JLG 600SJC Service And Maintenance Manual

Service and Maintenance Manual
Model
600SC
660SJC
S/N 0300174703
to Present
P/N - 3121607
March 10, 2014
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
COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.
• 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.
• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.
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.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
• 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 SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
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.
• 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.
3121607
– JLG Lift –
A-1
INTRODUCTION
REVISON LOG
Original Issue
A-2
- March 10, 2014
– JLG Lift –
3121607
TABLE OF CONTENTS
SECTION NO.
SECTION
A
B
C
SECTION
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
SECTION
2.1
2.2
2.3
2.4
2.5
2.6
3121607
TITLE
PAGE NO.
H - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
1 - SPECIFICATIONS
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-3
1-4
1-5
2 - GENERAL
Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do NOT Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-5
2-5
2-5
2-5
i
TABLE OF CONTENTS
SECTION NO.
SECTION
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
ii
TITLE
PAGE NO.
3 - CHASSIS & TURNTABLE
Chassis Components and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Track and Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replace Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Track tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Rubber Track Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Idler Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Install Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Rotary Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Hub-Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Hub-Shaft Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Carrier Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Wear Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
See Figure 3-34. Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Deutz D2.9 L4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Change Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Change Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Deutz D2011 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Checking Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Changing Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Clean Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
– JLG Lift –
3121607
TABLE OF CONTENTS
SECTION NO.
SECTION
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
SECTION
5.1
5.2
5.3
3121607
TITLE
PAGE NO.
4 - BOOM & PLATFORM
Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Disassembly/Assembly & Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switches and Cam Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Actuator for Internal LeakS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Support Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Platform Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Moving End Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-5
4-5
4-9
4-10
4-13
4-14
4-14
4-14
4-14
4-15
4-15
4-15
4-18
4-18
4-18
4-21
4-25
4-26
4-30
4-31
4-31
4-31
4-32
4-33
4-33
4-33
4-33
4-34
4-34
4-37
4-40
4-41
5 - HYDRAULICS
O-Ring Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems With Double Acting Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems With Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder. . . . . . . . . . . . . . . . . .
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders With Dual Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
5-1
5-1
5-2
5-2
5-2
5-3
5-3
5-3
5-3
5-3
5-4
5-4
iii
TABLE OF CONTENTS
SECTION NO.
5.4
5.5
5.6
5.7
5.8
5.9
SECTION
6.1
6.2
iv
TITLE
PAGE NO.
Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Boom Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cylinder Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Main Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Platform Level (Slave) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Jib Lift Cylinder (SJC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Hydraulic Pump (Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Inspect Parts For Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Reverse Shaft Rotation of Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Ports and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Remove and Install FNR and NFPE Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Remove and Install FNR and NFPE Control Orifices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Shaft Seal and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Hydraulic Component Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Platform Level Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Jib Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Jib Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
6 - JLG CONTROL SYSTEM
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Changing Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjust Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
– JLG Lift –
3121607
TABLE OF CONTENTS
SECTION NO.
6.3
6.4
SECTION
7.1
7.2
7.3
7.4
7.5
3121607
TITLE
PAGE NO.
Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applying Silicone Dielectric Compound to Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch HD, DT, DTM, DRC Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-1
7-2
7-2
7-3
7-3
7-4
7-4
7-4
7-5
7-5
7-5
7-6
7-6
7-6
7-7
7-7
7-7
7-8
7-8
7-8
7-9
7-9
v
LIST OF FIGURES
FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
2-1.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
3-26.
3-27.
3-28.
3-29.
3-30.
3-31.
3-32.
3-33.
3-34.
3-35.
3-36.
3-37.
3-38.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3-45.
3-46.
3-47.
3-48.
3-49.
3-50.
3-51.
3-52.
3-53.
vi
TITLE
PAGE NO.
Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Torque Chart - Sheet 1 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Torque Chart - Sheet 2 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Torque Chart - Sheet 3 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Deutz Engine and Hydraulic Operating Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Chassis Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Chassis Service Notes - 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chassis Service Notes - 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Track and Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bottom Track Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Upper Carrier Track Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Spring & Shock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Crawler Drive Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Crawler Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Crawler Drive - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Hose Routing - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Hose Routing - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Swing Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Swing Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Swing Drive Shim Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Swing Drive Pivot and Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Swing Drive Jam Nut and Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Main Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Hub-Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Hub-Shaft Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Carrier Subassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Swing Bearing Tolerance Measurement Location & Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Generator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Generator Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Generator Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Deutz D2.9 L4 Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Deutz D2.9 L4 Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Deutz 2.9 T4F Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Deutz D2011 Engine (Battery Engine Side) Installation - 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Deutz D2011 Engine (Battery Engine Side) Installation - 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Deutz D2011 Engine (Battery Tank Side) Installation - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Deutz D2011 Engine (Battery Tank Side) Installation - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Deutz Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
– JLG Lift –
3121607
LIST OF FIGURES
FIGURE NO.
3-54.
3-55.
3-56.
3-57.
3-58.
3-59.
3-60.
3-61.
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.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28.
4-29.
4-30.
4-31.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
5-14.
5-15.
5-16.
5-17.
5-18.
5-19.
5-20.
5-21.
3121607
TITLE
PAGE NO.
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR 2 Engine Plug Pin Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotator and Leveling Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Powertrack Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proximity Switch Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Wire Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Kink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sheave Groove Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Routing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proximity Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Articulating Jib Boom Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal Limit and Dual Capacity Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Switch Adjustments - CE Machines Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Bleed Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Section Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
3-56
3-57
3-58
3-59
3-60
3-61
3-62
3-63
4-1
4-1
4-2
4-2
4-3
4-3
4-4
4-4
4-4
4-5
4-5
4-6
4-7
4-8
4-8
4-9
4-9
4-10
4-11
4-12
4-13
4-14
4-16
4-17
4-19
4-20
4-30
4-31
4-33
4-33
4-33
5-3
5-7
5-8
5-8
5-8
5-9
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-12
5-12
5-13
5-13
5-13
5-14
5-15
5-15
vii
LIST OF FIGURES
FIGURE NO.
5-22.
5-23.
5-24.
5-25.
5-26.
5-27.
5-28.
5-29.
5-30.
5-31.
5-32.
5-33.
5-34.
5-35.
5-36.
5-37.
5-38.
5-39.
5-40.
5-41.
5-42.
5-43.
5-44.
5-45.
5-46.
5-47.
5-48.
5-49.
5-50.
5-51.
5-52.
5-53.
5-54.
5-55.
5-56.
5-57.
5-58.
5-59.
5-60.
5-61.
5-62.
5-63.
5-64.
5-65.
5-66.
5-67.
5-68.
5-69.
5-70.
5-71.
5-72.
5-73.
5-74.
5-75.
5-76.
5-77.
6-1.
6-2.
6-3.
6-4.
viii
TITLE
PAGE NO.
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Platform Level (Slave) Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Jib Lift Cylinder Assembly(660SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Shim Adjustable Charge Relief Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Gauge Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Location of Components - Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Articulating Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Hand-Held Analyzer (WANALYZER Controls and Display Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Controller Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Analyzer Platform Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Analyzer Ground Control Box Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
– JLG Lift –
3121607
LIST OF FIGURES
FIGURE NO.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
7-18.
7-19.
7-20.
7-21.
7-22.
7-23.
7-24.
7-25.
7-26.
7-27.
7-28.
7-29.
7-30.
7-31.
7-32.
7-33.
7-34.
7-35.
7-36.
7-37.
7-38.
7-39.
7-40.
3121607
TITLE
PAGE NO.
Analyzer Software Version 6.8 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Control Module Pin Connections 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Control Module Pin Connections 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applying Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dielectric Grease On Female Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brad Harrison/Phoenix Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Junior Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Contact Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Close Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seating Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Components 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Components 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform and Ground Control Electrical Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform and Ground Control Electrical Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Wiring Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz EMR2 Wiring Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Engine Harness Electrical Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Engine Harness Electrical Schematic 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crawler Hydraulic Drive Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crawler Hydraulic Drive Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Port Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Port Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crawler Drive Motor Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
6-8
6-9
6-10
6-11
6-12
6-13
6-45
6-46
6-47
6-48
6-49
6-50
7-1
7-2
7-2
7-3
7-4
7-4
7-4
7-4
7-5
7-5
7-5
7-5
7-6
7-6
7-6
7-6
7-7
7-7
7-7
7-8
7-8
7-9
7-9
7-9
7-9
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-18
7-19
7-20
7-21
7-22
7-23
7-24
ix
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
2-1
2-2
2-3
4-1
5-1
5-2
6-1
6-2
6-3
6-4
6-5
6-6
x
TITLE
PAGE NO.
