LOCTITE
AREA
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
FT-LB
6
7
12
13
22
23
32
36
75
86
IN-LB
LUB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
FT-LB
—
—
—
—
—
—
—
—
—
—
IN-LB
LOCTITE
262
TORQUE
Note: These torque values do not apply to cadmium plated fasteners.
1-1/2
1-3/8
1-1/4
1-1/8
1
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
8
6
4
SIZE
THDS.
PER
INCH
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
FT-LB
—
—
—
—
—
—
—
—
105
135
IN-LB
LOCTITE
242 OR
271
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
CLAMP
LOAD
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
1280
1440
1820
2000
2380
2720
3160
3560
FT-LB
12
13
23
25
41
43
60
68
144
168
IN-LB.
DRY OR
LOCTITE
263
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
960
1080
1360
1500
1780
2040
2360
2660
FT-LB
9
10
17
19
31
32
45
51
108
120
IN-LB
LUB
22
25
40
45
63
70
96
108
139
154
180
204
301
336
485
534
687
796
1030
1155
1453
1610
1907
2165
2530
2844
FT-LB
—
—
—
—
—
—
—
—
—
—
IN-LB
LOCTITE
262
TORQUE
30
30
50
55
80
90
120
130
165
190
240
265
420
465
660
725
990
1100
1400
1575
2000
2200
2625
3000
3475
3925
FT-LB
—
—
—
—
—
—
—
—
160
185
IN-LB
LOCTITE
242 OR
271
SAE GRADE 8 BOLTS & GRADE 8 NUTS
& SOCKET HEAD CAP SCREWS
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
SAE GRADE 5 BOLTS &
GRADE 2 NUTS
UNPLATED CAP SCREWS
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
—
—
—
—
—
—
—
—
3180
3640
LB.
25
27
45
50
70
75
110
115
155
165
210
220
365
400
585
635
865
915
1240
1380
1750
1880
2320
2440
3040
3270
FT-LB
—
—
—
—
—
—
—
—
160
168
IN-LB
PATCH
28
30
50
55
77
82
120
127
170
182
231
242
400
440
645
700
950
1000
1365
1520
1925
2070
2550
2685
3345
3600
FT-LB
—
—
—
—
—
—
—
—
168
178
IN-LB
PATCH
TORQUE
CLAMP WITHOUT WITH
LOAD LOC-WEL LOC-WEL
UNBRAKO 1960 SERIES
SOCKET HEAD
SECTION 1 - SPECIFICATIONS
Figure 1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)
1-9
1-10
– JLG Lift –
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
SQ. IN.
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
IN
0.1120
TENSILE
STRESS
AREA
BOLT
DIA.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
CLAMP
LOAD
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
N, m
.8
1.0
1.8
2.0
3.4
3.4
5
6
11
14
DRY OR
LOCTITE
263
N, m
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
N, m
.8
.8
1.4
1.6
2.4
2.6
3.6
4
8
10
N, m
LUB
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
N, m
—
—
—
—
—
—
—
—
—
—
N, m
LOCTITE
262
TORQUE
Note: These torque values do not apply to cadmium plated fasteners.
1-1/2
1-3/8
1-1/4
1-1/8
1
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
8
6
4
SIZE
THDS.
PER
INCH
26
28
47
54
75
81
115
136
163
183
224
258
386
447
644
705
915
997
1139
1254
1593
1763
2068
2373
2745
3118
N, m
—
—
—
—
—
—
—
—
12
15
LOCTITE
242 OR
271
N, m
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
CLAMP
LOAD
34
34
61
68
95
108
149
163
203
230
298
325
515
569
813
895
1220
1356
1735
1952
2468
2712
3227
3688
4284
4827
N, m
1.4
1.5
2.6
2.8
4.6
5
7
8
16
19
DRY OR
LOCTITE
263
N, m
24
27
47
47
75
81
108
122
149
176
230
244
380
434
624
678
922
1003
1302
1464
1844
2034
2413
2766
3200
3606
N, m
1.0
1.0
2.0
2.2
3.4
3.6
5
6
12
14
N, m
LUB
30
34
54
61
85
95
130
146
188
209
244
277
408
456
658
724
931
1079
1396
1566
1970
2183
2586
2935
3430
3856
N, m
—
—
—
—
—
—
—
—
—
—
N, m
LOCTITE
262
TORQUE
41
41
68
75
108
122
163
183
224
258
325
359
569
630
895
983
1342
1491
1898
2135
2712
2983
3559
4067
4711
5322
N, m
—
—
—
—
—
—
—
—
18
21
LOCTITE
242 OR
271
N, m
SAE GRADE 8 BOLTS & GRADE 8 NUTS
& SOCKET HEAD CAP SCREWS
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
SAE GRADE 5 BOLTS &
GRADE 2 NUTS
UNPLATED CAP SCREWS
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
—
—
—
—
—
—
—
—
3180
3640
LB.
CLAMP
LOAD
34
37
61
68
95
102
149
156
210
224
285
298
495
542
793
861
1173
1241
1681
1871
2373
2549
3145
3308
4122
4433
N, m
—
—
—
—
—
—
—
—
18
19
38
41
68
75
104
111
163
172
230
247
313
328
542
597
874
949
1288
1356
1851
2061
2610
2807
3457
3640
4535
4881
N, m
—
—
—
—
—
—
—
—
19
20
TORQUE
WITHOUT
WITH
LOC-WEL LOC-WEL
PATCH
PATCH
N, m
N, m
UNBRAKO 1960 SERIES
SOCKET HEAD
SECTION 1 - SPECIFICATIONS
Figure 1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners)
3121157
SECTION 1 - SPECIFICATIONS
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
CLASS 8.8 METRIC BOLTS &
CLASS 8 METRIC NUTS
SIZE
PITCH
CLASS 10.9 METRIC BOLTS &
CLASS 10 METRIC NUTS
TORQUE
TENSILE
STRESS
AREA
CLAMP
LOAD
sq. mm
TORQUE
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
CLAMP
LOAD
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
3
.5
5.03
2.19
1.3
1.0
1.2
1.4
3.13
1.9
1.4
1.5
2.1
3.5
.6
6.78
2.95
2.1
1.6
1.9
2.3
4.22
3.0
2.2
2.4
3.3
4
.7
8.78
3.82
3.1
2.3
2.8
3.4
5.47
4.4
3.3
3.5
4.8
5
.8
14.2
6.18
6.2
4.6
5.6
6.8
8.85
8.9
6.6
7.1
9.7
6
1
20.1
8.74
11
7.9
9.4
12
12.5
15
11
12
17
7
1
28.9
12.6
18
13
16
19
18
25
19
20
28
8
1.25
36.6
15.9
25
19
23
28
22.8
37
27
29
40
10
1.5
58.0
25.2
50
38
45
55
36.1
72
54
58
79
12
1.75
84.3
36.7
88
66
79
97
52.5
126
95
101
139
14
2
115
50.0
140
105
126
154
71.6
200
150
160
220
16
2
157
68.3
219
164
197
241
97.8
313
235
250
344
18
2.5
192
83.5
301
226
271
331
119.5
430
323
344
473
20
2.5
245
106.5
426
320
383
469
152.5
610
458
488
671
22
2.5
303
132.0
581
436
523
639
189.0
832
624
665
915
24
3
353
153.5
737
553
663
811
220.0
1060
792
845
1170
27
3
459
199.5
1080
810
970
1130
286.0
1540
1160
1240
1690
30
3.5
561
244.0
1460
1100
1320
1530
349.5
2100
1570
1680
2310
33
3.5
694
302.0
1990
1490
1790
2090
432.5
2600
2140
2280
2860
36
4
817
355.0
2560
1920
2300
2690
509.0
3660
2750
2930
4020
42
4.5
1120
487.0
4090
3070
3680
4290
698.0
5860
4400
4690
6440
Note: These torque values do not apply to cadmium plated fasteners.
METRIC CLASS 8.8
METRIC CLASS 10.9
Figure 1-5. Torque Chart - (N, m) - (For Metric Class Fasteners).
3121157
– JLG Lift –
1-11
SECTION 1 - SPECIFICATIONS
This page left blank intentionally.
1-12
– JLG Lift –
3121157
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.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The
following table outlines the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
environment, severity and frequency of usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to performing the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent
Inspection
The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
3121157
increased as environment, severity and frequency of
usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection
The Annual Machine Inspection must be performed by a
Factory-Certified Service Technician on an annual basis,
no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG Service
Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and
appropriate JLG inspection form for performance of this
inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.
Preventative Maintenance
In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.
– JLG Lift –
2-1
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.
Frequent Inspection
In service for 3 months or 150 hours, whichever comes first; or
Out of service for a period of more than 3
months; or
Purchased used.
Owner, Dealer, or User
Qualified JLG
Mechanic
Service and Maintenance
Manual and applicable JLG
inspection form.
Annual Machine
Inspection
Annually, no later than 13 months from the
date of the prior inspection.
Owner, Dealer, or User
Factory-Certified
Service Technician
Service and Maintenance
Manual and applicable JLG
inspection form.
Preventative
Maintenance
At intervals as specified in the Service and
Maintenance Manual.
Owner, Dealer, or User
Qualified JLG
Mechanic
Service and Maintenance
Manual
Type
Frequency
Pre-Start Inspection
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
2.2 SERVICE AND GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this book.
3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their containers until they are ready to be used.
Safety and Workmanship
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
Components Removal and Installation
Cleanliness
1. The most important single item in preserving the
long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.
2-2
– JLG Lift –
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90 degrees.
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.
3121157
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.
Pressure-Fit Parts
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.
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. (See
Torque Chart Section 1.)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.
Hydraulic System
Bearings
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain
and flush the entire system.
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.
2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the
inner race.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Lubrication
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.
Battery
Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.
Bolt Usage and Torque Application
1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
3121157
– JLG Lift –
2-3
SECTION 2 - GENERAL
3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
This will allow start up at temperatures down to -20
degrees F (-29 degrees C). However, use of this oil
will give poor performance at temperatures above
120 degrees F (49 degrees C). Systems using DTE
13 oil should not be operated at temperatures above
200 degrees F (94 degrees C) under any condition.
2.3 LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suction) lines.
Changing Hydraulic Oil
1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.
2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
components and generally results in faulty operation. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.
2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contaminants from the service container. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.
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. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is operating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
index of 152.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.
Lubrication Specifications
Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.
NOTE: Start-up of hydraulic system with oil temperatures
below -15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).
2-4
– JLG Lift –
3121157
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
1. Pinned joints should be disassembled
inspected if the following occurs:
Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, upper boom fully
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
If the machine does not pass this test, proceed with the
following.
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.
Cylinder Drift
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
Table 2-2. Cylinder Drift
Cylinder Bore Diameter
d. Debris embedded in liner surface.
Max. Acceptable Drift
in 10 Minutes
inches
mm
inches
mm
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):
3
76.2
0.026
0.66
a. Detectable wear in the bearing area.
3.5
89
0.019
0.48
4
101.6
0.015
0.38
b. Flaking, pealing, scoring, or scratches on the pin
surface.
5
127
0.009
0.22
c. Rusting of the pin in the bearing area.
6
152.4
0.006
0.15
7
177.8
0.005
0.13
8
203.2
0.0038
0.10
9
228.6
0.0030
0.08
4. Re-assembly of pinned joints using filament wound
bearings.
a. Housing should be blown out to remove all dirt
and debris...bearings and bearing housings
must be free of all contamination.
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.
The cylinder must have the normal load, which is the normal platform load applied.
If the cylinder passes this test, it is acceptable.
NOTE: This information is based on 6 drops per minute cylinder leakage.
3121157
– JLG Lift –
b. Bearing / pins should be cleaned with a solvent
to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave
pins).
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would damage the bearing during installation and operation.
2-5
SECTION 2 - GENERAL
2.6 WELDING ON JLG EQUIPMENT
NOTE: This instruction applies to repairs, or modifications to
the machine and to welding performed from the
machine on an external structure, or component,
Do the Following When Welding on JLG
Equipment
2.7 APPLYING SILICONE DIELECTRIC
COMPOUND TO ELECTRICAL
CONNECTIONS
Silicone Dielectric Compound must be used on all electrical connections for the following reasons:
• To prevent oxidation at the mechanical joint between
male and female pins.
• Disconnect the battery.
• Disconnect the moment pin connection (where fitted)
• Ground only to structure being welded.
Do NOT Do the Following When Welding on
JLG Equipment
• 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. This procedure
applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with
external seals.
• Ground on frame and weld on any other area than the
chassis.
1. To prevent oxidation, silicone grease must be
packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.
• Ground on turntable and weld on any other area than
the turntable.
• Ground on the platform/support and weld on any other
area than the platform/support.
• Ground on a specific boom section and weld on any
other area than that specific boom section.
NOTE: Over a period of time, oxidation increases electrical
resistance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed
around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the connector should also be sealed.
• Allow pins, wear pads, wire ropes, bearings, gearing,
seals, valves, electrical wiring, or hoses to be between
the grounding position and the welded area.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
NOTE: This condition is especially common when machines
are pressure washed since the washing solution is
much more conductive than water.
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to
the contacts only.
NOTE: Curing-type sealants might also be used to prevent
shorting and would be less messy, but would make
future pin removal more difficult.
2-6
– JLG Lift –
3121157
SECTION 2 - GENERAL
Assembly
2.8 AMP CONNECTOR
Applying Silicone Dielectric Compound to
AMP Connectors
Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 2-1.). Proceed as follows:
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. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely
around male and female pins on the inside of the
connector after the mating of the housing to the
header. This is easily achieved by using a syringe to
fill the header with silicone dielectric compound, to a
point just above the top of the male pins inside the
header. When assembling the housing to the
header, it is possible that the housing will become
air locked, thus preventing the housing latch from
engaging.
2. Pierce one of the unused wire seals to allow the
trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire
seal that has silicone dielectric compound escaping
from it.
Figure 2-1. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 2-3.).
2. Pull back on the contact wire with a force of 1 or 2
lbs. to be sure the retention fingers are holding the
contact (See Figure 2-3.).
Figure 2-2. AMP Connector
3121157
– JLG Lift –
2-7
SECTION 2 - GENERAL
Figure 2-3. 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 2-4.).
4. Slide the wedge lock into the housing until it is flush
with the housing (See Figure 2-5.).
Figure 2-5. Connector Assembly Figure 4
Figure 2-4. Connector Assembly Figure 3
2-8
– JLG Lift –
3121157
SECTION 2 - GENERAL
Figure 2-6. 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.
NOTE: The wedge lock should never be removed from the
housing for insertion or removal of the contacts.
Wedge Lock
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. This nullifies the effectiveness of the connector seals and could result in system failure.
The wedge lock has slotted openings in the forward, or
mating end. These slots accommodate circuit testing in
the field, by using a flat probe such as a pocket knife. DO
NOT use a sharp point such as an ice pick.
3121157
– JLG Lift –
2-9
SECTION 2 - GENERAL
Figure 2-7. Connector Installation
2-10
– JLG Lift –
3121157
SECTION 2 - GENERAL
2.9 DEUTSCH CONNECTORS
DT/DTP Series Disassembly
DT/DTP Series Assembly
A
A
B
B
C
C
D
Figure 2-8. DT/DTP Contact Installation
Figure 2-9. DT/DTP Contact Removal
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly
locked in place.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular
wedges are not oriented. Thy may go in either way.
1. Remove wedgelock using needlenose pliers or a
hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards,
while at the same time releasing the locking finger
by moving it away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact
may displace the seal.
NOTE: The receptacle is shown - use the same procedure
for plug.
3121157
– JLG Lift –
2-11
SECTION 2 - GENERAL
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
B
A
A
C
C
Figure 2-10. HD/HDP Contact Installation
Figure 2-12. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact
crimp barrel.
1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be
removed.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm that it is
properly locked in place.
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 2-11. HD/HDP Locking Contacts Into Position
NOTE: For unused wire cavities, insert sealing plugs for full
environmental sealing
2-12
B
Figure 2-13. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
– JLG Lift –
3121157
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Boom Assembly
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Preventive or Frequent3
Maintenance Maintenance Inspection
Annual4
(Yearly)
Inspection
9
1,2,4
1,2,4
1,2,9,12
1,2,9,12
Pivot Pins and Pin Retainers
1,2
1,2
Sheaves, Sheave Pins
1,2
1,2
Bearings
1,2
1,2
Wear Pads
1,2
1,2
Covers or Shields
1,2
1,2
1,2,3
1,2,3
Boom Weldments
Hose/Cable Carrier Installations
Extend/Retract Chain or Cable Systems
Platform Assembly
9
Platform
1,2
Railing
1,2
1,2
5
Gate
Floor
1,2
Turntable Assembly
1
1,2
1
1,5
1
1,2
1,2,10
1,2,10
1,2,14
1,2,3,13,14
1,2,5
1,2,5
5
1,2,5
9,5
Rotator
Lanyard Anchorage Point
Every 2
Years
2
9
Swing Bearing or Worm Gear
9
Oil Coupling
Swing Drive System
Turntable Lock
Hood, Hood Props, Hood Latches
Chassis Assembly
9
Tires
1
16,17
16,17,18
16,17,18
Wheel Nuts/Bolts
1
15
15
15
14,24
Wheel Bearings
5,8
Oscillating Axle/Lockout Cylinder Systems
Outrigger or Extendable Axle Systems
5,8
5,8
11
11
6
6
Steer Components
Drive Motors
Torque Hubs
Functions/Controls
9
Platform Controls
5
3121157
5
– JLG Lift –
2-13
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Preventive or Frequent3
Maintenance Maintenance Inspection
Annual4
(Yearly)
Inspection
5
5
6
6
Function Control Locks, Guards, or Detents
1,5
1,5
5
5
Footswitch
1,5
5
5
5
5
5
5
5
Ground Controls
Emergency Stop Switches (Ground & Platform)
Function Limit or Cutout Switch Systems
5
Capacity Indicator
Drive Brakes
5
Swing Brakes
5
5
Boom Synchronization/Sequencing Systems
5
5
3
3
9,11
11
11
1,7
7
7
9
9
Manual Descent or Auxiliary Power
Power System
9
Engine Idle, Throttle, and RPM
Engine Fluids (Oil, Coolant, Fuel)
11
Air/Fuel Filter
1,9
Exhaust System
Batteries
5
1,9
Battery Fluid
11
Battery Charger
5
Fuel Reservoir, Cap, and Breather
Hydraulic/Electric System
11,9
19
11
11
5
2
1,5
1,5
9
1,9
Hydraulic Pumps
1,9,7
Hydraulic Cylinders
1,2,9
2
1,2,9
1,2,9
1,2
1,2
Cylinder Attachment Pins and Pin Retainers
1,9
Hydraulic Hoses, Lines, and Fittings
1,9
12
1,2,9,12
1,2,9,12
1,9
2
1,5
1,5
7
7
7,11
7,11
20
20
Hydraulic Reservoir, Cap, and Breather
11
1,9
Hydraulic Filter
Hydraulic Fluid
Every 2
Years
11
Electrical Connections
1
Instruments, Gauges, Switches, Lights, Horn
1
24
5,23
General
Operators and Safety Manuals in Storage Box
21
21
21
21
ANSI and EMI Manuals/Handbooks Installed
Capacity Decals Installed, Secure, Legible
21
21
21
All Decals/Placards Installed, Secure, Legible
21
21
21
2-14
– JLG Lift –
3121157
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Walk-Around Inspection Performed
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Preventive or Frequent3
Maintenance Maintenance Inspection
Annual4
(Yearly)
Inspection
21
Annual Machine Inspection Due
21
No Unauthorized Modifications or Additions
21
21
All Relevant Safety Publications Incorporated
21
21
General Structural Condition and Welds
2,4
2,4
All Fasteners, Pins, Shields, and Covers
1,2
1,2
Grease and Lubricate to Specifications
22
22
21
21, 22
7
7
Function Test of All Systems
Every 2
Years
21
Paint and Appearance
Stamp Inspection Date on Frame
22
Notify JLG of Machine Ownership
22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
3121157
– JLG Lift –
2-15
SECTION 2 - GENERAL
4150548 A
Figure 2-14. Engine Operating Temperature Specifications - Deutz
2-16
– JLG Lift –
3121157
SECTION 2 - GENERAL
4150548 A
Figure 2-15. Engine Operating Temperature Specifications - Caterpillar
3121157
– JLG Lift –
2-17
SECTION 2 - GENERAL
This page left blank intentionally.
2-18
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
SECTION 3. UNDERCARRIAGE
3.1 ASSEMBLY
with bolts using impact wrench. Torque to 230 ft-lbs,
+15-0 (322 Nm, +21 -0).
1. Place frame into upside down position.
2. Make sure roller mounting rails are clean.
3. With air gun, blow out all 48 roller mounting holes.
Wipe mounting surfaces clean with rag. verify all
threads are clean of grease & oil.
4. Using crane, position and align (12) rollers, (6) per
side. Assemble with hardware and loctite. torque
(48) bolts to 200 ft.-lbs, +15-0 (280 Nm, +21 -0).