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Deutz TD 2.9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Mobilfluid 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Mobil DTE 13M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Mobil EAL H 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Exxon Univis HVI 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38
Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39
Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Help Message/Fault Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Fault Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS
Maximum Work Load (Capacity) - ANSI
Unrestricted:
Restricted - 600SC
Restricted - 660SJC
Maximum Work Load (Capacity) - CE &
Australia
Unrestricted:
Restricted - 600SC
Restricted - 660SJC
Maximum Travel Grade (Gradeability)*
Maximum Travel Grade (Side Slope)*
1.2 DIMENSIONAL DATA
500 lb. (227 kg)
1000 lb. (454 kg)
500 lb. (227 kg)
500 lb. (230 kg)
1000 lb. (450 kg)
500 lb. (230 kg)
55%
5°
Max.Vertical Platform Height:
600SC
660SJC
60 ft. 3 in. (18.36 m)
66 ft. 8 in. (20.32 m)
Max.Horizontal Platform Reach:
600SC
660SJC
49 ft. 6 in. (15.09 m)
56 ft. 9 in. (17.3 m)
Turning Radius
Maximum Ground Bearing Pressure
600SC
660SJC
0
5.45 psi (0.383 kg/cm2)
6.5 psi (0.457 kg/cm2)
Maximum Drive Speed:
1.6 mph (2.6 kph)
Max. Hydraulic System Pressure
4500 psi (310 Bar)
Maximum Wind Speed
Maximum Manual Force
Electrical System Voltage
Gross Machine Weight
(Platform Empty)
600SC
660SJC
* Boom in stowed position.
28 mph (12.5 m/s)
101 lb. (450 N)
12 Volts
Table 1-1. Dimensional Data
Machine Height (Stowed)
8 ft. 5 in. (2.57 m)
Machine Length (Stowed)
600SC
660SJ
27 ft. 11 in. (8.51 m)
35 ft. 8 in. (10.88 m)
Machine Width
8 ft 2 in. (2.49 m)
Ground Clearance
15 in. (0.38 m)
Platform Height
600SC
660SJ
60 ft. 3 in. (18.36 m)
66 ft. 8 in. (20.32 m)
Horizontal Reach
600SC
660SJC
49 ft. 6 in. (15.08 m)
56 ft. 9 in. (17.30 m)
Tail Swing
3 ft. 7-1/2 in. (1.10 m)
1.3 CAPACITIES
Table 1-2. Capacities
Fuel Tank
39 US. Gal (147.6 L)
Hydraulic Oil Tank
Total Volume
at Full Mark
Hydraulic System (Including Tank)
Engine Crankcase
22,500 lb. (10,205 kg)
27,100 lb. (12,292 kg)
26 U.S. Gal (98.4 L)
31.1 U.S. Gal (117.7 L)
Fuel Tank
40 U.S. Gal (151.4 L)
11 Qt (10.5 L)
39 US. Gal (147.6 L)
1.4 ENGINE DATA
Table 1-3. Deutz TD 2.9 Specifications
Fuel
67 hp (50 kW)
Torque
173 ft.lbs. (234 Nm) @ 1800rpm
Oil Capacity (Crankcase)
2.4 Gal (8.9 L) w/Filter
Cooling System
3.3 Gal (12.5 L)
Low RPM
1200 ±50 rpm
High RPM
2600±50 rpm
Alternator
95 Amp
Fuel Consumption
3121607
Ultra Low Sulfur Diesel (15 ppm)
Output
– JLG Lift –
0.65 GPH (2.48 lph)
1-1
SECTION 1 - SPECIFICATIONS
Platform Rotate: Platform level and completely rotated one
direction. Rotate opposite direction, record time. Rotate other
direction, record time.