9. Repeat process to opposite side:
10. Clean machined mounting surface (one side only)
with solvent rags.
NOTE: Sprockets are not directional.
5. Using brush and solvent container, wash both inside
and out on both motor mounts areas. Using dry
rags, wipe motor mount area dry, inside and outside.
11. Apply never seez to sprocket mounting area. Hook
to crane using strap and alignment pin. lift up and
onto motor drive. Secure with bolts and loctite.
torque to 230 ft-lbs, +15-0 (322 Nm, +21 -0).
6. Clean the machined mounting surfaces on each
drive motor.
7. Get hardware for mounting drive motors and place
washers onto each bolt and add loctite.
8. Lift the drive assembly into place using an adequate
lifting device and nylon straps. Level, check, and fill
(if needed) the oil content. Apply Never Seez to
motor mount area. Re-align the motor in the nylon
straps as needed & assemble to carbody. Secure
3121157
– JLG Lift –
3-1
SECTION 3 - UNDERCARRIAGE
Figure 3-1. Chassis Service Notes - Sheet 1 of 2
3-2
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
1
Track tension adjustment to be made between the idler and carrier roller - 0.781 inches (19.8
mm)
2
Never-Seez to be used on master link pin before assembly. Torque Pad bolts over master link to
65 ft-lbs +6,-6 then tighten 1/3 (120°)turn further.
3
Fill Plug
4
Check oil level of left & right crawler drives (0.69 gal. [2.6 L] grade 90 Gear Oil)
5
Drain Plug
6
Torque to 200 ft-lbs, +15 -0 (280 Nm, +21 -0)
7
Use Gradall 8381-3109 Large Button Head Grease Fitting Adapter to Adjust Tracks
8
Torque to 65 ft-lbs, +10 -0 (91 Nm, +15 -0)
9
Torque to 340 ft-lbs, +25 -0 (476 Nm, +35 -0)
10
Offset in Idler Spring from centerline of Idler to be oriented down.
11
Torque to 165 ft-lbs, +15 -0 (231 Nm, +21 -0)
12
Add Never-Seez to both mounting pilots Drive Motors
13
Torque to 230 ft-lbs, +15 -0 (322 Nm, +21 -0)
14
Torque to 93 ft-lbs, +10 -0 (130 Nm, +14 -0)
15
Torque to 53 ft-lbs, +5 -0 (74 Nm, +7 -0)
Figure 3-2. Chassis Service Notes - Sheet 2 of 2
3121157
– JLG Lift –
3-3
SECTION 3 - UNDERCARRIAGE
1.
2.
3.
4.
Counterweight
Cover Plate
Drive Assembly
Bottom Track Roller
5.
6.
7.
8.
Carrier Track Roller
Track Assembly
Drive Sprocket
Frame
9. Idler Assembly
10. Spring Assembly
11. Shock Assembly
Figure 3-3. Chassis Components
12. Repeat process to opposite side:
13. Assemble fitting and fitting seal into the end of each
shock assembly. Torque to chart specifications.
14. Assemble shock assembly into position. Secure with
bolts, washers, and loctite. Torque to 65 ft-lbs, +100 (91 Nm, +15 -0).
15. Repeat process to the opposite side.
16. Using an adequate lifting device, lift & turn over the
frame. Position the left and right frame sides on plywood and idler ends on 4 x 4 blocks.
17. Using an adequate lifting device, pick up spring
assembly upright onto idler assembly. Install using
bolts, washers, and loctite. Torque to 165 ft-lbs
(+15-0 (231 Nm, +21 -0). (Repeat for the other idler
assembly.)
18. Repeat process for opposite side.
3-4
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
19. Reference offset in idler spring from centerline of
idler (to be oriented down). Using gantry crane and
sling, pick up and slide spring / idler assembly into
pre-greased slider area, using nylon sledge hammer
lightly to assemble. Repeat for other side.
27. Route brake, shift, and drain hoses through rh side
frame. Lubricate o-rings, and hand tighten hoses to
RH drive motor fittings.
20. Repeat process for opposite side:
21. Push idler assembly against the seat. Using the special adapter, pump in grease to start expanding
shock assembly; just enough to inspect for proper
assembly prior to track installation.
22. Repeat process to opposite side:
23. Assemble fittings for hoses to both drive motors finger tight until correct positioning is established.
24. Install swivel supports with hardware and loctite.
Torque supports to 53 ft-lbs, +5-0 (74 Nm, +7 -0).
25. Lift swivel using supports previously installed, and
assemble to frame. Use loctite with bolts to help
secure. Torque to 68 ft-lbs.(95 Nm).
26. Guide in hoses from swivel area through each side
frame. Make initial connections for hoses from
swivel to drive motors.
3121157
28. Repeat hose routing process on LH side frame with
correct hoses to drive motor.
– JLG Lift –
3-5
SECTION 3 - UNDERCARRIAGE
1. Guide Roller
2. Shaft
3. Plug
4. Bearing
5. Ring
6. Seal
7. Mounting Bracket
8. O-ring
9. Roll Pin
Figure 3-4. Bottom Track Roller Assembly
3-6
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
1.
2.
3.
4.
Guide Roller
Shaft
Internal Cover
Bolt
5.
6.
7.
8.
Washer
Roller Bearing
Not Used
Seal Ring
9. Tension Ring
10. Collar
11. Packing Ring
12. Seal Ring
13. Cover
14. Cover Seal
15. Lockwasher
16. Bolt
Figure 3-5. Carrier Track Roller Assembly
3121157
– JLG Lift –
3-7
SECTION 3 - UNDERCARRIAGE
Figure 3-6. Hose Routing - Sheet 1 of 2
3-8
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
Figure 3-7. Hose Routing - Sheet 2 of 2
3121157
– JLG Lift –
3-9
SECTION 3 - UNDERCARRIAGE
29. Route reverse & forward hoses through frame one at
a time. Lubricate o-rings, and hand tighten to drive
motor fittings.
34. Move to drive motors. Starting with brake hose for
easy access, torque (3) small hoses on both sides of
the drive motor according to torque chart specifications.
35. Torque (2) large hoses on each drive motor according to torque chart specifications.
36. Install the swivel stabilizer and secure With Loctite.
Torque to 93 ft-lbs, +10-0 (130 Nm, +14 -0).
37. Clean split post on each side of the frame, and wipe
off grease from roller assembly. Apply Never-Seez.
Slide roller assembly into split post hole and secure
with nut, bolt, and loctite. Torque to 340 ft-lbs, +25-0
(476 Nm, +35 -0)on both sides.
38. Place washers on cover plate retaining bolts and
apply loctite on each bolt. Install the cover plates
and torque bolts according to chart specifications.
30. Assemble tee fittings in bottom ports '5' & '6'. Torque
per chart specs. route and connect, shift, & drain
hoses. Torque hoses according to chart specifications.
31. Assemble swivel tee fitting in bottom port '7'. Route
and connect brake hose. Torque hose & fitting
according to chart specifications.
32. Assemble fittings to center pin for reverse hoses,
ports '3' & '4'. Torque according to chart specifications. Route and connect hoses to fittings. Torque
hoses according to chart specifications.
33. Assemble fittings to center pin for forward hoses,
ports '1' & '2'. Torque according to chart specifications. Route and connect hoses to fittings. Torque
hoses according to chart specifications.
3-10
39. Using overhead crane, set the tracks in position on
the shop floor. Unroll track completely by crane lifting and pushing along. Using bolt cutters to cut wire
securing track pin. Unwrap pin and discard in trash.
repeat for second track.
40. Hook up crane to end of track and curl both ends of
both tracks inwards (for track pad accessibility).
41. Using an impact wrench, remove (4) track pads; one
on each end of each track. Set them aside with the
(4) bolts and nuts in each pad.
42. Using long pry bar, roll back each end of both tracks
flat onto the floor. Measure distance between both
tracks. Mark spacing on floor with chalk. use pry bar
to move track to mark and correct spacing.
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
1. Chain Assembly
2. Left Link
3. Right Link
4. Bearing
5. Hinge Pin
6. Bearing Splice
7. Splice Hinge Pin
8. Spacer
9. Track Cleat
Figure 3-8. Track Chain Assembly
3121157
– JLG Lift –
3-11
SECTION 3 - UNDERCARRIAGE
1.
2.
3.
4.
Idler
Shaft
Bearing
Roll Pin
5.
6.
7.
8.
Mounting Bracket
Seal
Seal
Seal Holder
9. Not Used
10. O-ring
11. Plug
12. Bracket
Figure 3-9. Idler Assembly
3-12
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
1.
2.
3.
4.
Mounting Flange
Spring
Base Plate
Locknut
5.
6.
7.
8.
Roll Pin
Piston/Rod
Wiper
Barrel
9. Seal
10. Seal
11. Fitting
Figure 3-10. Spring & Shock Assembly
3121157
– JLG Lift –
3-13
SECTION 3 - UNDERCARRIAGE
1.
2.
3.
4.
5.
Coupling
Stabilizer
Support
Spacer
Keeper
Figure 3-11. Rotary Coupling Installation
3-14
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
43. Get overhead crane and slings, then connect to the
carbody assembly. Have crane man lift up while
assisting with orientation and move it to the laid out
tracks. Position and align onto tracks and unhook
crane.
47. Apply never seez to pin. Line up end links. start pin
in hole by driving with a hammer. Place portable
power pin press over track and pin. place washers in
press ends. Actuate switch to operate press, then
carefully press in track pin.
44. Start the tracking process:
45. Using overhead crane, hook up and lift and curl
track up over carbody side frame. Perform step to
both ends of track. Align chain and c-clamp spacer
in two places on chain. Hammer in chain link aligning pin hole. Insert special alignment pin through
hole to temporarily hold track together.
46. Position wood blocks to frame rail for tracks to lay
onto when connecting track ends to get proper
extension for connecting end links.
3121157
– JLG Lift –
3-15
SECTION 3 - UNDERCARRIAGE
48. Repeat tracking process to opposite side of frame.
3.2 TRACK TENSIONING
49. Using overhead crane connect top of track to crane.
Lift slightly and remove wooden blocking used to
curl in tracks. Repeat on opposite side.
50. Re-assemble (4) track pads to assembled links.
1. In special grease fitting, pump in grease to add tension to track. Check for proper adjustment between
idler & carrier roller with "level" and gage (0.781in.
[19.8 mm]). Remove special fitting.
51. Torque track pad bolts to 65 ft-lbs, +6 (91 Nm,
+8.4), then tighten 1/3 turn (120°) further.
52. In special grease fitting, pump in grease to add tension to track. Check for proper adjustment between
idler & carrier roller with "level" and gage (0.781in.
[19.8 mm]). Remove special fitting.
2. Repeat process on opposite side:
3. In special grease fitting, pump in grease to add tension to track. Check for proper adjustment between
idler & carrier roller with "level" and gage (0.781).
Remove special fitting.
53. Repeat process on opposite side.
3-16
– JLG Lift –
3121157
SECTION 3 - UNDERCARRIAGE
3.3 RUBBER TRACK PAD INSTALLATION
1. Seat the rubber track pad over the center rib of the
steel track pad.
2. Apply Loctite #242 to the steel retaining plate bolts.
Install the bolts and flat washers to the end of the
rubber pad.
3. Torque the bolts to 70 ft-lbs. (97 Nm).
3121157
– JLG Lift –
3-17
SECTION 3 - UNDERCARRIAGE
This page left blank intentionally.
3-18
– JLG Lift –
3121157
SECTION 4 - TURNTABLE
SECTION 4. TURNTABLE
4.1 SWING HUB
1. Check the frame to bearing. Attach bolts as follows:
a. Elevate the fully retracted boom to 70 degrees
(full elevation).
Adjustment Procedures
1. Ensure swing drive is located on bearing gear max
eccentric tooth (high spot).
2. With mounting free to slide, shim between pinion
and bearing gear teeth to achieve 0.008 - 0.012
backlash.
b. At the positions indicated on Figure 2-45. try and
insert the 0.0015" feeler gauge between the bolt
head and hardened washer at the arrow indicated position.
c. Assure that the 0.0015" feeler gauge will not
penetrate under the bolt head to the bolt shank.
3. Install a pry bar into hole in turntable base plate and
pry swing hub back tight against shim and bearing.
d. Swing the turntable 90 degrees, and check
some selected bolts at the new position.
4. Torque bolts according to the torque chart in Section
1.
e. Continue rotating the turntable at 90 degrees
intervals until a sampling of bolts have been
checked in all quadrants.
2. Check the turntable to bearing. Attach bolts as follows:
4.2 SWING BEARING
Turntable Bearing Mounting Bolt Condition
Check
NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for
looseness.
a. Elevate the fully retracted boom to 70 degrees
(full elevation).
b. At the positions indicated on Figure 2-45. try and
insert the 0.0015" feeler gauge between the bolt
head and hardened washer at the arrow indicated position.
c. Lower the boom to horizontal and fully extend
the boom.
Figure 4-1. Swing Torque Hub Adjustment
3121157
– JLG Lift –
4-1
SECTION 4 - TURNTABLE
d. At the position indicated on figure 2-45. try and
insert the 0.0015" feeler gauge between the bolt
head and hardened washer at the arrow indicated position.
5. If bearing inspection shows no defects, reassemble
and return to service.
IMPORTANT
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS
ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE CENTER OF ROTATION.
BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING
BEARING BOLTS IS A MUST FOR SAFE OPERATION.
TURNTABLE REF.
SWING
BEARING
MEASURING
POINT
.0015" Feeler Gauge
Figure 4-2. Swing Bearing Bolt Feeler Gauge Check
Wear Tolerance
FRAME REF.
1. From the underside of the machine, at rear center,
with the boom fully elevated and fully retracted, as
shown in A, Figure 4-4., Swing Bearing Tolerance
Boom Placement, using a magnetic base dial indicator, measure and record the distance between the
swing bearing and turntable. (See Figure 4-3., Swing
Bearing Tolerance Measuring Point.)
2. At the same point, with the boom at horizontal and
fully extended, and the tower boom fully elevated as
shown in (Figure 4-4., Swing Bearing Tolerance
Boom Placement) B, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable. (See Figure 4-3.,
Swing Bearing Tolerance Measuring Point.)
3. If a difference greater than 0.057 in. (1.40 mm) is
determined, the swing bearing should be replaced.
Figure 4-3. Swing Bearing Tolerance Measuring Point
Swing Bearing Replacement
1. Removal.
a. From Ground Control station, operate the boom
adequately to provide access to frame opening
or, if equipped, to rotary coupling.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING
BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD
SLING SUPPORT AND/OR BLOCKING.
b. Attach an adequate support sling to the boom
and draw all slack from sling. Prop or block the
boom if feasible.
4. If a difference less than 0.057 in. (1.40 mm) is determined, and any of the following conditions exist, the
bearing should be removed, disassembled, and
inspected for the following:
c. From inside turntable, remove mounting hardware which attach rotary coupling retaining yoke
brackets to turntable.
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
IMPORTANT
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
d. Tag and disconnect the hydraulic lines from the
fittings on the top of the rotary coupling. Use a
suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports.
e. Attach suitable overhead lifting equipment to the
base of the turntable weldment.
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Figure 4-4. Swing Bearing Tolerance Boom Placement
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SECTION 4 - TURNTABLE
f. Use a suitable tool to scribe a line on the inner
race of the swing bearing and on the underside
of the turntable. This will aid in aligning the bearing upon installation. Remove the bolts and
washers which attach the turntable to the bearing inner race. Discard the bolts.
g. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame-mounted components.
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING
BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS.
SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK
BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE
THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
b. Apply a light coating of Loctite #271 to the new
bearing bolts, and loosely install the bolts and
washers through the frame and outer race of
bearing.
h. Carefully place the turntable on a suitably supported trestle.
i. 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 from the frame, then
move the bearing to a clean, suitably supported
work area.
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.
2. Installation.
a. Using suitable lifting equipment, carefully lower
the swing bearing into position on the frame.
Ensure the scribed line of the outer race of the
bearing aligns with the scribed line on the frame.
If a new swing bearing is used, ensure that the
filler plug fitting is at 90 degrees from the fore
and aft center line of the frame.
c. Refer to the Torque Sequence diagram as
shown in Figure 4-5., Swing Bearing Torque
Sequence. Spray a light coat of Safety Solvent
13 on the new bearing bolts. Then apply a light
coating of Loctite #271 to the new bearing bolts,
and install the bolts and washers through the
frame and outer race of the bearing. Tighten the
bolts to an initial torque of 240 FT. LBS. (326
Nm) w/Loctite.
d. Remove the lifting equipment from the bearing.
Figure 4-5. Swing Bearing Torque Sequence
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SECTION 4 - TURNTABLE
e. Using suitable lifting equipment, carefully position the turntable assembly above the machine
frame.
f. Carefully lower the turntable onto the swing
bearing, ensuring that the scribed line of the
inner race of the bearing aligns with scribed line
on the turntable. If a new swing bearing is used,
ensure that the filler plug fitting is at 90 degrees
from the fore and aft center line of the turntable.
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
2000 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.
2. Remove case seal (11) from housing (7) then
remove bleeder screw (14) from end cover (52).
g. Spray a light coat of Safety Solvent 13 on the
new bearing bolts. Then apply a light coating of
Loctite #271 to the new bearing bolts, and
install the bolts and washers through the turntable and inner race of the bearing.
3. Remove piston (22) from end cover (13).
4. Remove o-ring (17), back-up ring (16), o-ring (19)
and back-up ring (18) from piston (22).
h. Following the Torque Sequence diagram shown
in Figure 4-5., Swing Bearing Torque Sequence,
tighten the bolts to a torque of 240 ft. lbs. (326
Nm) w/Loctite.
5. Remove separators (10) from housing (52).
6. Remove stack assembly, consisting of discs (21),
return plate (8) and friction discs (20) from housing
(52).
i. Remove the lifting equipment.
j. Install the rotary coupling retaining yoke brackets, apply a light coating of Loctite #242 to the
attaching bolts and secure the yoke to the turntable with the mounting hardware.
7. Remove dowel pins (15), springs (5 & 6) from housing (52).
k. Connect the hydraulic lines to the rotary coupling as tagged prior to removal.
9. Remove shaft by pressing or using a soft mallet on
male end of shaft (51).
l. At ground control station, use boom lift control
to lower boom to stowed position.
m. Using all applicable safety precautions, activate
the hydraulic system and check the swing system for proper and safe operation.
8. Remove retaining ring (3) from housing (52).
10. Remove retaining ring (54) bearing (2) from shaft
(51).
11. Press rotary seal (1) from housing (51).
Inspection
Swing Bearing Torque Values.
1. Clean all parts thoroughly.
1. Outer Race - 240 ft. lbs. (326 Nm) w/Loctite, 220 ft.
lbs. (298 Nm) dry.
2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.
2. Inner Race - 240 ft. lbs. (326 Nm) w/Loctite, 220 ft.
lbs. (298 Nm) dry.
3. Discard seals and o-rings.
3. See Swing Bearing Torquing Sequence.
4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR
MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS THEREAFTER.
NOTE: Bearings may be reused if, after thorough inspection,
they are found to be in good condition.
Assembly
NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
4.3 SWING BRAKE - MICO
1. Press new rotary seal (1) into housing (52). Note the
direction of seal.
Disassembly
1. With shaft protrusion downward, remove end cover
(13) by removing capscrews (12).
2. Install new bearing (2) on shaft (51).
4. Install dowel pins (15), spring retainer (55), and
springs (5 & 6) into housing (52).
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3. Install shaft assembly and retaining ring (3) into
housing (52).
4-5
SECTION 4 - TURNTABLE
Figure 4-6. Swing Brake Assembly (Mico)
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SECTION 4 - TURNTABLE
NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
4.4 SPARK ARRESTER CLEANING
INSTRUCTIONS
5. Position new large diameter return plate (8) in housing with tabs guided by dowel pins (15) until disc
rests on springs (5 & 6).
1. Remove the cleanout plug in the bottom of spark
arrester (muffler).
NOTE: Discs (21 & 8) and friction discs (20) should remain
dry during installation. Oil will contaminate disc surfaces.
2. Without causing deformation (or any type of damage to the spark arrester) repeatedly tap on the
arrester near the cleanout plug. This may be enough
to begin drainage of the spark trap.
6. Place new disc (20) on shaft (51) until it contacts
return plate (8).
3. An industrial vacuum cleaner can do a complete job
at this point.
7. Add additional discs (21) as required to complete
assembly.
a. Or, IN A SAFE AREA, start the engine. Then
alternate between low idle and high idle for two
to three minutes.
8. Insert separators (10) in holes of return plate (8).
9. Install new o-ring (17), new back-up ring (16), new oring (19) and new back-up ring (18) on piston (22).
Insert piston (22) into end cover (13), being careful
not to shear o-rings or back-up rings.
b. Or, operate the engine as required by the application for two to three minutes.
4. Install the cleanout plug. (See Table 2-4. Preventive
Maintenance and Inspection Schedule.)
10. Install new case seal (11) in housing (52), then
install bleeder screw (14) in end cover.
11. Position end cover (13) on housing (52), aligning
dowel pins (15) with holes in end cover.
12. Insert capscrews (12) and tighten evenly to draw
end cover (13) to housing (52). Torque capscrews to
55 ft. lbs. (75 Nm).
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4-7
SECTION 4 - TURNTABLE
1.
2.
3.
4.
Battery
Battery Holddown
Gear Pump
Piston Pump
5.
6.
7.
8.
Air Cleaner
Fan
Motor Mount
Muffler
9.
10.
11.
12.
Front Right Engine Mounting Plate
Front Bottom Engine Mounting Plate
Rear Engine Mounting Plate
Radiator
13.
14.
15.
16.
Starter Relay
Aux Pump Relay
Restriction Indicator
Oil Drain Valve
Figure 4-7. Deutz Engine Installation - Sheet 1 of 2
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SECTION 4 - TURNTABLE
17.
18.
19.
20.
21.
Engine Tray
Engine Mounting Plate
Hayes Coupling
Pump Adapter Plate
Dipstick
22.
23.
24.
25.
Filler Cap
Oil Lube Pump
Oil Filter
Injector Pump
26.
27.
28.
29.
Fuel Filter
Fuel Supply Pump
Alternator
Starter
30.
31.
32.
33.
Temperature Sender
Oil Pressure Sensor
Speed Sensor
Throttle Actuator
Figure 4-8. Deutz Engine Installation - Sheet 2 of 2
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SECTION 4 - TURNTABLE
1.
2.
3.
4.
5.
6.
7.
Battery Hold-down
Battery
Air Cleaner
Coolant Overflow Container
Pump Coupling
Fan
Engine Mount
8. Muffler
9. Radiator
10. Starter Relay
11. Glow Plug Relay
12. Aux Power Relay
13. Restriction Indicator
14. Oil Drain Valve
Figure 4-9. Caterpillar Engine Installation - Sheet 1 of 2
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SECTION 4 - TURNTABLE
15.
16.
17.
18.
19.
20.
21.
Engine Tray
Piston Pump
Gear Pump
Fuel Filter
Alternator
Oil Pressure Switch
Oil Filter
22.
23.
24.
25.
26.
27.
Starter
Dipstick
Engine Temperature Sender
Throttle Actuator
Fuel Supply Pump
Water Pump
Figure 4-10. Caterpillar Engine Installation - Sheet 2 of 2
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SECTION 4 - TURNTABLE
4.5 DEUTZ EMR 2 (S/N 85110 TO PRESENT)
The EMR2 consists of the sensors, the control unit and the
actuator. Engine-side controls as well as the JLG Control
System are connected by means of separate cable harnesses to the EMR control unit.
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters In accordance with the information of the current
condition of the engine and the preconditions (throttle
position etc.), the EMR2 controls an actuator that operates
the control rod of the injection pump and thus doses the
fuel quantity in accordance with the performance requirements.
The exact position of the regulating rod is reported back
and, if necessary, is corrected, by means of the control
rod travel sensor, situated together with the rotation magnets in a housing of the actuator.
4-12
The EMR2 is equipped with safety devices and measures
in the hardware and software in order to ensure emergency running (Limp home) functions.
In order to switch the engine off, the EMR2 is switched in a
de-energized fashion over the ignition switch. A strong
spring in the actuator presses the control rod in the deenergized condition into the zero position. As a redundancy measure, an additional solenoid serves for switching off and this, independently of the actuator, also moves
the control rod in the de-energized condition into the zero
position.
After the programming, that is carried out over the
ISO9141 interface, the EMR2 is possesses a motor-specific data set and this is then fixedly assigned to the
engine. Included in this are the various application cases
as well as the customer’s wishes regarding a particular
scope of function.
Each EMR2 module is matched by serial number to the
engine. Modules cannot be swapped between engines.
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SECTION 4 - TURNTABLE
CONTROL ROD POSITION
SENSOR/ACTUATOR
COOLANT TEMPERATURE
SENSOR
POWER SUPPLY
CAMSHAFT SPEED
SENSOR
GLOW PLUG
JLG SYSTEM HANDLES ENGINE START/
STOP; EMR2 TAKES CONTROL OF THE
ENGINE AT 700RPM
JLG SYSTEM USES JLG ANALYZER TO
REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE &
FAULT REPORTING.
OIL PRESSURE
SENSOR
Figure 4-11. EMR 2 Engine Side Equipment
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4-13
Figure 4-12. Deutz EMR 2 Troubleshooting Flow Chart
SECTION 4 - TURNTABLE
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Figure 4-13. Deutz EMR 2 Vehicle Side Connection Diagram
SECTION 4 - TURNTABLE
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4-15
Figure 4-14. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
SECTION 4 - TURNTABLE
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Figure 4-15. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
SECTION 4 - TURNTABLE
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SECTION 4 - TURNTABLE
Figure 4-16. EMR 2 Engine Plug Pin Identification
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SECTION 4 - TURNTABLE
Figure 4-17. EMR 2 Vehicle Plug Pin Identification
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Figure 4-18. EMR2 Fault Codes - Sheet 1 of 5
SECTION 4 - TURNTABLE
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Figure 4-19. EMR2 Fault Codes - Sheet 2 of 5
SECTION 4 - TURNTABLE
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4-21
Figure 4-20. EMR2 Fault Codes - Sheet 3 of 5
SECTION 4 - TURNTABLE
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Figure 4-21. EMR2 Fault Codes - Sheet 4 of 5
SECTION 4 - TURNTABLE
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4-23
Figure 4-22. EMR2 Fault Codes - Sheet 5 of 5
SECTION 4 - TURNTABLE
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SECTION 5 - BOOM & PLATFORM
SECTION 5. BOOM & PLATFORM
5.1 PLATFORM
5.2 BOOM ROPE TORQUING PROCEDURES
Platform Sections Replacement
Torque Procedures
The platform is made up of five sections: floor, right side,
left side, back (console box mounting.) and gate. The sections are secured with huck magna grip fastener and collars. Replace damaged platform sections as follows:
1. Position boom in fully down and fully retracted position.
1. Support the huck collar with a sledge hammer or
other suitable support.
2. Using a hammer and chisel, remove the collar from
the fastener as shown in the diagram below.
Figure 5-2. Dimensions of Boom Sections
2. Clamp both threaded ends of wire rope to prevent
rotation.
NOTE: Do not clamp on threads.
Figure 5-1. Platform Section Replacement
3. When installing new section of platform replace
huck fasteners with 1/4 x 20 NC x 2 1/4" grade 5
bolts, flatwashers and locknuts.
4. When installing a new gate to platform, replace rivets with 1/4 x 20 NC x 2 “grade 5 bolts, flatwashers
and locknuts.
Figure 5-3. Clamping Wire Ropes
3. Install adjusting nuts (or remove nylon collar locknuts if re-adjusting) to both retract and extend wire
ropes.
4. Torque retract adjusting nuts (platform end) to 15 ft.
lbs. (20 Nm) alternating between the two wire ropes
and keeping approximately the same amount of
thread beyond the adjusting nut.
NOTE: Do not allow wire rope to rotate. This may damage
the wire rope.
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SECTION 5 - BOOM & PLATFORM
5. Repeat the torque procedure in step #4 to the
extend wire ropes (turntable end).
6. Extend the boom 2 - 3 feet using the telescope function. Repeat step #4.
7. Retract the boom 1 - 2 feet using the telescope function. Do not bottom out telescope cylinder. Repeat
step #5.
8. Extend the boom approximately 2 - 3 feet again and
check torque on the retract wire ropes.
9. Retract the boom without bottoming out telescope
cylinder and check torque on the extend wire ropes.
NOTE: Step #8 and #9 may need to be repeated to equalize
the torque on all 4 wire ropes.
10. After all wire ropes have been properly torqued,
install nylon collar locknuts. Remove all clamping
devices and install all covers and guards. Check the
boom for proper function.
5.3 WEAR PADS
Main Boom
1. Shim up wear pads to within 1/32 inch (.79 mm) tolerance between wear pad and adjacent surface.
2. Replace wear pads when worn within 1/16 inch (1.59
mm) and 1/8 inch (3.18 mm) - B, C, D of threaded
insert. See Location and Thickness Of Wear Pads.
3. Adjusting wear pads, removing or adding shims,
bolt length must also be changed.
a. When adding shims, longer bolts must be used
to ensure proper thread engagement in insert.
b. When shims are removed, shorter bolts must be
used so bolt does not protrude from insert and
come into contact with boom surface.
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Figure 5-4. Location and Thickness of Wear Pads
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SECTION 5 - BOOM & PLATFORM
5.4 WIRE ROPE
Three Month Inspection
1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays,
abuse, or any signs of abnormalities.
NOTE: The pictures in this paragraph are just samples to
show the replacement criteria of the rope.
Inspection
2. Check rope tension by deflecting the ropes by
hand...properly tensioned ropes should have little or
no movement.
1. Inspect ropes for broken wires, particularly valley
wire breaks and breaks at end terminations.
Seven Year Inspection
1. Mandatory wire rope and sheave replacement.
Additional inspection required if:
a. Machine is exposed to hostile environment or
conditions.
Flexing a wire rope can often expose broken wires
hidden in valleys between strands.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
2. Inspect ropes for corrosion.
d. Boom is overloaded or sustained a shock load.
3. Inspect ropes for kinks or abuse.
e. Boom exposed to electrical arc...wires may be
fused internally.
Replacement Criteria
1. Sheaves and wire rope must be replaced as sets.
A kink is caused by pulling down a loop
in a slack line during improper handling,
installation, or operation.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)
5. Sheaves failing wearout gage inspection.
5. Inspect sheaves for condition of flanges. (See
Dimension Of Sheaves for proper dimension.)
6. Ropes with 6 total broken wires in one rope lay, 3 in
one strand in one rope lay, 1 valley break, or 1 break
at any end termination.
6. Inspect sheaves with a groove wearout gauge for
excessive wear.
5.5 BOOM MAINTENANCE
Removal
1. Remove the platform/support as follows:
a. Disconnect electrical cable from control console.
Observe the groove so that it may be clearly seen
whether the contour of the gauge matches the
contour of the bottom of the groove.
7. Ropes passing inspection should be lubricated with
wire rope lubricant before reassembly.
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b. Remove the eight (8) bolts securing the platform
to the platform support, then remove the platform.
c. Using an overhead crane or suitable lifting
device, strap support the platform support.
d. Remove the six (6) bolts and locknuts securing
the support to the rotator.
5-3
SECTION 5 - BOOM & PLATFORM
Figure 5-5. Boom Assembly Cutaway - Sheet 1 of 3
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SECTION 5 - BOOM & PLATFORM
Figure 5-6. Boom Assembly Cutaway - Sheet 2 of 3
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5-5
SECTION 5 - BOOM & PLATFORM
Figure 5-7. Boom Assembly Cutaway - Sheet 3 of 3
e. Using a suitable brass drift and hammer, remove
the rotator shaft, then remove the support from
the rotator.
b. Remove hardware from pin #1. Using a suitable
brass drift and hammer remove pin #1 from the
fly boom.
c. Supporting the rotator, remove the hardware
from pin #2. Using a suitable brass drift and
hammer, remove pin #2 from the fly boom and
remove the rotator.
d. Telescope the fly section out approximately 20
inches (50.8 cm) to gain access to the slave leveling cylinder.
Figure 5-8. Location of Components - Platform Support
2. Remove the rotator and slave level cylinder from the
fly boom as follows:
e. Supporting the slave, cylinder remove the hardware from pin #3. Using a suitable brass drift
and hammer remove pin #3 from the fly boom.
f. Tag and disconnect hydraulic lines to the slave
leveling cylinder. Use a suitable container to
a. Tag and disconnect hydraulic lines to rotator.
Use suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
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SECTION 5 - BOOM & PLATFORM
retain any residual hydraulic fluid. Cap hydraulic
lines and ports. Remove the slave cylinder.
securing rail to the base boom section. Remove
powertrack from boom section.
Figure 5-10. Location of Components - Boom Power4. Remove boom assembly from machine as follows:
a. Using suitable lifting equipment, adequately
support boom assembly weight along entire
length.
Figure 5-9. Location of Components - Rotator and
Leveling Cylinder
3. Remove the powertrack from the boom as follows:
a. Disconnect wiring harness from ground control
box.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.
b. Tag and disconnect hydraulic lines from telescope cylinder. Use a suitable container to retain
any residual hydraulic fluid. Cap hydraulic lines
and ports.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.
c. Remove hardware securing the lift cylinder rod
end to the base boom section.
b. Tag and disconnect hydraulic lines from boom
to control valve. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic
lines and ports.
d. Using a suitable brass drift and hammer, remove
the lift cylinder pin from the base boom.
c. Disconnect the dual capacity indicator limit
switch from side of boom section.
f. Using a suitable brass drift and hammer, remove
the master cylinder pin from the base boom.
d. Remove hydraulic lines and electrical cables
from powertrack.
g. Remove hardware securing the pushbar to the
turntable upright.
e. Remove hardware securing the master cylinder
rod end to the base boom section.
e. Using a suitable lifting equipment, adequately
support powertrack weight along entire length.
f. Remove bolts #1 securing the push tube on the
fly boom section.
g. Remove bolts #2 securing the push tube on the
mid boom section.
WHEN REMOVING PIN FROM PUSHBAR. CARE MUST BE TAKEN
NOT TO DROP THE PUSHBAR ONTO THE WIRE ROPE ADJUSTMENT THREADS. FAILURE TO DO SO WILL RESULT IN DAMAGING THREADS.
h. With powertrack support and using all applicable safety precautions, remove bolts #3 and #4
h. Using a suitable brass drift and hammer, remove
the push bar pin from the turntable upright.
i. Remove hardware securing the boom pivot pin
to the turntable upright.
j. Using a suitable brass drift and hammer, remove
the pivot pin from the turntable upright.
k. Using all applicable safety precautions, carefully
lift boom assembly clear of turntable and lower
to ground or suitably supported work surface.
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5-7
SECTION 5 - BOOM & PLATFORM
Disassembly of Boom Sections
c. Remove hardware from the sheave pin; remove
pin and sheave from cylinder.
1. Remove hardware securing the push bar to aft end
of the telescope cylinder, then remove pin from cylinder.
2. Remove hardware securing the cover plate on the
bottom front of the base boom section.
NOTE: Do not allow wire rope to rotate. This may damage
the wire rope.
3. Clamp both threaded ends of wire rope to prevent
rotation. Note: Do not clamp on threads. Remove
jam nuts and nuts which secure the wire rope
adjustments to the bottom front of the base boom
section.
4. Remove hardware securing the wire rope adjustment block to aft end of the base boom section and
remove the block.
Figure 5-11. Disassembly of Sheave Assembly
5. Remove hardware securing the telescope cylinder
to aft end of the mid boom section.
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE
BOOM, IT MAY BE NECESSARY AT SOME POINT IN ORDER TO
CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM. CARE MUST
BE TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM.
DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE
IMPACT WITH THESE ASSEMBLIES.
6. Remove bolts securing wire rope attach bar to top of
fly boom section.
7. Pull the telescope cylinder and wire ropes partially
from aft end of the base boom section; secure the
cylinder with a suitable sling and lifting device at
approximately the center of gravity.
8. Carefully remove the telescope cylinder and sheave
assembly. Place telescope cylinder on a suitable
trestle.
a. Remove hardware from the wear pads; remove
wear pads from cylinder.
b. Remove hardware from the wire rope guard;
remove guard from cylinder.
9. Remove hardware which secures the wear pads to
the front of base boom section; remove wear pads
from the top, sides and bottom of the base boom
section.
10. Using an overhead crane or suitable lifting device,
remove mid and fly boom sections from base section. Note: When removing mid and fly boom sections from base boom section, retract wire rope
must be dragged along with boom sections.
11. Remove hardware which secures the wear pads to
the aft end of mid boom section; remove the wear
pads from the top, sides and bottom of the mid
boom section.
12. Remove hardware which secures the sheave guards
and sheave assemblies to mid boom section,
remove sheave assemblies from mid boom section.
13. Remove hardware which secures the wear pads to
the front of mid boom section; remove wear pads
from the top, sides and bottom of the mid boom section.
14. Using an overhead crane or suitable lifting device,
remove fly boom section from mid section. Note:
When removing fly boom section from mid boom
section, retract wire rope must be dragged along
with fly boom section.
15. Remove hardware which secures the wear pads to
the aft end of fly boom section; remove wear pads
from the top, sides and bottom of the fly boom section.
5-8
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SECTION 5 - BOOM & PLATFORM
16. When removing wire rope from fly boom section,
push the cable into fly boom. Route wire rope back
through holes in the side of the fly boom section.
NOTE: To check the size, contour and amount of wear, a
groove gauge is used. Replace the sheave if worn as
shown in the following drawing.
Figure 5-13. Dimension of Sheaves When New
Figure 5-12. Disassembly Wire Rope Routing Proce-
2. Inspect extend and retract wire rope sheave bearings for wear, scoring, or other damage, and for
ovality.
3. Inspect extend wire rope and retract wire rope
sheave pins for scoring, tapering and ovality.
Replace pins as necessary.
Inspection
NOTE: When inspecting pins and bearings Ref. to Pins and
Composite Bearing Repair Guidelines in Section 2.
1. Inspect all sheaves (extend and retract wire ropes
and telescope cylinder) for excessive groove wear,
burrs or other damage. Replace sheaves as necessary.
4. Inspect telescope cylinder sheave pin for scoring,
tapering and ovality. Replace pins as necessary.
5. Inspect boom pivot pin for wear, scoring, tapering
and ovality, or other damage. Replace pins as necessary.
6. Inspect telescope cylinder attach point for scoring,
tapering and ovality. Replace pins as necessary.
7. Inspect upper lift cylinder attach pin for wear, scoring, tapering and ovality, or other damage. Ensure
pin surfaces are protected prior to installation.
Replace pins as necessary.
8. Inspect inner diameter of boom pivot bushing for
scoring, distortion, wear, or other damage. Replace
bearing as necessary.
9. Inspect all wear pads for excessive wear or other
damage. Replace pads when worn to within 1/8 inch
(3.2 mm) of threaded insert.
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SECTION 5 - BOOM & PLATFORM
4. Install retract wire ropes into aft end of fly section,
route wire ropes thru holes in side of fly boom section and pull into slot.
10. Inspect extend and retract wire rope attach point
components for cracks, stretching, distortion, or
other damage. Replace components as necessary.
11. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.
12. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
Assembly
NOTE: When installing fly section wear pads, install same
number and thickness of shims as were removed
during disassembly.
1. Measure inside dimensions of the base and mid
sections to determine the number of shims required
for proper lift.
2. Measure inside dimensions of the mid section to
determine the number of shims required for proper
lift.
3. Install side, top and bottom wear pads to the aft end
of fly section; shim evenly to the measurements of
the inside of mid section.
Figure 5-14. Routing Installation of Retract Wire Ropes
5. Install side, top and bottom wear pads to the aft end
of mid section; shim evenly to the measurements of
the inside of mid section.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE
BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARED OF
CHAINS, TOOLS, AND OTHER OBSTRUCTIONS.
6. Shim the insides of the boom sections for a total of
1/16 inch (0.062) clearance (if the action is centered,
there will be 1/32 clearance on each side).
7. Slide fly boom section into the mid boom section.
Shim boom, if necessary, for a total of 1/16 inch
(0.062) clearance.
8. Install wear pads into the forward position of the mid
boom section. Shim boom, if necessary, for a total of
2/10 inch (0.20 m) clearance.
9. Properly position the retraction wire rope sheaves
assemblies at the aft end of the mid boom section;
ensure all sheave-to-mounting block attachment
holes align. Install the sheave pins and secure them
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SECTION 5 - BOOM & PLATFORM
with mounting hardware. Position retract wire ropes
onto the sheaves.
10. Install sheave guards to aft end of mid boom section
and secure with mounting hardware.
11. Slide mid boom section into the base boom section.
Allow the retraction wire ropes to trail between the
bottom surfaces of boom sections. Shim boom, if
necessary, for a total of 1/16 inch (0.062) clearance.
12. Install wear pads into the forward position of the
base boom section. Shim boom, if necessary, for a
total of 2/10 inch (0.20) clearance.
21. Align holes in aft end of the mid boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
NOTE: Boom wire ropes must be torqued after installation of
the boom assembly.
22. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure
with mounting hardware.
23. Install the hydraulic lines and electrical cables, and
the harnessing powertrack components as follows:
a. Align holes in powertrack rail with attachment
holes in side of the base boom section. Secure
the rail with mounting hardware.
13. Install sheave block to bottom of base boom section
and adjust block so that retract wire ropes do not
come into contact with boom surfaces.
b. Install powertrack to rail with mounting hardware.
14. Install wire rope threaded ends thru attachment
holes in the bottom of base boom section. Loosely
install nuts and jam nuts onto the threaded ends of
wire ropes.
c. Attach push tube bracket to the side of the mid
boom section with mounting hardware.
15. Align the telescope cylinder barrel-to-sheave attachment point. Install extend sheave pin through the
telescope cylinder barrel and sheave assembly;
secure pin with mounting hardware.