1.5 FUNCTION SPEEDS
Table 1-4. Function Speeds (In Seconds)
Function
600SC
660SJC
Lift Up
46 - 60
46 -60
Lift Down
33 - 43
33 - 43
Swing Right & Left*
79 - 101
79 - 101
Telescope In
22 - 33
25 - 33
Telescope Out
50 - 67
50 - 67
Platform Rotate Right & Left**
16 - 25
25-32
Jib Up
N/A
22 - 34
Jib Down
N/A
16 - 26
Drive Forward & Reverse
85-90
(1.55 MPH)
Drive (Out of Transport)
Forward & Reverse
80-85
(.40 MPH)
Jib: Platform level and centered with boom. Start with Jib
down. Jib up, record time. Jib down, record time.
Test Notes
1.
Start stop watch with function, not with controller or
switch.
2.
All speed tests are run from platform. Speeds do not
reflect ground control operation.
3.
Platform speed knob control must be at full speed
(turned clockwise completely).
85-90
(1.55 MPH)
4.
Test with oil temperature above 100° F (38° C). Function
speeds vary if hydraulic oil is cold and thick.
80-85
(.40 MPH)
5.
Some flow control functions may not work with speed
knob clicked into creep position.
*Max 10% Difference Between Left & Right
**Max 15% Difference Between Left & Right
1.6 TORQUE REQUIREMENTS
Table 1-5. Torque Requirements
Machine Orientation When Doing Speed Tests
Lift: Boom retracted. Telescope retracted. Lift up, record time,
Lift down, record time.
Swing: Boom at full elevation. Telescope retracted. Swing
turntable off center and stop. Swing opposite direction and
start test when centered. This eliminates controller ramp up
and ramp down affecting times.
Telescope: Boom at full elevation; Telescope retracted; Telescope out, record time. Telescope In, record time.
Tracking: Test to be done on a graveled level surface. Position
machine at a reference point (no steer correction) driving at
high speed. Results should be 4 - 6 ft (1.2 - 1.8 m) tracking error
at 200 ft (61 m).
Drive: Test to be done on a graveled level surface. Set Drive
Select Switch to High Speed. Start approximately 10 ft (7.6 m)
from starting point so unit is at maximum speed when starting
test. Record results for a 200 ft. (61 m) course. Drive forward,
record time. Drive reverse, record time.
Description
Torque Value (Dry)
Interval
Hours
Bearing To Chassis
190 ft. lbs.
(258 Nm)
50/600*
Bearing To Turntable
190 ft. lbs.
(258 Nm)
50/600*
Wire Rope
15 ft. lbs (20 Nm)
150
Wheel Lugs
170 ft. lbs (231 Nm)
150
Engine Mounting Bolts
165 ft. lbs. (231 Nm)
A/R
Engine Manifold Mounting Bolts
30 ft. lbs. (42 Nm)
A/R
*Check swing bearing bolts after first 50 hours of operation
and every 600 hours thereafter. (See Swing Bearing in Section
3.)
Drive (Out of Transport): Test should be done on a graveled
level surface. Set Drive Select Switch to High Engine, High
Speed. Select Platform Speed Knob out of creep speed. Raise
boom above horizontal. Results should be recorded for a 50 ft
(15.2 m) course. Drive forward, record time. Drive reverse,
record time.
1-2
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
1.7 HYDRAULIC OIL
Table 1-8. Mobil DTE 13M
Table 1-6. Hydraulic Oil
Hydraulic System
Operating
Temperature Range
S.A.E. Viscosity
Grade
+0° to + 180° F
(-18° to +83° C)
10W
+0° to + 210° F
(-18° to +99° C)
10W-20, 10W30
+50° to + 210° F
(+10° to +99° 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
NOTE:
Hydraulic oils require anti-wear qualities at least API Service Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service.