NOTE: Do not over tighten attach bolt on push tube bracket.
It should pivot freely.
16. Route extend wire ropes around extend sheave and
secure wire ropes to the telescope cylinder.
e. Install powertrack to push tube with mounting
hardware.
17. Install extend wire rope mounting blocks to threaded
ends of wire ropes. Loosely install nuts and jam nuts
onto the threaded ends of wire ropes.
f. Carefully feed the hoses and electrical cables
through the aft end of the powertrack rail, powertrack and push tube.
NOTE: When installing wire ropes, care must be taken not to
twist or cross the wire ropes.
g. Ensure all hoses and cables are properly routed
through the powertrack rail, powertrack and
push tube. Tighten or install all clamping or
securing apparatus to the hoses or cables, as
necessary.
18. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
d. Install slide block and wear pads to the powertrack rail with mounting hardware.
h. Install powertrack cover and push tube rods with
mounting hardware.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY INTO POSITION. DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
19. Align the cylinder with the slots at aft end of mid
boom section, then secure cylinder with mounting
hardware.
20. Align holes in aft end of the fly boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
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Figure 5-15. Reassembly of Components - Boom
Powertrack Assembly
5-11
SECTION 5 - BOOM & PLATFORM
Figure 5-16. Boom Powertrack Installation
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SECTION 5 - BOOM & PLATFORM
Installation
mer, remove the cylinder pin from articulating jib
boom.
1. Using a suitable lifting device, position boom
assembly on turntable so that the pivot holes in both
boom and turntable are aligned.
2. Install boom pivot pin, ensuring that location of hole
in pin is aligned with attach point on turntable.
3. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.
4. Align push bar pivot hole with pivot holes in turntable. Install push bar pivot pin, ensuring that location
of hole in pin is aligned with attach point on turntable.
5. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.
Figure 5-17. Location of Components - Articulating
Jib Boom
4. Remove mounting hardware from articulating jib
boom pivot pin #2. Using a suitable brass drift and
hammer, remove the pivot pin from boom assembly.
6. Connect all wiring to the ground control box.
7. Connect all hydraulic lines running along side of
boom assembly.
8. Using all applicable safety precautions, operate lifting device in order to position boom lift cylinder so
that holes in the cylinder rod end and boom structure are aligned. Insert the lift cylinder pin, ensuring
that location of hole in pin is aligned with attach
point on boom.
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.
2. Remove mounting hardware from rotator support
pins #5 and #6. Using a suitable brass drift and
hammer, remove the pins from rotator support.
9. Align holes in boom structure with hole in master
cylinder. Insert the master cylinder pin, ensuring that
location of hole in pin is aligned with attach point on
boom.
10. Adjust retract and extend cables to the proper
torque. Refer to paragraph 2-6, boom cable torque
procedures.
11. Using all applicable safety precautions, operate
machine systems and raise and extend boom fully,
noting the performance of the extension cycle.
3. Remove mounting hardware from lift cylinder pin
#7. Using a suitable brass drift and hammer, remove
the cylinder pin from articulating jib boom.
Inspection
NOTE: When inspecting pins and bearings refer to Pins and
Composite Bearing Repair Guidelines in Section 2.
12. Retract and lower boom, noting the performance of
the retraction cycle.
5.6 ARTICULATING JIB BOOM
1. Inspect articulating fly boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace
pins as necessary.
2. Inspect articulating fly boom pivot attach points for
scoring, tapering and ovality, or other damage.
Replace pins as necessary.
Removal
1. For platform/support removal see platform/support
removal diagram. See Section 5.5, Boom Maintenance.
3. Inspect inner diameter of articulating fly boom pivot
bearings for scoring, distortion, wear, or other damage. Replace bearings as necessary.
2. Position the articulating jib boom level with ground.
4. Inspect lift cylinder attach pin for wear, scoring,
tapering and ovality, or other damage. Ensure pin
surfaces are protected prior to installation. Replace
pins as necessary.
3. Remove mounting hardware from slave leveling cylinder pin #1. Using a suitable brass drift and ham-
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5-13
SECTION 5 - BOOM & PLATFORM
5. Inspect inner diameter of rotator attach point bearings for scoring, distortion, wear, or other damage.
Replace bearing as necessary.
4. Align articulating jib boom with attach hole in articulating jib boom pivot weldment. Using a soft head
mallet, install rotator support pin #4 into articulating
jib boom and secure with mounting hardware.
6. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.
5. Align bottom tubes with attach holes in articulating
jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #3 into articulating jib
boom pivot weldment and secure with mounting
hardware.
7. Inspect structural units of articulating jib boom
assembly for bending, cracking, separation of
welds, or other damage. Replace boom sections as
necessary.
6. 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.
Assembly
NOTE: For location of components See Section 5-17., Location of Components - Articulating Jib Boom.
7. Align the slave leveling cylinder with attach holes in
articulating jib boom pivot weldment. Using a soft
head mallet, install slave leveling cylinder pin #1
into articulating jib boom pivot weldment and secure
with mounting hardware.
1. Align lift cylinder with attach holes in articulating jib
boom. Using a soft head mallet, install cylinder pin
#7 into articulating jib boom and secure with mounting hardware.
2. Align rotator support with attach hole in articulating
jib boom. Using a soft head mallet, install rotator
support pin #6 into articulating jib boom and secure
with mounting hardware.
5.7 LIMIT SWITCH ADJUSTMENT
Adjust switches and cam valve as shown in Limit Switches
Adjustment.
3. Align bottom tubes with attach holes in rotator support. Using a soft head mallet, install rotator support
pin #5 into articulating jib boom and secure with
mounting hardware.
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SECTION 5 - BOOM & PLATFORM
Figure 5-18. Limit Switches Adjustments
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5-15
SECTION 5 - BOOM & PLATFORM
5.8 ROTATOR - HELAC
5. Remove the two (2) setscrew (4) from bottom of
actuator (1). Discard setscrew.
Disassembly
1. Place actuator on a clean workbench.
2. Remove all hydraulic fittings.
3. Using a suitable hammer and chisel remove the portion of end cap securing setscrew.
Figure 5-22. Removing Setscrew
6. Place two (2) 3/8"x16NC bolts in threaded holes in
bottom of the actuator. Using a suitable bar, unscrew
the end cap (5). Remove the end cap from actuator
(1).
Figure 5-20. Removing Portion of End Cap
4. Using a torch, apply heat to the setscrews on the
bottom of actuator.
Figure 5-23. Removing End Cap
Figure 5-21. Heating Setscrew
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SECTION 5 - BOOM & PLATFORM
Figure 5-19. Rotator Assembly (Helac)
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– JLG Lift –
5-17
SECTION 5 - BOOM & PLATFORM
7. Remove the shaft (2) from piston sleeve (3) and the
actuator housing (1).
cases, depending on the required accuracy of the
application.
3. Check the ring gear for wear and weld damage to
the pins.
4. Inspect the cylinder bore for wear and scratches.
Assembly
NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
1. Install new seal (7) and bearing (6) on the piston
sleeve (3).
NOTE: Apply a coat of grease to the thrust ring before sliding onto the shaft.
2. Install new seal (8), thrust ring (10) and bearing (9)
on shaft (2).
Figure 5-24. Removing Shaft from Housing
NOTE: Apply a coat of grease to the thrust ring before sliding onto the end cap.
8. Remove piston sleeve (3) from housing (1).
3. Install new seals (11), back-up ring (12), cap bearing
(13), bearing packing (14) and thrust ring (10) on
end cap (5).
4. Place the actuator in the vertical position, install the
piston sleeve (3) in timed relation to the housing (1).
DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS IT
WILL MARK THE CYLINDER BORE.
NOTE: The timing marks (the small punch marks on the
face of each gear), must be aligned for proper shaft
orientation. (See Actuator Timing.)
5. Install the shaft (2) into housing (1) by aligning the
proper punched timing marks. (See Actuator Timing.)
Figure 5-25. Removing Sleeve from Housing
9. Remove all seals and bearings from grooves. Discard seals.
6. Temporarily tape the threaded portion of the shaft
will help installation past the shaft seals (masking
tape).
7. The end cap (5) is torqued to 40 - 50 ft. lbs. (54 - 68
Nm), such that the actuator begins rotation at
approximately 100 psi (6.895 Bar) pressure.
Inspection
1. Clean all parts thoroughly.
2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.
NOTE: A small amount of wear in the spline teeth will have
little effect on the actuator strength. New spline sets
are manufactured with a backlash of about 0.005 in.
per mating set. After long service, a backlash of
about 0.015 per set may still be acceptable in most
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SECTION 5 - BOOM & PLATFORM
8. The end cap must be secured against the shaft by
installing axial set screws (4).
Figure 5-26. Actuator Timing
5.9 FOOT SWITCH ADJUSTMENT
Adjust so that functions will operate when pedal is at center of travel. If switch operates within last 1/4 in. (6.35 mm)
of travel, top or bottom, it should be adjusted.
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SECTION 5 - BOOM & PLATFORM
This page left blank intentionally.
5-20
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3121157
SECTION 6 - HYDRAULICS
SECTION 6. HYDRAULICS
6.1 VALVES - THEORY OF OPERATION
6.2 CYLINDERS - THEORY OF OPERATION
Solenoid Control Valve
Control valves used are four-way three-position solenoid
valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit with
the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral) the valve
spool returns to neutral (center) and oil flow is then
directed through the valve body and returns to reservoir. A
typical control valve consist of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring loaded
to center position, therefore when the control is released,
the spool automatically returns to neutral, prohibiting any
flow through the circuit.
Relief Valves
Relief valves are installed at various points within the
hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of
travel and the flow of pressurized fluid continues from the
system control. The relief valve provides an alternate path
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pressure of the component is reached.
Systems Incorporating Double Acting
Cylinders
Cylinders are of the double acting type. Systems incorporating double acting cylinders are as follows: Slave Level,
Master Level, Lift, Telescope, Articulating Jib Boom Lift. A
double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by
actuating the corresponding control valve to the piston
side of the cylinder) forces the piston to travel toward the
rod end of the barrel, extending the cylinder rod (piston
attached to rod). When the oil flow is stopped, movement
of rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and
the cylinder rod will retract.
Systems Incorporating Holding Valves
Holding valves are used in the - Lift, Telescope, Lockout,
Slave Level and Articulating Jib Boom Lift circuits to prevent retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and its
related control valve.
6.3 CYLINDER CHECKING PROCEDURE
NOTE: Cylinder check must be performed anytime a system
component is replaced or when improper system
operation is suspected.
Cylinders Without Counterbalance Valves
Master Cylinder and Steer Cylinder
1. Using all applicable safety precautions, activate
engine and fully extend cylinder to be checked. Shut
down engine.
2. Carefully disconnect hydraulic hoses from retract
port of cylinder. There will be some initial weeping of
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be
no further drainage from the retract port.
3. Activate engine and extend cylinder.
4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repair must be
made.
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SECTION 6 - HYDRAULICS
5. With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.
5. If no repairs are necessary or when repairs have
been made, replace counterbalance valve and carefully connect hydraulic hoses to cylinder port block.
6. Activate engine and retract cylinder. Check extend
port for leakage.
6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic system and run cylinder through one complete cycle to
check for leaks.
7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
than 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.
Cylinders With Single Counterbalance
Valve
Lift Cylinder
Cylinders With Dual Counterbalance
Valves
Articulating Jib Boom Lift, and Slave), Slave Level,
Telescope
OPERATE ALL FUNCTIONS FROM GROUND CONTROLS ONLY.
1. Using all applicable safety precautions, activate
hydraulic system.
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.
1. Using all applicable safety precautions, activate
hydraulic system.
IF WORKING ON THE PLATFORM LEVEL CYLINDER, STROKE
PLATFORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS
AT A 45 DEGREE ANGLE.
WHEN WORKING ON THE MAIN LIFT CYLINDER, RAISE THE
BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. DO NOT
WORK ON THE CYLINDER WITHOUT A SUITABLE PROP IN
PLACE.
2. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn IGNITION SWITCH to ON, move control switch or lever
for applicable cylinder in each direction, then turn
IGNITION SWITCH to OFF. If machine is equipped
with hydraulic control valves, move control lever for
applicable cylinder in each direction. This is done to
relieve pressure in the hydraulic lines. Carefully
remove hydraulic hoses from appropriate cylinder
port block.
3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should be no further leakage from
the ports. If leakage continues at a rate of 6-8 drops
per minute or more, the counterbalance valve is
defective and must be replaced.
4. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge, there should be no further leakage from the
ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.
6-2
– JLG Lift –
2. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn IGNITION SWITCH to ON, move control switch or lever
for applicable cylinder in each direction, then turn
IGNITION SWITCH to OFF. If machine is equipped
with hydraulic control valves, move control lever for
applicable cylinder in each direction. This is done to
relieve pressure in the hydraulic lines. Remove
hoses from appropriate cylinder port block.
3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should be no further leakage from
the ports. If leakage continues at a rate of 6-8 drops
per minute or more, the counterbalance valve is
defective and must be replaced.
4. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge, there should be no further leakage from the
ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.
5. If no repairs are necessary or when repairs have
been made, replace counterbalance valve and carefully connect hydraulic hoses to cylinder port block.
6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic system and run cylinder through one complete cycle to
check for leaks.
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SECTION 6 - HYDRAULICS
6.4 CYLINDER REPAIR
the eight (8) cylinder head retainer cap screws, and
remove cap screws from cylinder barrel.
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.
Disassembly
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.
Figure 6-2. Cap Screw Removal
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Discard o-rings.
6. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
4. Place the cylinder barrel into a suitable holding fixture.
Figure 6-3. Cylinder Rod Support
Figure 6-1. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch
for easy realignment. Using an allen wrench, loosen
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7. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
– JLG Lift –
8. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.
6-3
SECTION 6 - HYDRAULICS
9. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
10. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.
11. Remove the bushing from the piston.
10. Inspect threaded portion of head for damage. Dress
threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
Figure 6-4. Tapered Bushing Removal
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod/barrel
must be replaced.
12. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.
c. Lubricate inside of steel bushing with WD40
prior to bearing installation.
13. Remove and discard the piston o-rings, seal rings,
and backup rings.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing.
14. Remove piston spacer, if applicable, from the rod.
15. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals,
and wiper seals.
NOTE: Install pin into the composite bearing dry. Lubrication
is not required with nickel plated pins and bearings.
Cleaning and Inspection
1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.
6-4
Figure 6-5. Composite Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
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SECTION 6 - HYDRAULICS
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
Assembly
1. 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.
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to
assembly.
1. A special tool is used to install a new rod seal into
the applicable cylinder head gland groove.
Figure 6-7. Poly-Pak Piston Seal Installation
Figure 6-6. Rod Seal Installation
Figure 6-8. Wiper Seal Installation
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
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SECTION 6 - HYDRAULICS
2. Place a new “o”ring and back-up seal in the applicable outside diameter groove of the cylinder head.
6. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the solid seal.)
NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal.(See magnified insert in Figure 6-10.)The split of seals and
backup rings are to be positioned so as not to be in
alignment with each other.
Figure 6-9. Installation of Head Seal Kit
3. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
4. Carefully slide the piston spacer on the rod.
NOTE: Upper telescope cylinder piston has an o-ring
installed inside the spacer.
5. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side facing the O-ring is grooved.)
Figure 6-10. Piston Seal Kit Installation
7. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as
possible.
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
9. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
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SECTION 6 - HYDRAULICS
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.
NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil.
TIGHTEN THE CAPSCREWS FOR THE TAPERED BUSHING
SECURELY. (SEE TABLE 6-1, CYLINDER HEAD AND TAPERED
BUSHING TORQUE SPECIFICATIONS.)
10. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and
into the tapped holes in the piston.
Figure 6-12. Seating the Tapered Bearing
13. Retorque the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 6-1,
Cylinder Head and Tapered Bushing Torque Specifications.)
14. Remove the cylinder rod from the holding fixture.
15. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 6-10.)
Figure 6-11. Tapered Bushing Installation
11. Tighten the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 6-1,
Cylinder Head and Tapered Bushing Torque Specifications.
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in
contact with the bushing in the spaces between
the capscrews.
16. Position the cylinder barrel in a suitable holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
17. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
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SECTION 6 - HYDRAULICS
19. Secure the cylinder head gland using the washer
ring and socket head bolts. (See Table 6-1.)
Table 6-2. Holding Valve Torque Specifications
Description
SUN - 7/8 HEX M20 X 1.5 THDS.
30-35 ft. lbs.
(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS.
45-50 ft. lbs.
(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS.
Figure 6-13. Rod Assembly Installation
20. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
21. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 6-2, Holding Valve Torque
Specifications).
Table 6-1. Cylinder Head and Tapered Bushing Torque
Specifications.
Head Torque
Value (Wet)
Tapered Bushing
Torque Value
(Wet)
Lift Cylinder
275 ft. lbs.
(373 Nm)
30 ft. lbs.
(41 Nm)
Articulating Lift Cylinder
30 ft. lbs.
(41 Nm)
5 ft. lbs.
(9 Nm)
Slave Cylinder
30 ft. lbs.
(41 Nm)
5 ft. lbs.
(9 Nm)
Master Cylinder
30 ft. lbs.
(41 Nm)
5 ft. lbs.
(9 Nm)
Telescope
Cylinder
50 ft. lbs.
(68 Nm)
9 ft. lbs.
(12 Nm)
Lockout Cylinder
80 ft. lbs.
(109 Nm)
N/A
Articulating Slave Cylinder
50 ft. lbs.
(68 Nm)
9 ft. lbs.
(12 Nm)
Articulating
Master Cylinder
50 ft. lbs.
(68 Nm)
9 ft. lbs.
(12 Nm)
Description
6-8
Torque Value
150-160 ft. lbs.
(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS.
50-55 ft. lbs.
(68-75 Nm)
RACINE - 1 3/8 HEX 1 3/16 - 12 THDS.
75-80 ft. lbs.
(102-109 Nm)
RACINE - 1 7/8 HEX 1 5/8 - 12 THDS.
100-110 ft. lbs.
(136-149 Nm)
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON
THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE
EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD.
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SECTION 6 - HYDRAULICS
6.5 CYLINDER REMOVAL AND
INSTALLATION
29. Remove hardware securing telescope cylinder to aft
end of the mid boom section.
Main Boom Telescope Cylinder Removal
22. Place machine on a flat and level surface, with main
boom in the horizontal position.
23. Shut down engine. Support main boom basket end
with a prop. (See Figure 6-14., Boom Positioning
and Support, Cylinder Repair).
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
24. Tag and disconnect hydraulic lines to telescope cylinder. Use a suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
25. Remove the hardware securing cover plate on bottom of the base boom section and remove cover.
NOTE: Do not allow cable to rotate. This may damage the
cable.
26. Clamp both threaded ends of cable to prevent rotation. Note: Do not clamp on threads. Remove jam
nuts and loosen adjustment nuts so there is slack in
the cables. Remove the hardware securing push bar
to turntable and telescope cylinder.
27. Using a suitable brass drift, carefully drive the push
bar pins from the telescope cylinder rod and turntable.
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE
BOOM, IT MAY BE NECESSARY AT SOME POINT TO TURN THE
CYLINDER SLIGHTLY IN ORD ER TO CLEAR ASSEMBLIES
MOUNTED WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE
THE CYLINDER SLOWLY INTO POSITION: DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE
ASSEMBLIES.
30. Remove bolts securing cable attach bar to top of fly
boom section.
31. Pull the telescope cylinder and cables partially from
aft end of the base boom section; secure the cylinder with a suitable sling and lifting device at approximately the center of gravity.
32. Carefully remove the telescope cylinder and sheave
assembly. Place telescope cylinder on a suitable
trestle.
Main Boom Telescope Cylinder Installation
1. Route extend cables around extend sheave and
secure cables to the telescope cylinder.
2. Install extend cables mounting blocks to threaded
ends of cables. Loosely install nuts and jam nuts
onto the threaded end of cables.
NOTE: When installing cables care must be taken not to
twist or cross the cables.
28. Remove hardware securing cable adjustment block
to aft end of the base boom section and remove
block.
3. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
Figure 6-14. Boom Positioning and Support, Cylinder Repair
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SECTION 6 - HYDRAULICS
4. Install extend cable mounting blocks to threaded
ends of cables. Loosely install nuts and jam nuts
onto the threaded ends of cables.
Main Boom Lift Cylinder Removal
1. Place the machine on a flat and level surface. Start
the engine and place the main boom in the horizontal position. Shut down engine and prop the boom.
(See Figure 6-14., Boom Positioning and Support,
Cylinder Repair).
NOTE: When installing cables, care must be taken not to
twist or cross the cables.
5. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
2. Remove the hardware retaining the cylinder rod
attach pin to the boom. Using a suitable brass drift,
drive out the cylinder rod attach pin.
3. Using auxiliary power, retract the lift cylinder rod
completely.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY INTO POSITION: DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
6. Carefully install the telescope cylinder barrel end
support into slots in mid boom and secure with
blocks and bolts. Use Loctite #242 on bolts.