NOTE:
Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types. They may not contain
required additives or be of comparable viscosities. If
hydraulic oil other than Mobil 424 is desired, contact JLG
Industries for proper recommendations.
at 40° C
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
Table 1-9. UCon Hydrolube HP-5046
Type
Synthetic Biodegradable
Specific Gravity
1.082
Pour Point, Max
-58°F (-50°C)
pH
9.1
Viscosity
Table 1-7. Mobilfluid 424
at 0° C (32° F)
340 cSt (1600SUS)
SAE Grade
10W30
at 40° C (104° F)
46 cSt (215SUS)
Gravity, API
29.0
at 65° C (150° F)
22 cSt (106SUS)
Density, Lb/Gal. 60°F
7.35
Viscosity Index
170
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
3121607
– JLG Lift –
1-3
SECTION 1 - SPECIFICATIONS
Table 1-10. Mobil EAL H 46
Type
Synthetic Biodegradable
ISO Viscosity Grade
46
Specific Gravity
.910
Pour Point
-44°F (-42°C)
Flash Point
500°F (260°C)
Operating Temp.
0 to 180°F (-17 to 162°C)
Weight
7.64 lb. per gal.
(0.9 kg per liter)
Viscosity
at 40° C
45 cSt
at 100° C
8.0 cSt
Viscosity Index
153
Table 1-11. Exxon Univis HVI 26
Specific Gravity
32.1
Pour Point
-76°F (-60°C)
Flash Point
217°F (103°C)
1.8 MAJOR COMPONENT WEIGHTS
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Table 1-12. Major Component Weights
660SJ
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
Viscosity
at 40° C
25.8 cSt
at 100° C
9.3 cSt
Viscosity Index
376
NOTE:
1-4
ExxonMobil recommends checking oil viscosity
yearly.
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
6
2
4
3
1
9
5
7,8
3
Figure 1-1. Maintenance and Lubrication
1. Swing Bearing
1.9 OPERATOR MAINTENANCE
NOTE:
The following numbers correspond to those in Figure 1-1.,
Maintenance and Lubrication.
Table 1-13. Lubrication Specifications.
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-L2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L2104C
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.
3121607
– JLG Lift –
Lube Point(s) - 1 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access. Apply grease and rotate
in 90 degree intervals until bearing is completely
lubricated.
1-5
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 shown by Condition Indicator.
6. Hydraulic TankLube Point(s) - Fill Cap
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
Capacity - 26 gal. Tank; 40 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 shown by Condition Indicator.
1-6
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
7. Oil Change w/Filter - Deutz D2.9
8. Air Filter - Deutz D2.9
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 8.45 Qt (8 L) Crankcase and Filter
Interval - Every Year or 600 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
shown by condition indicator
MINIMUM OIL
LEVEL
MAXIMUM OIL
LEVEL
3121607
– JLG Lift –
1-7
SECTION 1 - SPECIFICATIONS
Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
1-8
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
3121607
– JLG Lift –
1-9
SECTION 1 - SPECIFICATIONS
Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
1-10
– JLG Lift –
3121607
SECTION 1 - SPECIFICATIONS
Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
3121607
– JLG Lift –
1-11
SECTION 1 - SPECIFICATIONS
Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
1-12
– JLG Lift –
3121607
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1
MACHINE PREPARATION, INSPECTION, AND
MAINTENANCE
Annual Machine Inspection
General
This section provides information needed by personnel
responsible to place machine in operation readiness and
maintain its safe operating condition. For maximum service
life and safe operation, ensure all necessary inspections and
maintenance have been completed before placing machine in
service.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive
inspection and preventive maintenance program. The following table outlines periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your
national, regional, or local regulations for further requirements
for aerial work platforms. Frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.
The Annual Machine Inspection must be performed on an
annual basis, no later than thirteen (13) months from the date
of the prior Annual Machine Inspection. JLG Industries recommends this task be performed by a Factory-Trained Service
Technician. JLG Industries, Inc. recognizes a Factory-Trained
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
Inspection and Preventive Maintenance Schedule for items
requiring inspection. Reference 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 current
machine ownership.
Preventive Maintenance
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a
Pre-Start Inspection of the machine before use daily or at each
change of operator. Reference the Operator’s and Safety Manual for Pre-Start Inspection procedures. The Operator and
Safety Manual must be read and understood in its entirety
before 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.
In conjunction with 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 Preventive Maintenance Schedule and appropriate areas of this manual for servicing and maintenance procedures. Frequency of service and maintenance must be
increased as environment, severity and frequency of usage
requires.
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. Frequency of this inspection must be increased as environment,
severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form
and Inspection and Preventive Maintenance Schedule for
items requiring inspection. Reference appropriate areas of this
manual for servicing and maintenance procedures.
3121607
– 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
Operation 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 date of
prior inspection.
Owner, Dealer, or User
Factory-Trained Service
Technician
(Recommended)
Service and Maintenance Manual
and applicable JLG inspection form.
Preventive
Maintenance
At intervals as specified in Service and Maintenance Manual.
Owner, Dealer, or User
Qualified JLG Mechanic
Service and Maintenance Manual
Type
Frequency
Pre-Start Inspection
2.2
3.
SERVICE AND GUIDELINES
General
Following information is provided to assist you in using servicing and maintenance procedures in this manual.
Components Removal and Installation
Safety and Workmanship
Your safety, and that of others, is the first consideration in
maintenance of equipment. Always be conscious of weight.
Never attempt to move heavy parts without aid of a mechanical device. Do not allow heavy objects to rest in an unstable
position. Ensure adequate support is provided when raising a
portion of the equipment.
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 the capacity of an eyebolt or similar
bracket lessens, as the angle between the supporting
structure and component becomes less than 90
degrees.
3.
If a part resists removal, check to see if all nuts, bolts,
cables, brackets, wiring, etc., have been removed and no
adjacent parts are interfering.
Cleanliness
2-2
1.
The most important single item in preserving the long
service life of a machine is to keep dirt and contamination out of vital components. Shields, covers, seals, and
filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a
schedule to function properly.
2.
Any time air, fuel, or oil lines are disconnected, clean
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 contamination.
Clean and inspect all parts during servicing or maintenance. Ensure all passages and openings are unobstructed. Cover all parts to keep them clean. Make sure
all parts are clean before they are installed. New parts
should remain in their containers until ready to be used.
– JLG Lift –
3121607
SECTION 2 - GENERAL
2.
Component Disassembly and Reassembly
Complete procedural steps in sequence when disassembling
or reassembling a component. Do not partially disassemble or
assemble one part, then start on another. Always recheck your
work to ensure nothing is overlooked. Do not make any
adjustments, other than those recommended, without obtaining proper approval.
Pressure-Fit Parts
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, and
their receptacles, when disconnecting or removing them from
the unit. This ensures correct reinstallation.
Hydraulic System
When assembling pressure-fit parts, use a molybdenum disulfide base compound or equivalent to lubricate the mating surface.
Bearings
1.
Unless specific torque requirements are given within the
text, use standard torque values on heat-treated bolts,
studs, and steel nuts, in accordance with recommended
shop practices. (See Torque Chart in Section 1.)
When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used,
but do not spin the bearing.
2.
Discard bearings if 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 ready to install.
4.
Lubricate new or used serviceable bearings before
installation. Apply pressure to the outer race when
pressing a bearing into a retainer or bore. Apply pressure to the inner race If bearing is installed on a shaft.
Gaskets
1.
Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.
2.
Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components as needed to aid assembly.
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
Check holes in gaskets align with openings in mating parts. If
it is necessary to hand-fabricate a gasket, use gasket material
or stock of equivalent material and thickness. Be sure to cut
holes in the correct location. Blank gaskets can cause serious
system damage.
Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.
Bolt Usage and Torque Application
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1.
Always use new replacement hardware when installing
locking fasteners. 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.
3121607
– JLG Lift –
2-3
SECTION 2 - GENERAL
2.3
3.
LUBRICATION AND INFORMATION
While 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 machine back in
service.
Hydraulic System
1.
2.
3.
4.
The primary enemy of a hydraulic system is contamination. Contaminants can enter the system by using inadequate hydraulic oil; allowing moisture, grease, filings,
sealing components, sand, etc., to enter when performing maintenance; or allowing the pump to cavitate due
to insufficient system warm-up or leaks in pump supply
(suction) lines.