7. Align holes in aft end of the fly boom section with
holes in cable mounting block, then secure with
mounting hardware.
4. Disconnect, cap and tag the main boom lift cylinder
hydraulic lines and ports.
5. Remove barrel end attach pin retaining hardware.
Using a suitable brass drift drive out the barrel end
attach pin from the turntable.
6. Remove the cylinder from the turntable and place in
a suitable work area.
Main Boom Lift Cylinder Installation
8. Align holes in aft end of the base boom section with
holes in cable mounting block, then secure with
mounting hardware.
9. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.
10. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure
with mounting hardware.
11. Align holes in push bar with holes in turntable. Install
push bar pin and secure with mounting hardware.
NOTE: Boom cables must be torqued after installation of the
telescope cylinder. (See Section 4 - Boom & Platform)
1. Install lift cylinder in place using suitable slings or
supports, aligning attach pin mounting holes on the
turntable.
2. Using a suitable drift, drive the barrel end attach pin
through the mounting holes in the lift cylinder and
the turntable. Secure in place with the pin retaining
hardware.
3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.
4. Using auxiliary power, extend the cylinder rod until
the attach pin hole aligns with those in the boom.
Using a suitable soft mallet, drive the cylinder rod
attach pin through the boom and lift cylinder. Secure
the pin in place with attaching hardware.
5. Remove boom prop and overhead crane. Activate
hydraulic system.
6. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
7. Check fluid level of hydraulic tank and adjust as necessary.
6-10
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SECTION 6 - HYDRAULICS
6.6 PRESSURE SETTING PROCEDURES
Articulating Jib Boom (If Equipped)
1. Install pressure gauge at quick disconnect on articulating valve.
Main Relief, Steer, Swing and Lift Down
1. Install pressure gauge at quick disconnect on port
MP on main valve.
2. With the aid of an assistant, activate articulating jib
up.
2. With the aid of an assistant, activate telescope in.
3. While monitoring pressure gauge, adjust articulating
jib up relief to 2500 PSI (172.4 Bar).
3. While monitoring pressure gauge, adjust main relief
to 3000 PSI (206.85 Bar).
4. With the aid of an assistant, activate steer left.
5. While monitoring pressure gauge, adjust steer left
relief to 1800 PSI (124.1 Bar).
4. With the aid of an assistant, activate articulating jib
down.
5. While monitoring pressure gauge, adjust activate
articulating jib down relief to 1200 PSI (82.7 Bar).
6. With the aid of an assistant, activate steer right.
7. While monitoring pressure gauge, adjust steer right
relief to 1800 PSI (124.1 Bar).
8. With the aid of an assistant, activate swing left or
right.
9. While monitoring pressure gauge, adjust swing relief
to 1700 PSI (117.2 Bar).
10. With the aid of an assistant, activate lift down.
11. While monitoring pressure gauge, adjust lift down
relief to 1500 PSI (103.4 Bar).
Platform Level
Figure 6-15. Articulating Jib Boom Pressure
Adjustments
1. Install pressure gauge at quick disconnect on port
M3 on main valve.
2. With the aid of an assistant, activate platform level
forward.
3. While monitoring pressure gauge, adjust platform
level relief to 2800 PSI (193.06 Bar).
4. Install pressure gauge at quick disconnect on port
M4 on main valve.
5. With the aid of an assistant, activate platform level
backward.
6. While monitoring pressure gauge, adjust platform
level relief to 1800 PSI (124.11 Bar).
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SECTION 6 - HYDRAULICS
Figure 6-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2
6-12
– JLG Lift –
3121157
SECTION 6 - HYDRAULICS
Figure 6-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2
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SECTION 6 - HYDRAULICS
Figure 6-18. Location of Components - Main Control Valve (Sheet 1 of 2)
6-14
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3121157
SECTION 6 - HYDRAULICS
Figure 6-19. Location of Components - Main Control Valve (Sheet 2 of 2)
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SECTION 6 - HYDRAULICS
A.
B.
C.
D.
18-20 ft.lbs. (24.5-27 Nm)
25-27 ft.lbs. (34-37 Nm)
4-5 ft.lbs. (6.5-9.5 Nm)
60 in. lbs. (7 Nm)
Figure 6-20. Main Control Valve Torque Values
6-16
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3121157
SECTION 6 - HYDRAULICS
1.
2.
3.
4.
Flow Control Cartridge
Directional Control Valve
Relief Cartridge
Relief Cartridge
Figure 6-21. Platform Valve Identification
A. 18-20 ft.lbs. (24.5-27 Nm)
B. 60 in. lbs. (7 Nm)
Figure 6-22. Platform Valve Torque Values
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SECTION 6 - HYDRAULICS
6.7 HYDRAULIC PUMP (GEAR)
7. Remove pump from vise and place on clean work
bench, remove the four hex head bolts and spacers
if applicable.
Disassembly
NOTE: The following general instructions also apply to multiple section gear pumps, the only extra parts are the
coupling between the drive shafts and the center distance plate which divides the two pump sections.
This repair procedure also applies to the "W" series
Gear Motors.
1. It is very important to work in a clean work area
when repairing hydraulic products. Plug ports and
wash exterior of pump with a proper cleaning solvent before continuing.
2. Remove port plugs and drain oil from pump.
8. Lift and remove end cover.
3. Use a permanent marker pen to mark a line across
the mounting flange, gear housing and end cover.
This will assure proper reassembly and rotation of
pump.
9. Carefully remove gear housing and place on work
bench. Make sure the rear bearing block remains on
the drive and idler shafts.
4. Remove key from drive shaft if applicable.
5. Clamp the mounting flange in a protected jaw vise
with the pump shaft facing down.
6. Loosen the four metric hex head bolts.
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SECTION 6 - HYDRAULICS
10. Remove rear bearing block from drive and idler
shafts.
13. Remove the front bearing block.
14. Turn the mounting flange over, with the shaft seal up,
and remove the retaining ring with proper snap ring
pliers.
11. Remove idler shaft from bearing block.
12. Remove drive shaft from mounting flange. There is
no need to protect the shaft seal as it will be
replaced as a new item.
15. Remove the oil seal from mounting flange, be careful not to mar or scratch the seal bore.
16. Remove the dowel pins from the gear housing. Do
not lose pins.
17. Remove seals from both bearing blocks and discard.
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SECTION 6 - HYDRAULICS
Inspect Parts For Wear
1. Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they
will be placed as new items.
2. Check drive shaft spine for twisted or broken teeth,
check keyed drive shaft for broken or chipped keyway. No marks or grooves on shaft in seal area,
some discoloration of shaft is allowable.
3. Inspect both the drive gear shaft and idler gear
shafts at the bearing points and seal area for rough
surfaces and excessive wear.
4. Inspect gear face for scoring or excessive wear. If
the face edge of gear teeth are sharp, they will mill
into the bearing blocks. If wear has occurred, the
parts are unusable.
5. Inspect bearing blocks for excessive wear or scoring
on the surfaces which are in contact with the gears.
Also inspect the bearings for excessive wear or scoring.
6. Inspect the area inside the gear housing. It is normal
for the surface inside the gear housing to show a
clean "wipe" on the inside surface on the intake side.
There should not be excessive wear or deep
scratches and gouges.
6-20
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SECTION 6 - HYDRAULICS
General Information
It is important that the relationship of the mounting flange,
bearing blocks and gear housing is correct. Failure to
properly assemble this pump will result with little or no
flow at rated pressure.
bore. Uniform pressure must be used to prevent
misalignment or damage to the seal.
Reverse Shaft Rotation of Pump
NOTE: This pump is not bi-rotational, if the shaft rotation
must be changed the following procedure must be
followed.
Reversing the shaft rotation of the "W" series gear pump
may be accomplished by rotating, as a group, the two
bearing blocks and the gear housing 180° in relationship
to the remaining parts of the pump. This procedure will
place the pressure port on the opposite side of the pump
from its original position.
2. Install retaining ring in groove in seal bore of mounting flange.
Assembly
NOTE: New seals should be installed upon reassembly of
pump or motor. deter to page 8 for the necessary kit
part numbers for the W-600, W-900 and W-1500
pumps and motors.
3. Place front and back bearing blocks on a clean surface with the E-seal grooves facing up. Apply a light
coating of petroleum jelly in the grooves. Also coat
the E-seal and backup with the petroleum jelly, this
will help keep the seals in place during reassembly.
1. Install new shaft seal in mounting flange with part
lumber side facing outboard. Press the seal into the
seal lore until the seal reaches the bottom of the
4. Place the E-seals, flat side outward, into the grooves
in both bearing blocks. Follow by carefully placing
the backup ring, flat side outward, in the groove
made by the E-seal and the groove in the bearing
block. (Note: in the W900 series pump, in the center
of the backup ring and E-seal there is a notch make
sure that these notches line up so the backup ring
will set flush with the E-seal). The backup ring in the
W1500 pump is symmetrical.
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SECTION 6 - HYDRAULICS
5. Place mounting flange, with shaft seal side down, on
a clean flat surface.
6. Apply a light coating of petroleum jelly to the
exposed face of the front bearing block.
7. Insert the drive end of the drive shaft through the
bearing block with the seal side down, and the open
side of the E-seal pointing to the intake side of the
pump.
11. Install two dowel pins in the holes in the mounting
flange or two long dowel pins through gear housing
if pump is a multiple section pump.
12. To install the O-rings in the gear housing, apply a
light coating of petroleum jelly in the grooves on
both sides of the gear housing. Also coat the new Orings and install them in the grooves.
8. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal.
Remove the seal sleeve from shaft.
9. Install the idler gear shaft in the remaining position in
the bearing block. Apply a light coat of clean oil to
the face of the drive and idler gears.
13. Gently slide the gear housing over the rear bearing
block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place
with hands, do not force or use any tool. Check to
make sure the in-take port in the housing is on the
same side as the open end of the E-seal and that the
marked lines on the mounting flange and gear housing are in alignment.
14. The surface of the rear bearing block should be
slightly below the face of the gear housing. If the
bearing block sits higher then the rear face of the
gear housing then the E-seal or o-ring have shifted
10. Pick up the rear bearing block, with seal side up and
with open end of the E-seal facing the intake side of
the pump, place over the drive and idler gear shafts.
6-22
– JLG Lift –
3121157
SECTION 6 - HYDRAULICS
out of the groove. If this is the case, remove the gear
housing and check for proper seal installation.
the pump and check for assembly problems, then
reassemble the pump.
15. Install the two remaining dowel pins in the rear of the
gear housing, if applicable, and place the end cover
over the back of the pump.
20. The name plate located on the end cover contains
the build date code and the model number. Please
refer to this information when corresponding with
the J.S. Barnes Service Department.
Table 6-3.Hydraulic Pump Bolt Torque Chart
Torque
Values, Black
Oxide End
Cover
Torque
Values, Zinc
Plated End
Cover
Pump Series
Thread Size
W-600
M 8 x 1.25
18-21 ft.lb.
24-30 Nm
16-18 ft.lb.
21.7-24.4 Nm
W-900
M 10 x 1.5
50-55 ft.lb.
68-75 Nm
38-43 ft.lb.
51.5-58.3 Nm
W-1500
M 12 x 1.75
80-85 ft.lb.
108-115 Nm
68-73 ft.lb.
92.2-99 Nm
16. Install the four spacers, if applicable, and hex head
bolts through the bolt holes in the end cover, hand
tighten.
17. Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts to
the torque specifications in the torque chart. All
torque figures are for "dry torque" bolts.
18. Remove pump from vise.
19. Place a small amount of clean oil in the inlet of the
pump and rotate the drive shaft away from the inlet
one revolution. If the drive shaft binds, disassemble
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6-23
SECTION 6 - HYDRAULICS
Placing Pump Back Into Service
6.8 VARIABLE PUMP
1. If shop test stand is available, the following procedure for testing rebuilt pumps is recommended:
a. Mount pump on test stand making sure that the
proper level of clean oil is available in the reservoir. Check suction line for leaks and obstructions.
b. Start pump and run for three minutes at zero
pressure.
Ports and Pressure Gauges
Proper servicing of pumps and motors requires that pressure be measured and monitored at various points in the
hydraulic circuit. The Series 42 pump has several locations at which to take these measurements. The following
outlines show the locations of the various gauge ports.
The following table shows the recommended gauge size
and the fitting size for each port.
c. Intermittently load pump to 500 P.S.I. for three
minutes.
d. Intermittently load pump to 1000 P.S.I. for three
minutes.
e. Intermittently load pump to 2000 P.S.I. for three
minutes.
f. Remove pump from test stand and check for
freeness of drive shaft. Check pump for signs of
external leakage.
Table 6-4. Recommended Gauge Size
Gauge
Port
Name
Pressure
Measured
Recommended
Gauge Size
PSI
Bar
Fitting
M1 & M2
System
Pressure
Ports A & B
10000
600
9/16-18 ORF
M3
Charge
1000
60
3/4-16 ORF
a. For engine driven pumps, mount pump on
equipment and run pump at 1/2 engine speed at
zero pressure for three minutes.
M4 & M5
Servo
1000
60
9/16-18 ORF
L1 & L2
Case
500
35
1-1/16-12 ORF
b. By operating control valve, build pressure intermittently for three minutes.
S
Charge Pump
Inlet Vacuum
30 in. Hg Vac.
1
1-1/16-12 ORF
2. If shop test stand is not available, the following procedure for testing rebuilt pumps is recommended:
c. Increase engine speed to full throttle and build
pressure intermittently for three minutes.
d. Stop engine and check pump for external leaks.
NFPE Control
The 3-position FNR control and the electric and hydraulic
non-feedback proportional (NFPE and NFPH) controls are
non-feedback type controls. The FNR and NFPE controls
consist of modules mounted on the pump housing. The
hydraulic input for NFPH is received through ports on the
top of the pump [9/16–18 SAE O-ring fitting].
The non-feedback controls are set at the factory. The control modules can be removed to clean the ports and
change the O-rings.
The orifice plugs for the FNR and NFPE are located inside
the servo piston covers. The orifice plugs for the NFPH are
located in the NFPH ports. Orifice plugs may be cleaned
or replaced.
6-24
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SECTION 6 - HYDRAULICS
Removal and Installation of FNR and NFPE
Modules
SHIM ADJUSTABLE STYLE
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to housing
[4 mm Int. Hex], and remove module from pump
housing.
3. Remove O-rings from the control ports. Examine
ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].
Removal and Installation of FNR and NFPE
Control Orifices
NOTE: Future models may contain an orifice plate between
module and pump housing. This will take the place
of the orifice plugs beneath the servo piston cover.
1. Remove servo piston cover.
1. Plug
2. O-ring
3. Shims
4. Spring T-Seal
5. Poppet
Figure 6-23. Shim Adjustable Charge Relief Valve
Components
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
1. Remove the shim adjustable charge relief valve plug
[1 in Hex] from the pump housing. Remove the Oring from the plug.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].
Charge Relief Valve
The charge relief valve may be removed for cleaning and
installation of fresh O-rings. The pressure setting may be
changed. However, note that the setting will vary for different charge flows which depends on charge pump size
and pump speed. The factory setting is set relative to case
pressure at 1800 rpm. The actual charge pressure will
vary at different speeds.
2. Remove the spring and poppet from the housing.
3. Do not alter the shims which may be installed
between the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar /
1.25 mm (58 psi / 0.050 in). The effective setting will
vary.
To confirm the charge relief valve setting, measure
charge pressure (port M3) with the pump in stroke.
The charge pressure should level off when the relief
setting is reached.
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6-25
SECTION 6 - HYDRAULICS
1.
System Pressure Gauge Port M2
2.
System Pressure Port B
3.
System Pressure Port A
4.
System Pressure Gauge Port M1
5.
Servo Pressure Gauge Port M5
6.
Case Drain Port L2 (non-feedback)
7.
Case Drain Port L2
8.
Servo Pressure Gauge Port L4
9.
Case Drain Port L1
10.
Case Drain Port L1 (non-feedback)
11.
Charge Pressure Gauge
12.
Charge Pump Inlet Port S
Figure 6-24. Gauge Port Locations
6-26
– JLG Lift –
3121157
SECTION 6 - HYDRAULICS
Plug/
Fitting
#
Torque
lb. ft.
Nm
N/A
N/A
11/16
20-35
27-47
3
9/16
70-100
95-135
4
Case Drain Port L1
N/A
N/A
5
Charge Pressure
Gauge M3
N/A
N/A
6
Charge Pump Inlet
Port S
85
115
7
Case Drain Port L2
N/A
N/A
8
Port N
N/A
N/A
9
System Gauge M1 &
M2
N/A
N/A
1
Servo Gauge Port
M4
2
10 System Ports A&B
85
115
11 11/16
20-35
27-47
12 9/16
70-100
95-135
13 11/16
20-35
27-47
14 Servo Gauge M5
15 11/16
N/A
N/A
20-35
27-47
Figure 6-25. Plugs/Fittings Size & Torque
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SECTION 6 - HYDRAULICS
5. Install a new O-ring on the valve plug. Reinstall the
poppet, spring, and plug (with shims and O-ring)
into the pump housing [55-135 Nm (40-100 ft•lbf)].
Shaft Seal and Shaft Replacement
SCREW ADJUSTABLE STYLE
1. Retaining Ring
1. Lock Nut
2. O-ring
3. Plug
4. Spring T-Seal
5. Poppet
2. Seal Carrier Assembly
Figure 6-27. Shaft Seal Components
Figure 6-26. Screw Adjustable Charge Relief
Valve Components
1. Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment
when assembling, Remove the screw adjustable
charge relief valve plug by loosening the lock nut [11/16 in Hex] and unscrewing the plug [8 mm Int.
Hex]. Remove the O-ring from the plug.
A lip type shaft seal is used in Series 42 pumps. This seal
and/or the shaft can be replaced without major disassembly of the unit. Replacement generally requires removal of
the pump from the machine.
2. Remove the spring and poppet from the housing.
3. Inspect the poppet and mating seat in the housing
for damage or foreign material.
4. Install a new O-ring on the valve plug. Reinstall the
poppet and spring. Reinstall the plug with its lock
nut [47-57 Nm (34-42 ft•lbf)], aligning the marks
made at disassembly.
5. Check and adjust, if necessary, the charge pressure.
For screw adjustable "anti-stall" charge relief valves,
an approximate rule of thumb is 2.8 bar / quarter
turn (40 psi / quarter turn).
To confirm the charge relief valve setting, measure
charge pressure (port M3) with the pump in stroke.
The charge pressure should level off when the relief
setting is reached.
6-28
– JLG Lift –
1. O-ring
2. Seal
3. Seal Carrier
4. Sealant may be used on outside diameter
5. Inside Lip (face down)
6. Press Seal to Bottom of Seal Carrier
Figure 6-28. Installation of Shaft Seal
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SECTION 6 - HYDRAULICS
1. Position the pump with the shaft facing up.
rier. If the shaft is not being replaced proceed to step
11.
NOTE: If the unit is positioned horizontally when the shaft is
removed, the cylinder block could move out of
place, making shaft installation difficult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To install a
new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the shaft
bearing side down, and press out the old seal. An
appropriately sized pipe spacer or socket wrench
can be used as a press tool. Once removed, the seal
is not reusable.
6. Inspect the seal carrier and the new seal for damage. Inspect the sealing area on the shaft for rust,
wear, or contamination. Polish the sealing area on
the shaft if necessary.
7. Press the new seal into the shaft bearing side of the
seal carrier. The seal lip must face the outside of the
pump. Be careful not to damage the seal. The outside diameter of the seal may be coated with a sealant (e.g. Loctite High Performance Sealant #59231)
prior to installation. This aids in preventing leaks
caused by damage to the seal bore in the seal car-
1. Key
2. Shaft Assembly
3. Retaining Ring
4. Roller Bearing
5. Shaft
Figure 6-29. Shaft Components
8. Remove the shaft and roller bearing assembly from
the pump or motor. The bearing assembly can be
transferred to the new shaft (steps 9 and 10).
9. Remove the retaining ring that secures roller bearing
assembly with a snap ring plier. Remove the roller
bearing assembly. Place roller bearing assembly on
new shaft and secure with the retaining ring.
10. Place roller bearing assembly on new shaft and
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin plastic
to prevent damage to the seal lip during installation.
64 Lubricate the inside diameter of the shaft seal
with petroleum jelly.
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6-29
SECTION 6 - HYDRAULICS
12. Place the O-ring onto the shaft bearing and lubricate
with petroleum jelly.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress the
cylinder block spring while pressing the seal carrier
into place.
8. Install the gerotor drive pin into the hole in the drive
coupling, and retain with grease or petroleum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from the
pump shaft. Different couplings are used with the
different auxiliary pad options.
14. Install the retaining ring.
10. Install the gerotor assembly onto the coupling.
Charge Pump
The charge pump may be disassembled to inspect
and clean, or to change the auxiliary shaft drive coupling.
1. Remove auxiliary pump, if necessary.
2. Remove the screws retaining the charge pump
cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A" auxiliary mounting pad charge pump cover, while six (6)
screws are used with the SAE "B" auxiliary mounting
pad charge pump cover). Remove the charge pump
cover, gasket, and the cover locating pins.