Design and manufacturing tolerances of component
working parts are very close. The smallest amount of dirt
or other contamination entering a system can cause
wear or damage to components and faulty operation.
Take every precaution to keep hydraulic oil clean including reserve oil in storage. Check, clean, and
replace hydraulic system filters as at intervals specified
in the Lubrication Chart in Section 1. Always examine filters for metal particles.
Cloudy oils indicate high moisture content which permits organic growth and causes oxidation or corrosion.
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil.
It is not advisable to mix oils of different brands or types.
They may not contain required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to ambient temperatures in which the
machine is operating, are recommended for use.
Lubrication Specifications
Specified lubricants, as recommended by component manufacturers, are always the best choice. However, multi-purpose
greases usually have qualities which meet a variety of single
purpose grease requirements. Should questions arise regarding use of greases in maintenance stock, consult your local
supplier for evaluation. Refer to Section 1 for an explanation of
lubricant key designations in the Lubrication Chart.
2.4
CYLINDER DRIFT TEST
Measure maximum acceptable cylinder drift using the following methods.
Platform Drift
Measure platform drift to ground. Lower booms (if equipped)
slightly elevated, main boom fully extended with rated load in
platform and power off. Maximum allowable drift is 2 inches (5
cm) in 10 minutes. If machine does not pass this test, proceed
with the following.
Cylinder Drift
NOTE: Metal particles may appear in oil or filters of new machines
due to wear-in of meshing components.
Table 2-2. Cylinder Drift
Cylinder Bore Diameter
Hydraulic Oil
1.
Refer to Section 1 for viscosity ranges.
Changing Hydraulic Oil
1.
2.
2-4
Filter elements must be changed after the first 50 hours
of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use
only those oils meeting or exceeding specifications 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.
Keep hydraulic oil clean. If oil must be poured from original container into another, clean all possible contaminants from the service container. Always clean filter
mesh element and replace cartridge any time system oil
is changed.
Max. Acceptable Drift
in 10 Minutes*
inches
mm
inches
mm
3
76.2
0.026
0.66
3.5
89
0.019
0.48
4
101.6
0.015
0.38
5
127
0.009
0.22
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
*Based on 6 drops per minute cylinder leakage.
Measure drift at cylinder rod with a calibrated dial indicator.
Cylinder oil must be at stabilized ambient temperature.
Cylinder must have normal platform load applied.
Cylinder is acceptable if it passes this test.
– JLG Lift –
3121607
SECTION 2 - GENERAL
2.5
PINS AND COMPOSITE BEARING REPAIR
GUIDELINES
2.6
NOTE: This instruction applies to repairs, or modifications to the
machine and to welding performed from the machine on
an external structure, or component,
Filament wound bearings.
1.
Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG Equipment:
a. Excessive sloppiness in joints.
• Disconnect battery.
b. Noise originating from joint during operation.
2.
WELDING ON JLG EQUIPMENT
• Disconnect moment pin connection (where fitted)
Filament wound bearings should be replaced if any of
the following is observed:
• Ground only to structure being welded.
Do NOT Do the Following When Welding on JLG
Equipment:
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
d. Debris embedded in liner surface.
3.
Pins should be replaced if any of the following is
observed (Clean pin before inspection):
a. Detectable bearing area wear.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
RING, BOOM WIRE ROPES ETC.
b. Flaking, peeling, scoring, or scratches on pin surface.
4.
c. Rusting of pin in bearing area.
• Do NOT ground on frame and weld on any other area than
chassis.
Re-assembly of pinned joints using filament wound
bearings:
• Do NOT ground on turntable and weld on any other area
than turntable.
a. Blow out housing using compressed air to remove
all dirt and debris. Bearings and bearing housings
must be free of all contamination.
b. Clean bearings and pins with solvent to remove all
grease and oil.
NOTE: Filament wound bearings are a dry joint and should not be
lubricated unless otherwise instructed (i.e. sheave pins).
• Do NOT ground on platform/support and weld on any
other area than platform/support.
• Do NOT ground on a specific boom section and weld on
any other area than that specific boom section.
• Do NOT allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between
grounding position and welded area.
c. Inspect pin to ensure it is free of burrs, nicks, and
scratches which can damage bearing during installation and operation.