3. Remove the gerotor cover assembly from the
charge pump cover or the back of the pump housing. Remove the gerotor cover O-rings. Two (2) Orings are used on the gerotor cover of all pumps.
(An additional O-ring was used on the gerotor cover
of very early production pumps with the SAE "A" pad
option.)
4. Remove the gerotor assembly from the gerotor
cover or pump housing.
11. Install the gerotor cover locating pin into the pump
housing. Install the gerotor cover assembly over the
gerotor. The locating pin must engage the slot in the
gerotor cover.
NOTE: The charge pump rotation is determined by the location of the gerotor recess and pressure balance hole
in the gerotor cover. Different gerotor covers are
used for clockwise and counterclockwise rotation
pumps.
12. Install new pressure balance O-rings onto the gerotor cover and retain with petroleum jelly or grease.
(An additional O-ring was used on the gerotor cover
of very early production pumps with the SAE "A" pad
option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins.
Install the charge pump cover screws and torque
evenly [36-43 Nm (26-32 ft•lbf)].
15. If necessary, reinstall auxiliary pump.
5. Remove the gerotor drive pin and drive coupling.
Remove the gerotor cover locating pin from the
pump housing.
6. Each part should be inspected separately if they are
to be reused. If either of the gerotor assembly parts
needs to be replaced, they must both be replaced.
Always replace the O-rings and charge pump cover
gasket. Inspect the journal bearing in the gerotor
cover for excessive wear.
6-30
– JLG Lift –
3121157
SECTION 6 - HYDRAULICS
1.
Cover Retaining Screw
2.
O-ring
3.
Gerotor Cover
4.
Gerotor Assembly
5.
Drive Coupling
6.
Gerotor Cover Locating Pin
7.
Charge Pump Cover Locating Pin
8.
Gerotor Drive Pin
9.
Gasket
Figure 6-30. Charge Pump Components
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6-31
SECTION 6 - HYDRAULICS
6.9 HYDRAULIC PUMP W/HAYES PUMP
DRIVE COUPLING LUBRICATION
Any time pump or pump drive coupling is removed coat,
pump and drive coupling splines with Lithium Soap Base
Grease (TEXACO CODE 1912 OR EQUIVALENT) coupling
is greased prior to assembly.
6.10 HYDRAULIC COMPONENT START-UP
PROCEDURES AND
RECOMMENDATIONS
From a hydrostatic component standpoint, the goal at
system start up is to put into functional operation, the
hydrostatic system in such a way as to preserve the
designed life span of the system. The following start-up
procedure should be adhered to whenever a new pump
or motor is initially installed into a machine, or a system is
restarted after either a pump or motor has been removed
and/or replaced.
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK
FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING THE
PROCEDURE IN ORDER TO PREVENT INJURY. TAKE NECESSARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/
MACHINE.
Prior to installing the pump and/or motor, inspect the
unit(s) for damage that may have been incurred during
shipping and handling. Make certain that all system components (reservoir, hoses, valves, fittings, heat exchanger,
etc.) are clean prior to filling with fluid.
Fill the reservoir with recommended hydraulic fluid. This
fluid should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine movement.
NOTE: If a pump or motor is being replaced due to internal
damage, the remaining units (pump or motors) need
to be inspected for damage and contamination, and
the entire hydraulic system will need to be flushed
and the fluid replaced. Failure to do so may cause
considerable damage to the entire system.
The inlet line leading from the reservoir to the pump must
be filled prior to start-up. Check the inlet line for property
tightened fittings and make sure it is free of restrictions
and air leaks.
6-32
NOTE: In most cases, the reservoir is above the pump inlet
so that the pressure head created by the higher oil
level helps to keep the inlet pressures within an
acceptable range and prevent high vacuum levels.
However, due to hose routing or low reservoir locations, there may be air trapped within this line. It is
important to assure that the air is bled from this line.
This can be accomplished by loosening the hose at
the fitting closest the pump. When oil begins to flow,
the line is full, the air has been purged, and the fitting
can be retightened to its specified torque. If the tank
needs to be pressurized in order to start the flow of
oil, a vacuum reading should be taken at the inlet of
the pump during operation in order to verify that the
pump is not being asked to draw an inlet vacuum
higher than it is capable of.
Be certain to fill the pump and/or motor housing with
clean hydraulic fluid prior to start up. Fill the housing by
pouring filtered oil into the upper case drain port.
NOTE: It is highly recommended to use the highest possible
case drain port, this ensures that the housing contains as much oil as possible and offers the greatest
amount of lubrication to the internal components.
NOTE: In initial start-up conditions, it may be convenient to
fill the housing, just prior to installing the case drain
line. Component, (especially motor), location may be
such that access to the case drain port after installation is not realistic.
NOTE: Make certain that the oil being used to fill the component housing is as clean as possible, and store the
fill container in such a way as to prevent it from
becoming contaminated.
Install a 60 bar (or 1000 psi) pressure gauge in the charge
pressure gauge port in order to monitor the charge pressure during start-up.
It is recommended that the external control input signal,
(electrical connections for EDC), be disconnected at the
pump control until after initial start-up. This will ensure that
the pump remains in its neutral position.
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
ACTUATED DURING INITIAL START-UP.
"Jog" or slowly rotate the engine until charge pressure
starts to rise. Start the engine and run at the lowest possible RPM until charge pressure has been established.
Excess air should be bled from the system lines as close
to the motors as possible.
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SECTION 6 - HYDRAULICS
NOTE: With the engine on low idle, "crack", (loosen-don't
remove), the system lines at the motor(s). Continue
to run the engine at low idle and tighten the system
lines as soon as oil is observed to leak from them.
When oil is observed to "leak" at the motor the line is
full, the air has been purged, and the system hoses
should be retightened to their specified torque.
Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
be as indicated in the pump model code. If charge pressure is inadequate, shut down and determine the cause
for improper pressure.
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR' S ABILITY TO CONTROL THE MACHINE.
Shut down the engine and connect the external control
input signal. Also reconnect the machine function(s), if
disconnected earlier. Start the engine, checking to be certain the pump remains in neutral. With the engine at normal operating RPM, slowly check for forward and reverse
machine operation.
Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes.
Shut down engine, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
The machine is now ready for operation.
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6-33
SECTION 6 - HYDRAULICS
This page left blank intentionally.
6-34
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
SECTION 7. JLG CONTROL SYSTEM
7.1 INTRODUCTION
WHEN INSTALLING A NEW GROUND 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. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE
COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 12 volt based
motor control unit installed on the boom lift.
The JLG Control System has reduced the need for
exposed terminal strips, diodes and trimpots and provides
simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,
creep, min speed, and max.-speed for all boom, drive,
and steering functions.
The upper lift, swing, and drive are controlled by individual
joysticks, with steering being controlled by a rocker switch
built into the top the drive joystick. To activate Drive, Lift,
and Swing simply pull up on the slide lock location on the
joystick and move the handle into the direction desired.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation
and maximum cycle time. Ground control speeds for all
boom functions can also be programmed into the 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 a soft touch system, head and tail lights,
and ground alarm. These options may be added later but
must be programmed into the control system when
installed.
The Control System may be accessed utilizing a custom
designed, hand held analyzer (Analyzer Kit, JLG part no.
2901443) which will display two lines of information at a
time, by scrolling through the program.
NOTE: Each module has a label with the JLG part number
and a serial number which contains a date code.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
Level, and item menus
To return home or access
previous menu
Left & Right Arrow Keys
Up & Down Arrow Keys
Used to move between Top Level,
Sub Level, and item menus
Value Selector
Figure 7-1. Hand Held Analyzer
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7-1
SECTION 7 - JLG CONTROL SYSTEM
Figure 7-2. ADE Block Diagram
7-2
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
7.2 TO CONNECT THE JLG CONTROL
SYSTEM ANALYZER
The top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
1. Connect the four pin end of the cable supplied with
the analyzer, to the controller module located in the
platform box or at the controller module in the
ground control box and connect the remaining end
of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of
the cable; the cable cannot be connected backwards.
2. Power up the Control System by turning the lower
key to the platform or ground position and pulling
both emergency stop buttons on.
If you press ENTER, at the HELP: PRESS ENTER display,
and a fault is present, the analyzer display will scroll the
fault across the screen. If there was no fault detected, the
display will read: HELP: EVERYTHING OK. If powered up
at the ground station, the display will read: GROUND OK.
If ENTER is pressed again, the display moves to the following display:
7.3 USING THE ANALYZER
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
LOGGED HELP
1: POWER CYCLE (0/0)
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. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
3121157
At this point, the analyzer will display the last fault the system has seen, if any are present. You may scroll through
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To
return to the beginning, press ESC. two times. POWER
CYCLE (0/0) indicates a power up.
– JLG Lift –
7-3
SECTION 7 - JLG CONTROL SYSTEM
PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 7-3. Analyzer Connecting Points
7-4
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
When a top level menu is selected, a new set of menu
items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ESC. key.
7.4 CHANGING THE ACCESS LEVEL OF THE
HAND HELD ANALYZER
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. To change the access level,
the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
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– JLG Lift –
7-5
SECTION 7 - JLG CONTROL SYSTEM
Figure 7-4. Control Module Location
7-6
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Once the correct password is displayed, press ENTER.
The access level should display the following, if the password was entered correctly:
7.5 ADJUSTING PARAMETERS USING THE
HAND HELD ANALYZER
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular personality. If the value does not change when pressing the
up and won arrows, check the access level to ensure you
are at access level 1.
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7-7
SECTION 7 - JLG CONTROL SYSTEM
7.6 MACHINE SETUP
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
ITS 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. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE
COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
7.7 LEVEL VEHICLE DESCRIPTION
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE
TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL
SURFACE.
GROUND ALARM:
2 = LIFT DOWN
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 lifting down. 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.
NOTE: Refer to Table 7-1, Personality Ranges/Defaults, and
in this Service Manual for the recommended factory
settings.
NOTE: Password 33271 will give you access to level 1,
which will permit you to change all machine personality settings.
There is a setting that JLG strongly recommends that you
do not change. This setting is so noted below:
ELEVATION CUTBACK
Place machine in stowed position with the boom between
the rear wheels.
To level machine chose:
CALIBRATION:
TILT SENSOR
Press ENTER.
When prompted, swing machine 180°
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
7-8
Press ENTER.
– JLG Lift –
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Figure 7-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
SECTION 7 - JLG CONTROL SYSTEM
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– JLG Lift –
7-9
Figure 7-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4
SECTION 7 - JLG CONTROL SYSTEM
7-10
– JLG Lift –
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Figure 7-7. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4
SECTION 7 - JLG CONTROL SYSTEM
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– JLG Lift –
7-11
Figure 7-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4
SECTION 7 - JLG CONTROL SYSTEM
7-12
– JLG Lift –
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– JLG Lift –
Figure 7-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
NOTE: Some screens may not be available depending upon machine configuration.
SECTION 7 - JLG CONTROL SYSTEM
7-13
Figure 7-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4
SECTION 7 - JLG CONTROL SYSTEM
7-14
– JLG Lift –
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Figure 7-11. Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4
SECTION 7 - JLG CONTROL SYSTEM
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– JLG Lift –
7-15
Figure 7-12. Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4
SECTION 7 - JLG CONTROL SYSTEM
7-16
– JLG Lift –
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SECTION 7 - JLG CONTROL SYSTEM
7.8 MACHINE PERSONALITY SETTINGS
NOTE: Personality settings can be adjusted within the
adjustment range in order to achieve optimum
machine performance.
Table 7-1. Personality Ranges/Defaults
FUNCTION
DRIVE
PERSONALITY
RANGE
DEFAULTS - 600S
ACCELeration
0.1s to 5.0s
2.0
DECELeration
0.1s to 3.0s
2.0
Forward MINimum speed
0 to 35%
4
Forward MAXimum speed
0 to 100%
35
REVerse MINimum speed
0 to 35%
4
REVerse MAXimum speed
0 to 100%
35
ELEVATED MAXimum speed
0 to 50%
15
CREEP MAXimum speed
0 to 50%
25
800 to 2900
1800
ACCELeration
0.1 to 5.0
N/A
DECELeration
0.1 to 3.0
N/A
MlNimum UP speed
0 to 60%
N/A
MAXimum UP speed
0 to 100%
N/A
MINimum DOWN speed
0 to 60%
N/A
MAXimum DOWN speed
0 to 100%
N/A
800 to 2900
N/A
ACCELeration
0.1 to 5.0
2.0
DECELeration
0.1 to 3.0
1.0
MlNimum UP speed
0 to 60%
40
MAXimum UP speed
0 to 100%
80
CREEP Maximum UP speed
0 to 65%
55
MINimum DOWN speed
0 to 60%
40
MAXimum DOWN speed
0 to 100%
70
CREEP maximum DOWN speed
0 to 75%
55
800 to 2900
1800
Engine RPM
TOWER LIFT
Engine RPM
UPPER LIFT
Engine RPM
3121157
– JLG Lift –
7-17
SECTION 7 - JLG CONTROL SYSTEM
Table 7-1. Personality Ranges/Defaults
FUNCTION
SWING
PERSONALITY
RANGE
DEFAULTS - 600S
ACCELeration
0.1 to 5.0s
2.0
DECELeration
0.1 to 3.0s
1.8
MINimum LEFT speed
0 to 50%
30
MAXimum LEFT speed
0 to 100%
65
CREEP maximum LEFT speed
0 to 65%
45
MINimum RIGHT speed
0 to 50%
30
MAXimum RIGHT speed
0 to 100%
65
CREEP maximum RIGHT speed
0 to 65%
45
800 to 2900
1400
ACCELeration
0.1 to 5.0
3.5
DECELeration
0.1 to 3.0
0.8
MINimum IN speed
0 to 65%
45
MAXimum IN speed
0 to 100%
75
MINimum OUT speed
0 to 65%
45
MAXimum OUT speed
0 to 100%
70
800 to 2900
1800
ACCELeration
0.1 to 5.0
N/A
DECELeration
0.1 to 3.0
N/A
MINimum IN speed
0 to 65%
N/A
MAXimum IN speed
0 to 100%
N/A
MINimum OUT speed
0 to 65%
N/A
MAXimum OUT speed
0 to 100%
N/A
800 to 2900
N/A
ACCELeration
0.1 to 5.0
2.5
DECELeration
0.1 to 3.0
0.5
MINimum UP speed
0 to 65%
48
MAXimum UP speed
0 to 100%
52
MlNimum DOWN speed
0 to 65%
45
MAXimum DOWN speed
0 to 100%
50
800 to 2900
1500
Engine RPM
TELESCOPE UPPER
Engine RPM
TELESCOPE TOWER
Engine RPM
BASKET LEVEL
Engine RPM
7-18
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-1. Personality Ranges/Defaults
FUNCTION
BASKET ROTATE
PERSONALITY
RANGE
DEFAULTS - 600S
ACCELeration
0.1 to 5.0
1.8
DECELeration
0.1 to 3.0
0.7
MlNimum LEFT speed
0 to 65%
46
MAXimum LEFT speed
0 to 100%
50
MINimum RIGHT speed
0 to 65%
46
MAXimum RIGHT speed
0 to 100%
50
800 to 2900
1500
ACCELeration
0.1 to 5.0
5.0
DECELeration
0.1 to 3.0
1.0
MINimum UP speed
0 to 65%
46
MAXimum UP speed
0 to 100%
52
MINimum DOWN speed
0 to 65%
45
MAXimum DOWN speed
0 to 100%
52
800 to 2900
1800
0 to 100%
100
800 to 2900
1800
Tower LIFT UP speed
0 to 100%
N/A
Tower LIFT DOWN speed
0 to 100%
N/A
Upper LIFT UP
0 to 100%
60
Upper LIFT DOWN
0 to 100%
60
SWING speed
0 to 100%
60
Upper TELEscope speed
0 to 100%
70
Tower TELEscope speed
0 to 100%
N/A
BASKET ROTATE speed
0 to 100%
50
BASKET LEVEL speed
0 to 100%
50
JIB LIFT speed
0 to 100%
50
Engine RPM
JIB LIFT
Engine RPM
STEER
MAXimum speed
Engine RPM
GROUND MODE
NOTE:
Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.
4150365-3
3121157
– JLG Lift –
7-19
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
None
Description
Priority
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.
1
EVERYTHING OK
The “normal” help message in platform mode
GROUND MODE OK
The “normal” help message in ground mode
FSW OPEN
A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP –
CREEP SWITCH OPEN
All function speeds are limited to creep because the creep switch is open.
RUNNING AT CREEP – TILTED All boom function speeds are limited to creep because the vehicle is tilted
AND ABOVE ELEVATION
and above elevation.
RUNNING AT CUTBACK –
ABOVE ELEVATION
Drive speed is limited to “ELEVATED MAX” because the vehicle is above
elevation.
TILT SENSOR OUT OF RANGE The tilt sensor has indicated a tilt angle greater than 19 degrees for more
than 4 seconds. Not reported during 2 second power-up.
LOAD SENSOR READING
UNDER WEIGHT
The load sensor is reading 20% or more under the calibrated zero point.
This fault may occur if the basket is resting on the ground. Not reported
during 2 second power-up.
1/1
Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED
2/1
Flash code 2/1 indicates problems with footswitch.
2
FSW FAULTY
The two footswitch inputs have read the same state for more than one second.
KEYSWITCH FAULTY
Both platform and ground modes are selected simultaneously
2/2
Flash code 2/2 indicates problems with drive & steer selection. Except
where noted, these faults are not reported during 2 second power-up
sequence.
DRIVE LOCKED – JOYSTICK
MOVED BEFORE FOOTSWITCH
Drive was selected before and during footswitch closure. Can be reported
during power-up sequence.
FSW INTERLOCK TRIPPED
Footswitch was closed for seven seconds with no function selected. Can
be reported during power-up sequence.
3
STEER LOCKED – SELECTED Steer was selected before and during footswitch closure.
BEFORE FOOTSWITCH
STEER SWITCHES FAULTY
Both steer switches are active together.
DRIVE / STEER WITH NO
QPROX
This fault only occurs with inductive joysticks. It occurs if the joystick is
moved out of the neutral position with no Qprox sensors active.
D/S JOY. QPROX BAD
These faults only occur with inductive joysticks. They indicate that the QProx sensor is reading above 3.18 volts.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage
is less than the centertap voltage minus half the center tap voltage minus
0.3 volts. If the centertap is at the high end of the range, these faults will be
triggered below 1.05 volts. If the centertap is at the low end of the range,
these faults will be triggered below 0.79 volts.
7-20
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
D/S JOY. OUT OF RANGE
HIGH
Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage
is more than the centertap voltage plus half the centertap voltage plus 0.3
volts. If the centertap is at the high end of the range, these faults will be triggered above 4.35 volts. If the centertap is at the low end of the range, these
faults will be triggered above 3.8 volts.
D/S JOY. CENTER TAP BAD
Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/.1 volt range around these values where the fault may be indicated.
Inductive joysticks: These faults occur when the center tap voltage is not
between 2.18 volts and 2.70 volts. Due to resistor tolerances there is a +/.1 volt range around these values where the fault may be indicated.
WAITING FOR FSW TO BE
OPEN
Footswitch was closed when platform mode was selected. Can be
reported during power-up sequence.
2/3
3121157
Description
Flash code 2/3 indicates problems with boom function selection.
LIFT/SWING LOCKED – JOYSTICK MOVED BEFORE
FOOTSWITCH
Platform upper lift or swing was selected before and during footswitch closure.
PUMP SWITCHES FAULTY –
CHECK DIAGNOSTICS/
BOOM
A boom function (lower lift, telescope, basket level, basket rotate, jib) has
both directions selected together.
PUMP SWITCHES LOCKED –
SELECTED BEFORE FOOTSWITCH
A platform boom function (lower lift, telescope, basket level, basket rotate,
jib) was selected before key switch or footswitch closure.
PUMP SWITCHES LOCKED –
SELECTED BEFORE AUX
POWER
A ground boom function (lower lift, telescope, basket level, basket rotate,
jib) was selected before aux power.
LIFT / SWING WITH NO
QPROX
This fault only occurs with inductive joysticks. It occurs if the joystick is
moved out of the neutral position with no Qprox sensors active.
l/s joy. qprox bad
These faults only occur with inductive joysticks. They indicate that the QProx sensor is reading above 3.18 volts.
l/s joy. out of range low
Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage
is less than the centertap voltage minus half the center tap voltage minus
0.3 volts. If the centertap is at the high end of the range, these faults will be
triggered below 1.05 volts. If the centertap is at the low end of the range,
these faults will be triggered below 0.79 volts.
l/s joy. out of range high
Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage
is more than the centertap voltage plus half the centertap voltage plus 0.3
volts. If the centertap is at the high end of the range, these faults will be triggered above 4.35 volts. If the centertap is at the low end of the range, these
faults will be triggered above 3.8 volts.
– JLG Lift –
Priority
3
7-21
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
l/s joy. center tap bad
Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/.1 volt range around these values where the fault may be indicated.
Inductive joysticks: These faults occur when the center tap voltage is not
between 2.18 volts and 2.70 volts. Due to resistor tolerances there is a +/.1 volt range around these values where the fault may be indicated.
PUMP SWITCHES LOCKED –
SELECTED BEFORE START
SWTICH
This fault occurs when a hydraulic function switch is closed before the start
switch is closed.
FOOTSWITCH SELECTED
BEFORE START
The user attempted to start the machine with the footswitch engaged.
2/4
Priority
Flash code 2/4 indicates that steering digital inputs are faulty.
NOT REQUIRED
2/5
4
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.
DRIVE PREVENTED – ABOVE Drive is selected while above elevation and drive cutout is configured to
ELEVATION
prevent drive.
DRIVE PREVENTED – BOOM
SELECTED
Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – TILTED
& ABOVE ELEVATION
Drive is selected while tilted and above elevation and tilt is configured to
cutout drive.
User changed the model number using the analyzer. User must cycle
MODEL CHANGED –
HYDRAULICS SUSPENDED – power before the hydraulics system will be active again.
CYCLE EMS
2/7
Flash code 2/7 indicates that the accelerator input is faulty.
NOT REQUIRED
2/8
Flash code 2/8 indicates a problem with a hydraulic filter. Not
reported during 2 second power-up.
RETURN FILTER BYPASSED
Hydraulic return filter clogged
charge pump filter bypassed
Charge pump filter clogged
3/1
Flash code 3/1 indicates that a contactor did not close when energized.
NOT REQUIRED
3/2
Flash code 3/2 indicates that a contactor did not open when energized.
NOT REQUIRED
3/3
Flash code 3/3 indicates a driver problem. All driver faults are
detected in a similar manner. Open circuit faults are detected when the
analog feedback reads too high and the output is commanded off.
Short to ground is detected when the analog feedback reads low and
the output is commanded on. Short to battery is detected when the
analog feedback reads Vbat and the output is commanded off. Not
reported during 2 second power-up.
11
5
6
ALTERNATOR/ECM POWER
SHORT TO GROUND
HOUR METER SHORT TO
GROUND
7-22
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
HOUR METER SHORT TO
BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT
HORN SHORT TO BATTERY
AUX POWER SHORT TO
GROUND
AUX POWER OPEN CIRCUIT
AUX POWER SHORT TO BATTERY
GLOW PLUG SHORT TO
GROUND
GLOW PLUG OPEN CIRCUIT
GLOW PLUG SHORT TO BATTERY
LP LOCK SHORT TO
GROUND
LP LOCK OPEN CIRCUIT
LP LOCK SHORT TO BATTERY
LP START ASSIST SHORT TO
GROUND
LP START ASSIST OPEN CIRCUIT
LP START ASSIST SHORT TO
BATTERY
MAIN DUMP SHORT TO
GROUND
MAIN DUMP OPEN CIRCUIT
MAIN DUMP SHORT TO BATTERY
PARKING BRAKE SHORT TO
GROUND
PARKING BRAKE OPEN CIRCUIT
PARKING BRAKE SHORT TO
BATTERY
START SOLENOID SHORT TO
GROUND
START SOLENOID OPEN CIRCUIT
START SOLENOID SHORT TO
BATTERY
STEER DUMP SHORT TO
GROUND
3121157
– JLG Lift –
7-23
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO
BATTERY
TWO SPEED SHORT TO
GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO BATTERY
GROUND ALARM SHORT TO
GROUND
GROUND ALARM OPEN CIRCUIT
GROUND ALARM SHORT TO
BATTERY
GENERATOR SHORT TO
GROUND
GENERATOR OPEN CIRCUIT
GENERATOR SHORT TO BATTERY
WELDER SHORT TO
GROUND
WELDER OPEN CIRCUIT
WELDER SHORT TO BATTERY
HEAD TAIL LIGHT SHORT TO
GROUND
HEAD TAIL LIGHT OPEN CIRCUIT
HEAD TAIL LIGHT SHORT TO
BATTERY
BASKET UP OVERRIDE
SHORT TO GROUND
Only occurs on machines with electronic leveling systems.
BASKET UP OVERRIDE OPEN Only occurs on machines with electronic leveling systems.
CIRCUIT
BASKET UP OVERRIDE
SHORT TO BATTERY
Only occurs on machines with electronic leveling systems.
BASKET UP SHORT TO
GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN CIRCUIT
7-24
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
BASKET DOWN SHORT TO
BATTERY
BASKET DOWN OVERRIDE
SHORT TO GROUND
Only occurs on machines with electronic leveling systems.
BASKET DOWN OVERRIDE
OPEN CIRCUIT
Only occurs on machines with electronic leveling systems.
BASKET DOWN OVERRIDE
SHORT TO BATTERY
Only occurs on machines with electronic leveling systems.
BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO
BATTERY
BASKET LEFT SHORT TO
GROUND
BASKET RIGHT SHORT TO
GROUND
BASKET RIGHT OPEN CIRCUIT
BASKET RIGHT SHORT TO
BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB DOWN SHORT TO
GROUND
JIB DOWN OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB LEFT SHORT TO
GROUND
JIB LEFT OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB RIGHT SHORT TO
GROUND
JIB RIGHT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
TOWER UP SHORT TO
GROUND
TOWER UP OPEN CIRCUIT
TOWER UP SHORT TO BATTERY
TOWER DOWN SHORT TO
GROUND
3121157
– JLG Lift –
7-25
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
TOWER DOWN OPEN CIRCUIT
TOWER DOWN SHORT TO
BATTERY
TOWER IN SHORT TO
GROUND
TOWER IN OPEN CIRCUIT
TOWER IN SHORT TO BATTERY
TOWER OUT SHORT TO
GROUND
TOWER OUT OPEN CIRCUIT
TOWER OUT SHORT TO BATTERY
UPPER IN SHORT TO
GROUND
UPPER IN OPEN CIRCUIT
UPPER IN SHORT TO BATTERY
UPPER OUT SHORT TO
GROUND
UPPER OUT OPEN CIRCUIT
UPPER OUT SHORT TO BATTERY
LIFT UP DUMP SHORT TO
GROUND
LIFT UP DUMP OPEN CIRCUIT
LIFT UP DUMP SHORT TO
BATTERY
LIFT DOWN HOLDING
SHORT TO GROUND
LIFT DOWN HOLDING OPEN
CIRCUIT
LIFT DOWN SHORT TO BATTERY
HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation. It may be reported
during self test.
7-26
FORD ECM POWER OPEN
CIRCUIT
This fault cannot be detected during normal operation. It may be reported
during self test.
FORD ECM POWER SHORT
TO BATTERY
This fault cannot be detected during normal operation. It may be reported
during self test.
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
3/4
Description
Priority
Flash code 3/4 indicates a driver problem on a platform valve block
valve driver. All driver faults are detected in a similar manner. Open circuit faults are detected when the analog feedback reads too high and
the output is commanded off. Short to ground is detected when the
analog feedback reads low and the output is commanded on. Short to
battery is detected when the analog feedback reads Vbat and the output is commanded off. Not reported during 2 second power-up.
6
BASKET UP SHORT TO BATTERY
BASKET UP SHORT TO
GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO
BATTERY OR OPEN CIRCUIT
Only occurs on machines with electronic basket leveling
BASKET DOWN SHORT TO
BATTERY
BASKET DOWN SHORT TO
GROUND
bASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO
BATTERY OR OPEN CIRCUIT
Only occurs on machines with electronic basket leveling.
BASKET LEFT SHORT TO
BATTERY
BASKER LEFT SHORT TO
GROUND
BASKET LEFT OPEN CIRCUIT
BASKET RIGHT SHORT TO
BATTERY
BASKET RIGHT SHORT TO
GROUND
BASKET RIGHT OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB DOWN SHORT TO
GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB LEFT SHORT TO
GROUND
3121157
– JLG Lift –
7-27
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
JIB RIGHT SHORT TO
GROUND
JIB RIGHT OPEN CIRCUIT
PLATFORM CONTROL VALVE Only occurs on machines with electronic basket leveling
SHORT TO BATTERY
PLATFORM CONTROL VALVE Only occurs on machines with electronic basket leveling
SHORT TO GROUND
PLATFORM CONTROL VALVE Only occurs on machines with electronic basket leveling
OPEN CIRCUIT
3/5
Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED
4/2
Flash code 4/2 indicates that the engine is over temperature. NOT
REQUIRED
4/3
Flash code 4/3 indicates problems with the engine. Except where
noted, these faults are not reported during 2 second power-up
sequence.
7-28
high engine temp
Occurs when the engine temperature is above 117 degrees Celsius for the
Ford engines, and above 130 degrees Celsius for the Deutz engines.
AIR FILTER BYPASSED
Air filter clogged
NO aLTERNATOR OUTPUT
The engine has been running for 15 seconds or more and the battery voltage is still below 12.5 volts.
LOW Oil PrESSURE
If a Deutz engine is installed, the oil pressure is below 8 PSI and the engine
has been running for at least 10 seconds. If a Ford engine is installed, the
Ford ECM has reported a low oil pressure fault.
OIL PRESSURE SHORT TO
BATTERY
If a Deutz engine is installed, this indicates that the oil pressure sensor is
reading above 6.6 volts.
OIL PRESSURE SHORT TO
GROUNd
If a Deutz engine is installed, this indicates that the oil pressure sensor is
reading below 0.1 volts for more than 5 seconds. This fault is not detected
during crank.
COOLANT TEMPERATURE
SHORT TO GROUND
If a Deutz engine is installed, this indicates that the coolant temperature is
reading below 0.1 volts.
FORD FAULT CODE ##
All Ford fault codes except 63 are simply passed through from the FORD
ECM. They only occur if a Ford engine is selected in the machine configuration digits. Can be reported during power-up sequence.
FORD FAULT CODE
UNKNOWN
An unrecognized Ford ECM fault code has been received. Can be
reported during power-up sequence.
485 communications lost
This fault only occurs with a Ford engine. It occurs when no responses are
received from the ECM for 2.5 seconds. Can be reported during power-up
sequence.
FUEL SENSOR SHORT TO
BATTERY
Indicates that the fuel sensor is reading above 4.3 volts.
FUEL SENSOR SHORT TO
GROUND
Indicates that the fuel sensor is reading below 0.2 volts.
– JLG Lift –
9
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
4/4
Description
Flash code 4/4 indicates problems with the battery supply. Not
reported during 2 second power-up.
BATTERY LOW
Battery voltage is below 11V for more than 5 seconds. This fault is not
detected during crank. This is a warning – the controller does not shut
down.
BATTERY TOO HIGH –
SYSTEM SHUT DOWN
Battery voltage is above 16V. EMS recycle required.
BATTERY TOO LOW –
SYSTEM SHUT DOWN
Battery voltage is below 9V.
5/5
Flash code 5/5 indicates problems with vehicle engine RPM or the
encoder. Not reported during 2 second power-up.
SPEED SENSOR READING
INVALID SPEED
This fault is detected with diesel engines only. The RPM pickup is indicating a speed that greater than 4000 RPM or approximately 8875 Hz.
SPEED INPUT LOST
This fault is detected with diesel engines only. It occurs if there is no RPM
detected and the oil pressure input is reading above 8 PSI for more than
three seconds. This is probably due to wiring problems at the ground module or a faulty speed sensor.
6/6
Flash code 6/6 indicates problems with the CAN bus.
CAN BUS FAILURE:
7/7
Priority
7
8
10
The ground module or platform module is not receiving CAN messages.
This is probably due to wiring problems between the platform and ground
modules.
Flash code 7/7 indicates problems with a motor.
NOT REQUIRED
9/9
Flash code 9/9 indicates problems with the controller.
PLATFORM MODULE
SOFTWARE UPDATE
REQUIRED
Platform module code is too old to support the EIM or BPE load sensor and
the machine is configured to use one of these two sensors. The PM code
must be updated to a newer version.
HIGH RESOLUTION A2D
FAILURE –INTERRUPT LOST
The ADS1213 chip in the platform module has stopped asserting its interrupt(DRDY) line for some reason. An EMS cycle is required.
HIGH RESOLUTION A2D
FAILURE-REINIT LIMIT
The ADS1213 has needed to be reset 3 or more times.
PLATFORM MODULE FAILURE: hwfs CODE 1
Platform module V(Low) FET has failed
11
GROUND MODULE FAILURE: Ground module V(Low) FET has failed
hwfs CODE 1
3121157
GROUND SENSOR REF
VOLTAGE OUT OF RANGE
These faults occur when the seven volt reference voltage used for the joysticks, sensors, etc. goes out of range. Not reported during 2 second
power-up.
PLATFORM SENSOR REF
VOLTAGE OUT OF RANGE
These faults occur when the seven volt reference voltage used for the joysticks, sensors, etc. goes out of range. Not reported during 2 second
power-up.
EEPROM FAILURE – CHECK
ALL SETTINGS
A critical failure occurred with the EEPROM. Personalities, machine configuration digits, etc. may be reset to default values and should be
checked.
– JLG Lift –
7-29
SECTION 7 - JLG CONTROL SYSTEM
Table 7-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
CHASSIS TILT SENSOR NOT
GAIN CALIBRATED
Description
Priority
Indicates that the chassis tilt sensor calibration information has been lost.
Machine will indicate that it is tilted at all times. This calibration data is programmed into the unit at the factory.
CHASSIS TILT SENSOR GAIN Indicates that the chassis tilt sensor calibration has become corrupted.
OUT OF RANGE
7-30
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-3. Machine Configuration Programming Information
Configuration Digit
Number
Description
Default Number
MODEL NUMBER:
1
1
2
3
4
5
6
7
8
9
10
400S
450A
510A
600S
600A
600SC
601S
740A
800A
800S
1
MARKET:
2
0
1
2
3
4
5
ANSI USA
ANSI EXPORT
CSA
CE
AUSTRALIA
JAPAN
0
ENGINE:
3*
* Engine selections vary
depending on model selection.
1
FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1)
11
2
FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
3
DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)
4
DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)
5
CAT. 3024C: CAT 3024C Diesel (Tier 2)
6
CAT. 3044C: CAT 3044C Diesel (Tier 2)
7
DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)
8
DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)
9
FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)
10
FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)
11
DEUTZ ECM: Engine Control Module - ECM
FLYWHEEL TEETH:
4*
0
133 TEETH: 133 flywheel teeth.
* This menu item is only visible if
Deutz engine selections 3 or 4 are
selected.
1
110 TEETH: 110 flywheel teeth.
GLOW PLUG:
5
0
NO GLOW PLUGS: No glow plugs installed.
1
W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;
engine start can be attempted at any time during pre-glow.
2
W/ STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;
engine start is NOT permitted until pre-glow is finished.
3121157
– JLG Lift –
1
1
7-31
SECTION 7 - JLG CONTROL SYSTEM
Table 7-3. Machine Configuration Programming Information
Configuration Digit
ENGINE SHUTDOWN:
6
TILT:
7*
* Certain market selections
will limit tilt options.
Number
Description
0
DISABLED: No engine shutdown.
1
ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 psi.
1
5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 5 degrees and above elevation; also reduces drive speed to creep.
2
4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also reduces drive speed to creep.
3
3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also reduces drive speed to creep.
4
4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 4 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up.
5
3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up.
Default Number
1
1
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and
will sound the platform alarm when the machine is also above elevation.
JIB:
8*
0
NO: No jib installed.
* Only visible under certain
model selections
1
YES: Jib installed which has up and down movements only.
4 WHEEL STEER:
9*
0
NO: No four-wheel steer installed.
* Only visible under certain
model selections.
1
YES: Four-wheel steer installed.
SOFT TOUCH:
10*
0
NO: No soft touch system installed.
* Only visible under certain
model selections.
1
YES: Soft touch system installed.
GEN SET/WELDER:
11
0
NO: No generator installed.
1
BELT DRIVE: Belt driven setup.
GEN SET CUTOUT:
12*
0
MOTION ENABLED: Motion enabled when generator is ON.
* Only visible if Gen Set /
Welder Menu selection is not 0.
1
MOTION CUTOUT: Motion cutout in platform mode only.
H & T LIGHTS:
13
0
NO: No head and tail lights installed.
1
YES: Head and tail lights installed.
CABLE SWITCH:
14*
0
NO: No broken cable switch installed.
* Only visible under certain
model selections.
1
YES: Broken cable switch installed.
7-32
0
– JLG Lift –
0
0
0
0
0
0
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-3. Machine Configuration Programming Information
Configuration Digit
Number
Description
LOAD SYSTEM:
15*
0
NO: No load sensor installed.
* Market selections will limit
certain load system options.
1
WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2
sec OFF).
2
CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
sec ON, 2 sec OFF).
3
CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform
alarm beeps (5 sec ON, 2 sec OFF).
4
SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).
0
1 ON ROTATOR: Use the on-board load sensor for all models except those which use the
Leveling Platform Module.
1
4 UNDER PLATFORM: Use the EIM for load sensing.
FUNCTION CUTOUT:
17*
0
NO: No drive cutout.
* Market selections will limit
certain function cutout options.
1
BOOM CUTOUT: Boom function cutout while driving above elevation.
2
DRIVE CUTOUT: Drive cutout above elevation.
3
DRIVE CUT E&T: Drive cutout above elevation and tilted.
0
NO: No ground alarm installed.
1
DRIVE: Travel alarm sounds when the drive function is active (Option).
2
DESCENT: Descent alarm sounds when lift down is active (Option).
3
MOTION: Motion alarm sounds when any function is active (Option).
DRIVE:
19*
0
4WD: Four wheel drive.
* Only visible under certain
model selections.
1
2WD: Two wheel drive.
2
2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.
0
CELSIUS: Celsius unit selection.
1
FAHRENHEIT: Fahrenheit unit selection.
LEVELING MODE:
21*
0
ALL FUNCTIONS: Platform level with all functions.
* Only visible on 800S models.
1
LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
LOAD SENSOR:
16*
* Only visible if Load Sensor
Menu selection is not 0.
* Market selections will limit
certain load sensor options.
GROUND ALARM:
18
TEMPERATURE:
20
Default Number
0
1
0
0
0
1
0
4150364-12
3121157
– JLG Lift –
7-33
SECTION 7 - JLG CONTROL SYSTEM
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic
underlined numbers indicate the default when the option is factory installed.
HEAD & TAIL LIGHTS
4 WHEEL STEER
GEN SET CUTOUT
GEN SET / WELDER
JIB
0
11
0
1
2
0
1
1
2
3
4
5
0
0
0
1
0
1
0
1
0
1
ANSI EXPORT
6
1
11
0
1
2
0
1
1
2
3
4
5
0
0
0
1
0
1
0
1
0
1
CSA
6
2
11
0
1
2
0
1
1
2
3
4
5
0
0
0
1
0
1
0
1
0
1
CE
6
3
11
0
1
2
0
1
X
X
3
X
5
0
0
0
1
0
1
0
1
0
1
AUSTRALIA
6
4
11
0
1
2
0
1
X
X
3
X
5
0
0
0
1
0
1
0
1
0
1
JAPAN
6
5
11
0
1
2
0
1
1
2
3
4
5
0
0
0
1
0
1
0
1
0
1
SOFT TOUCH
ENGINE
6
TILT
MARKET
ANSI USA
GLOW PLUGS
MODEL NUMBER
ENGINE SHUTDOWN
600SC
TEMPERATURE
DRIVE TYPE
GROUND ALARM
FUNCTION CUTOUT
LOAD SENSOR
LOAD SYSTEM
CABLE BREAK SWITCH
600SC
ANSI USA
0
1
0
X
X
X
X
0
1
0
X
X
X
0
1
2
3
0
1
2
0
1
ANSI EXPORT
0
1
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
CSA
0
1
0
X
X
X
X
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
CE
0
1
0
X
2
3
X
0
1
0
1
X
X
0
1
2
3
0
1
2
0
1
AUSTRALIA
0
1
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
JAPAN
0
1
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
7-34
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined
numbers indicate the default when the option is factory installed.
HEAD & TAIL LIGHTS
4 WHEEL STEER
GEN SET CUTOUT
GEN SET / WELDER
JIB
0
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
ANSI EXPORT
6
1
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
CSA
6
2
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
CE
6
3
11
0
1
2
0
1
X
X
3
X
5
1
0
0
1
0
1
0
1
0
1
AUSTRALIA
6
4
11
0
1
2
0
1
X
X
3
X
5
1
0
0
1
0
1
0
1
0
1
JAPAN
6
5
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
SOFT TOUCH
ENGINE
6
TILT
MARKET
ANSI USA
GLOW PLUGS
MODEL NUMBER
ENGINE SHUTDOWN
600SJC
ANSI USA
0
1
ANSI EXPORT
0
1
CSA
0
1
CE
0
1
0
AUSTRALIA
0
1
0
JAPAN
0
1
0
3121157
0
1
2
3
4
TEMPERATURE
DRIVE TYPE
GROUND ALARM
FUNCTION CUTOUT
LOAD SENSOR
LOAD SYSTEM
CABLE BREAK SWITCH
600SJC
0
1
0
X
X
X
0
1
2
3
0
1
2
0
1
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
0
1
0
1
X
X
0
1
2
3
0
1
2
0
1
2
3
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
– JLG Lift –
7-35
SECTION 7 - JLG CONTROL SYSTEM
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined
numbers indicate the default when the option is factory installed.
HEAD & TAIL LIGHTS
4 WHEEL STEER
GEN SET CUTOUT
GEN SET / WELDER
JIB
0
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
ANSI EXPORT
6
1
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
CSA
6
2
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
CE
6
3
11
0
1
2
0
1
X
X
3
X
5
1
0
0
1
0
1
0
1
0
1
AUSTRALIA
6
4
11
0
1
2
0
1
X
X
3
X
5
1
0
0
1
0
1
0
1
0
1
JAPAN
6
5
11
0
1
2
0
1
1
2
3
4
5
1
0
0
1
0
1
0
1
0
1
SOFT TOUCH
ENGINE
6
TILT
MARKET
ANSI USA
GLOW PLUGS
MODEL NUMBER
ENGINE SHUTDOWN
660SJC
ANSI USA
ANSI EXPORT
0
1
0
X
X
X
X
0
1
2
3
4
0
0
X
X
X
0
1
2
1
0
1
1
TEMPERATURE
DRIVE TYPE
GROUND ALARM
FUNCTION CUTOUT
LOAD SENSOR
LOAD SYSTEM
CABLE BREAK SWITCH
660SJC
0
1
2
3
0
1
2
0
3
0
1
2
3
1
0
1
2
0
2
3
0
1
2
1
3
0
1
2
0
1
0
1
CSA
0
1
0
X
X
X
X
0
CE
0
1
0
X
2
3
X
0
1
0
1
X
X
0
1
2
3
0
1
2
0
1
AUSTRALIA
0
1
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
JAPAN
0
1
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
2
0
1
7-36
0
1
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
OK
0
0
CLEARS WHEN FAULT IS REMOVED
DRIVING AT CREEP - TILTED
0
0
CLEARS WHEN FAULT IS REMOVED
FSW OPEN
0
0
CLEARS WHEN FAULT IS REMOVED
RUNNING AT CREEP - CREEP SWITCH OPEN
0
0
CLEARS WHEN FAULT IS REMOVED
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
0
0
CLEARS WHEN FAULT IS REMOVED
RUNNING AT CUTBACK - ABOVE ELEVATION
0
0
CLEARS WHEN FAULT IS REMOVED
TILT SENSOR OUT OF RANGE
0
0
CLEARS WHEN FAULT IS REMOVED
LOAD SENSOR READING UNDER WEIGHT
0
0
CLEARS WHEN FAULT IS REMOVED
FSW FAULTY
2
1
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
KEYSWITCH FAULTY
2
1
CLEARS WHEN FAULT IS REMOVED
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
2
2
CLEARS WHEN FAULT IS REMOVED
FSW INTERLOCK TRIPPED
2
2
CLEARS WHEN FAULT IS REMOVED
STEER LOCKED - SELECTED BEFORE FOOTSWITCH
2
2
CLEARS WHEN FAULT IS REMOVED
STEER SWITCHES FAULTY
2
2
CLEARS WHEN FAULT IS REMOVED
D/S JOY. QPROX BAD
2
2
CLEARS WHEN FAULT IS REMOVED
L/S JOY. QPROX BAD
2
3
CLEARS WHEN FAULT IS REMOVED
D/S JOY. OUT OF RANGE LOW
2
2
CLEARS WHEN FAULT IS REMOVED
D/S JOY. OUT OF RANGE HIGH
2
2
CLEARS WHEN FAULT IS REMOVED
L/S JOY. OUT OF RANGE LOW
2
3
CLEARS WHEN FAULT IS REMOVED
L/S JOY. OUT OF RANGE HIGH
2
3
CLEARS WHEN FAULT IS REMOVED
D/S JOY. CENTER TAP BAD
2
2
CLEARS WHEN FAULT IS REMOVED
L/S JOY. CENTER TAP BAD
2
3
CLEARS WHEN FAULT IS REMOVED
WAITING FOR FSW TO BE OPEN
2
2
CLEARS WHEN FAULT IS REMOVED
PUMP POT FAULTY
2
3
CLEARS WHEN FAULT IS REMOVED
PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
2
3
CLEARS WHEN FAULT IS REMOVED
PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH
2
3
CLEARS WHEN FAULT IS REMOVED
PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH
2
3
CLEARS WHEN FAULT IS REMOVED
FOOTSWITCH SELECTED BEFORE START
2
3
CLEARS WHEN FAULT IS REMOVED
BOOM PREVENTED - DRIVE SELECTED
2
5
CLEARS WHEN FAULT IS REMOVED
DRIVE PREVENTED - ABOVE ELEVATION
2
5
CLEARS WHEN FAULT IS REMOVED
DRIVE PREVENTED - TILTED & ABOVE ELEVATION
2
5
CLEARS WHEN FAULT IS REMOVED
DRIVE PREVENTED - BOOM SELECTED
2
5
CLEARS WHEN FAULT IS REMOVED
3121157
– JLG Lift –
7-37
SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
FORD ECM POWER SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HORN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HORN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HORN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
AUX POWER SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
AUX POWER OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
AUX POWER SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GLOW PLUG SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GLOW PLUG OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GLOW PLUG SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP LOCK SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP LOCK OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP LOCK SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP START ASSIST SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP START ASSIST OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
LP START ASSIST SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
MAIN DUMP SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
MAIN DUMP OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
MAIN DUMP SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
PARKING BRAKE SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
PARKING BRAKE OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
PARKING BRAKE SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
START SOLENOID SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
START SOLENOID OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
START SOLENOID SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
STEER DUMP SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
STEER DUMP OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
STEER DUMP SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TWO SPEED SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TWO SPEED OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TWO SPEED SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
ALARM SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
ALARM OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
7-38
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
ALARM SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GENERATOR SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GENERATOR OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
GENERATOR SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HEAD TAIL LIGHT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HEAD TAIL LIGHT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HEAD TAIL LIGHT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HOUR METER SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
HOUR METER SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET UP SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET UP OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET UP SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET DOWN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET DOWN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET DOWN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET LEFT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET LEFT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET LEFT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET RIGHT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET RIGHT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BASKET RIGHT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB UP SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB UP OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB UP SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB DOWN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB DOWN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB DOWN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB LEFT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB LEFT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB LEFT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB RIGHT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB RIGHT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
JIB RIGHT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
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SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
TOWER UP SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER UP OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER UP SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER DOWN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER DOWN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER DOWN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER IN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER IN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER IN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER OUT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER OUT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
TOWER OUT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER IN SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER IN OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER IN SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER OUT SHORT TO GROUND
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER OUT OPEN CIRCUIT
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
UPPER OUT SHORT TO BATTERY
3
3
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
FUEL SENSOR SHORT TO BATTERY
3
3
CLEARS WHEN FAULT IS REMOVED
FUEL SENSOR SHORT TO GROUND
3
3
CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE SHORT TO BATTERY
4
3
CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE SHORT TO GROUND
4
3
CLEARS WHEN FAULT IS REMOVED
COOLANT TEMPERATURE SHORT TO GROUND
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 12
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 13
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 14
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 15
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 21
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 22
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 23
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 24
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 25
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 26
4
3
CLEARS WHEN FAULT IS REMOVED
7-40
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
FORD FAULT CODE 31
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 32
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 33
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 34
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 35
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 36
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 41
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 42
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 43
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 44
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 45
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 46
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 51
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 52
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 53
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 54
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 55
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 56
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 57
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 61
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 62
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 63
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 64
4
3
CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE UNKNOWN
4
3
CLEARS WHEN FAULT IS REMOVED
RETURN FILTER BYPASSED
2
8
CLEARS WHEN FAULT IS REMOVED
CHARGE PUMP FILTER BYPASSED
2
8
CLEARS WHEN FAULT IS REMOVED
BATTERY LOW
4
4
CLEARS WHEN FAULT IS REMOVED
BATTERY TOO HIGH - SYSTEM SHUT DOWN
4
4
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
BATTERY TOO LOW - SYSTEM SHUT DOWN
4
4
CLEARS WHEN FAULT IS REMOVED
SPEED SENSOR READING INVALID SPEED
5
5
CLEARS WHEN FAULT IS REMOVED
SPEED INPUT LOST
5
5
CLEARS WHEN FAULT IS REMOVED
ENGINE TEMP HIGH
4
3
CLEARS WHEN FAULT IS REMOVED
AIR FILTER BYPASSED
4
3
CLEARS WHEN FAULT IS REMOVED
3121157
– JLG Lift –
7-41
SECTION 7 - JLG CONTROL SYSTEM
Table 7-4. Fault Code Listing
HELP MESSAGE
FAULT
FAULT REMOVAL
NO ALTERNATOR OUTPUT
4
3
CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE LOW
4
3
CLEARS WHEN FAULT IS REMOVED
485 COMMUNICATIONS LOST
4
3
CLEARS WHEN FAULT IS REMOVED
CAN BUS FAILURE
6
6
CLEARS WHEN FAULT IS REMOVED
LOAD SENSOR NOT CALIBRATED
9
9
CLEARS WHEN FAULT IS REMOVED
TILT SENSOR NOT CALIBRATED
9
9
CLEARS WHEN FAULT IS REMOVED
EEPROM FAILURE - CHECK ALL SETTINGS
9
9
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
PLATFORM MODULE FAILURE: HWFS CODE 1
9
9
CLEARS WHEN FAULT IS REMOVED
GROUND MODULE FAILURE: HWFS CODE 1
9
9
CLEARS WHEN FAULT IS REMOVED
7-42
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
7.9 ANALYZER DIAGNOSTICS MENU
STRUCTURE
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
In the following structure descriptions, an intended item is
selected by pressing ENTER; pressing ESC steps back to
Table 7-5. Adjustments - Personality Descriptions
DRIVE
ACCEL …
Displays/adjusts drive acceleration
DECEL …
Displays/adjusts drive deceleration
MIN FORWARD …
Displays/adjusts minimum forward drive speed
MAX FORWARD …
Displays/adjusts maximum forward drive speed
MIN REVERSE …
Displays/adjusts minimum reverse drive speed
MAX REVERSE …
Displays/adjusts maximum reverse drive speed
ELEVATED MAX …
Displays/adjusts maximum drive speed
NOTE: used when elevation cutout switches are limiting maximum speed
CREEP MAX …
Displays/adjusts maximum drive speed
NOTE: used when creep switch on pump pot is active
STEER MAX …
Displays/adjusts the maximum steer speed
LIFT
ACCEL …
Displays/adjusts upper lift acceleration
DECEL …
Displays/adjusts upper lift deceleration
MIN UP …
Displays/adjusts minimum upper lift up speed
MAX UP …
Displays/adjusts maximum upper lift up speed
CREEP UP …
Displays/adjusts maximum upper lift up speed
NOTE: used when creep switch on pump pot is active
MIN DOWN …
Displays/adjusts minimum upper lift down speed
MAX DOWN …
Displays/adjusts maximum upper lift down speed
CREEP DOWN …
Displays/adjusts maximum upper lift down speed
NOTE: used when creep switch on pump pot is active
3121157
– JLG Lift –
7-43
SECTION 7 - JLG CONTROL SYSTEM
Table 7-5. Adjustments - Personality Descriptions
SWING
ACCEL …
Displays/adjusts swing acceleration
DECEL …
Displays/adjusts swing deceleration
MIN LEFT …
Displays/adjusts minimum swing left speed
MAX LEFT …
Displays/adjusts maximum swing left speed
CREEP LEFT …
Displays/adjusts maximum swing left speed
NOTE: used when creep switch on pump pot is active
MIN RIGHT …
Displays/adjusts minimum swing right speed
MAX RIGHT …
Displays/adjusts maximum swing right speed
CREEP RIGHT …
Displays/adjusts maximum swing right speed
NOTE: used when creep switch on pump pot is active
UPPER TELESCOPE
ACCEL …
Displays/adjusts telescope acceleration
DECEL …
Displays/adjusts telescope deceleration
MIN IN …
Displays/adjusts minimum telescope in speed
MAX IN …
Displays/adjusts maximum telescope in speed
MIN OUT …
Displays/adjusts minimum telescope out speed
MAX OUT …
Displays/adjusts maximum telescope out speed
BASKET LEVEL
ACCEL …
Displays/adjusts basket level acceleration
DECEL …
Displays/adjusts basket level deceleration
MIN UP …
Displays/adjusts minimum basket level up speed
MAX UP …
Displays/adjusts maximum basket level up speed
MIN DOWN …
Displays/adjusts minimum basket level down speed
MAX DOWN …
Displays/adjusts maximum basket level down speed
BASKET ROTATE
ACCEL …
Displays/adjusts basket rotate acceleration
DECEL …
Displays/adjusts basket rotate deceleration
MIN LEFT …
Displays/adjusts minimum basket rotate left speed
MAX LEFT …
Displays/adjusts maximum basket rotate left speed
MIN RIGHT …
Displays/adjusts minimum basket rotate right speed
MAX RIGHT …
Displays/adjusts maximum basket rotate right speed
7-44
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-5. Adjustments - Personality Descriptions
JIB LIFT
Not displayed if JIB = NO
ACCEL …
Displays/adjusts jib acceleration
DECEL …
Displays/adjusts jib deceleration
MIN UP …
Displays/adjusts minimum jib up speed
MAX UP …
Displays/adjusts maximum jib up speed
MIN DOWN …
Displays/adjusts minimum jib down speed
MAX DOWN …
Displays/adjusts maximum jib down speed
MIN LEFT …
Displays/adjusts minimum jib left speed
MAX LEFT …
Displays/adjusts maximum jib left speed
MIN RIGHT …
Displays/adjusts minimum jib right speed
MAX RIGHT …
Displays/adjusts maximum jib right speed
STEER
MAX SPEED …
Displays/adjusts maximum steer speed, which applies when vehicle speed is at minimum
GROUND MODE
LIFT UP …
Displays/adjusts fixed lift up speed
LIFT DOWN …
Displays/adjusts fixed lift down speed
SWING …
Displays/adjusts fixed swing speed
TELE …
Displays/adjusts fixed telescope speed
BASKETLEVEL …
Displays/adjusts fixed basket level speed
BASKETROTATE …
Displays/adjusts fixed basket rotate speed
JIB (U/D) …
Displays/adjusts jib lift speed
Not displayed if JIB = NO
JIB (L/R)…
Displays/adjusts jib swing speed
Not displayed if JIB = NO
3121157
– JLG Lift –
7-45
SECTION 7 - JLG CONTROL SYSTEM
Table 7-6. Diagnostic Menu Descriptions
DRIVE
DRIVE FOR …
Displays drive joystick direction & demand
STEER …
Displays steer switch direction & demand
NOTE: steer demand is inversely proportional to vehicle speed
BRAKES …
Displays brake control system status
CREEP …
Displays pump pot creep switch status
TWO SPEED ...
Displays two speed switch status
2 SPEED MODE
Displays status of two speed valve
HIGH ENGINE
Displays high engine switch status
BOOM
U LIFT UP …
Displays lift joystick direction & demand
SWING LEFT …
Displays swing joystick direction & demand
LEVEL UP …
Displays basket level switch direction & demand
NOTE: demand is controlled by the pump pot
ROT. LEFT …
Displays basket rotate switch direction & demand
NOTE: demand is controlled by the pump pot
U TELE IN …
Displays telescope switch direction & demand
NOTE: demand is controlled by the pump pot
JIB UP …
Displays jib lift switch direction & demand
NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO
JIB LEFT …
Displays jib swing switch direction & demand
NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO
PUMP POT …
Displays pump pot demand
ENGINE
7-46
START …
Displays start switch status
AIR FILTER …
Displays air filter status
BATTERY …
Displays measured battery voltage
COOLANT …
Displays coolant temperature
OIL PRS …
Displays oil pressure status
FUEL SELECT …
Displays selected fuel (Dual Fuel only)
FUEL LEVEL …
Displays fuel level status
RPM
Displays Engine RPM
GM BATTERY
Displays battery voltage at ground module
– JLG Lift –
3121157
SECTION 7 - JLG CONTROL SYSTEM
Table 7-6. Diagnostic Menu Descriptions
PM BATTERY …
Displays battery voltage at platform module
TEMP ...
Displays ground module temperature
ELEV. CUTOUT …
Displays elevation cutout switch status
FUNC. CUTOUT …
Displays function cutout switch status
CREEP…
Displays creep switch status
TILT …
Displays measured vehicle tilt
AUX POWER …
Displays status of auxiliary power switch
HORN …
Displays status of horn switch
R FILTER …
Displays status of return filter switch
C FILTER …
Displays status of charge pump filter
LOAD LENGTH …
Displays length switch status
ANGLE …
Displays angle switch status
LOAD …
Displays load sensor value
NOTE: Not displayed if load = 0.
DATALOG
ON …
Displays total controller on (EMS) time
ENGINE …
Displays engine run time
DRIVE …
Displays total controller drive operation time
LIFT …
Displays total controller lift operation time
SWING …
Displays total controller swing operation time
TELE …
Displays total controller tele operation time
MAX.TEMP …
Displays maximum measured heatsink temp.
MIN.TEMP …
Displays minimum measured heatsink temp.
MAX.VOLTS …
Displays maximum measured battery voltage
RENTAL …
Displays total controller operation time
NOTE: can be reset
ERASE RENTAL
Not available at password level 2
YES:ENTER, NO:ESC
ENTER resets rental datalog time to zero
VERSIONS
3121157
GROUND …
Displays ground module software version
PLATFORM …
Displays platform module software version
ANALYSER …
Displays Analyzer software version
– JLG Lift –
7-47
SECTION 7 - JLG CONTROL SYSTEM
This page left blank intentionally.
7-48
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
SECTION 8. SCHEMATICS
8.1 GENERAL
8.3 HYDRAULIC CIRCUIT CHECKS
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.
The best place to begin the problem analysis is at the
power source (pump). Once it is determined that the
pump is serviceable, then a systematic check of the circuit
components, beginning with the control, would follow. For
aid in troubleshooting, refer to the Illustrated Parts Manual
for hydraulic diagrams of the various circuits
8.2 TROUBLESHOOTING
It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.
It should be recognized that the majority of the problems
arising in the machine will be centered in the hydraulic
and electrical systems.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine
if the circuit is lacking hydraulic oil and electrical control
power. This can be ascertained by overriding the bypass
valve (mechanically or electrically) so that oil is available
to the function valve, then overriding the function valve
mechanically. If the function performs satisfactorily, the
problem exists with the control circuit.
3121157
– JLG Lift –
8-1
SECTION 8 - SCHEMATICS
Figure 8-1. Electrical Components - Sheet 1 of 2
8-2
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
Figure 8-2. Electrical Components - Sheet 2 of 2
3121157
– JLG Lift –
8-3
SECTION 8 - SCHEMATICS
Figure 8-3. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 1 of 2
8-4
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
1870174-D
Figure 8-4. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 2 of 4
3121157
– JLG Lift –
8-5
SECTION 8 - SCHEMATICS
Figure 8-5. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 3 of 4
8-6
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
1870174-D
Figure 8-6. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 4 of 4
3121157
– JLG Lift –
8-7
SECTION 8 - SCHEMATICS
Figure 8-7. Electrical Schematic - Deutz EMR2 - Sheet 1 of 4
8-8
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
1870194-B
Figure 8-8. Electrical Schematic - Deutz EMR2 - Sheet 2 of 4
3121157
– JLG Lift –
8-9
SECTION 8 - SCHEMATICS
Figure 8-9. Electrical Schematic - Deutz EMR2 - Sheet 3 of 4
8-10
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
1870194-B
Figure 8-10. Electrical Schematic - Deutz EMR2 - Sheet 4 of 4
3121157
– JLG Lift –
8-11
SECTION 8 - SCHEMATICS
Figure 8-11. Hydraulic Schematic - Sheet 1 of 4
8-12
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
2792593-B
Figure 8-12. Hydraulic Schematic - Sheet 2 of 4
3121157
– JLG Lift –
8-13
SECTION 8 - SCHEMATICS
Figure 8-13. Hydraulic Schematic - Sheet 3 of 4
8-14
– JLG Lift –
3121157
SECTION 8 - SCHEMATICS
2792593-B
Figure 8-14. Hydraulic Schematic - Sheet 4 of 4
3121157
– JLG Lift –
8-15
SECTION 8 - SCHEMATICS
This page left blank intentionally.
8-16
– JLG Lift –
3121157
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: (61) 2 65 811111
Fax: (61) 2 65 810122
JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: (49) 421 693 500
Fax: (49) 421 693 5035
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: (55) 19 3295 0407
Fax: (55) 19 3295 1025
JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: (31) 23 565 5665
Fax: (31) 23 557 2493
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 91 4320 245
Fax: (48) 91 4358 200
JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: (44) 1 698 811005
Fax: (44) 1 698 811055
JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: (34) 93 77 24700
Fax: (34) 93 77 11762
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: (39) 02 9359 5210
Fax: (39) 02 9359 5845
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: (46) 8 506 59500
Fax: (46) 8 506 59534
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