3121607
– JLG Lift –
2-5
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
Pre-Delivery2
or Frequent3
Inspection
Annual4
(Yearly)
Inspection
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
AREA
Weekly
Preventive
Maintenance
Monthly
Preventive
Maintenance
Every 2
Years
Boom Assembly
Boom Weldments
Hose/Cable Carrier Installations
Extend/Retract Chain or Cable Systems
Boom Assembly
14
Platform Assembly
Platform
1,2
Railing
Gate
5
Floor
Rotator
9,5
Lanyard Anchorage Point
1
1,2
1
1,5
1
1,2
15
1,2,10
1,2,10
1,2,14
1,2,3,13,14
11
11
1,2,5
1,2,5
5
1,2,5
16,17
16,17,18
16,17,18
15
15
15
Turntable Assembly
Swing Bearing
Oil Coupling
9
Swing Drive System
Turntable Lock
Hood, Hood Props, Hood Latches
Chassis Assembly
Tires
Wheel Nuts/Bolts
Wheel Bearings
14,24
Oscillating Axle/Lockout Cylinder Systems
5,8
Extendable Axle Systems
5,8
5,8
Steer Components
Spindle Thrust Bearing/Washers
1,2
Drive Hubs
2-6
11
– JLG Lift –
11
3121607
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Weekly
Preventive
Maintenance
Monthly
Preventive
Maintenance
Pre-Delivery2
or Frequent3
Inspection
Annual4
(Yearly)
Inspection
Every 2
Years
Functions/Controls
Platform Controls
5
6
6
Ground Controls
5
6
6
1,5
5
5
Footswitch
5
5
Emergency Stop Switches (Ground & Platform)
5
5
Function Limit or Cutout Switch Systems
5
5
Drive Brakes
5
Swing Brakes
5
Auxiliary Power
5
5
3
3
Function Control Locks, Guards, or Detents
Power System
Engine Idle, Throttle, and RPM
Engine Fluids (Oil, Coolant, Fuel)
9,11
11
11
Air/Fuel Filter
1,7
7
7
9
9
Exhaust System
1,9
Batteries
1,9
Battery Fluid
11
Battery Charger
5
Fuel Reservoir, Cap, and Breather
19
11
11
5
2
1,5
1,5
Hydraulic/Electric System
Hydraulic Pumps
Hydraulic Cylinders
1,9
1,9,7
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
Hydraulic Reservoir, Cap, and Breather
1,9
2
1,5
1,5
Hydraulic Filter
1,9
7
7
7,11
7,11
20
20
Hydraulic Fluid
Electrical Connections
1
Instruments, Gauges, Switches, Lights, Horn
1
24
5,23
General
Operation and Safety Manuals in Storage Box
21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only)
21
21
Capacity Decals Installed, Secure, Legible
21
21
All Decals/Placards Installed, Secure, Legible
21
21
3121607
– JLG Lift –
2-7
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA
Weekly
Preventive
Maintenance
Monthly
Preventive
Maintenance
Pre-Delivery2
or Frequent3
Inspection
Annual4
(Yearly)
Inspection
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
Function Test of All Systems
21
21, 22
Paint and Appearance
7
7
Stamp Inspection Date on Frame
22
Notify JLG of Machine Ownership
22
Every 2
Years
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
2-8
– JLG Lift –
3121607
SECTION 2 - GENERAL
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Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications
3121607
– JLG Lift –
2-9
SECTION 2 - GENERAL
NOTES:
2-10
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3. CHASSIS & TURNTABLE
3.1 CHASSIS COMPONENTS AND SERVICING
3
5
4
6
7
2
8
9
10
1
11
12
28
13
18
27
17
19
20
22
14
21
16
23
1.
2.
3.
4.
5.
6.
Track Chain Assembly
Undercarriage
Bolt
Flat Washer
Drive Assembly
Drive Sprocket
7.
8.
9.
10.
11.
12.
Flanged Bolt
Cover Plate
Lockwasher
Bolt
Bolt
Locknut
13.
14.
15.
16.
17.
18.
Carrier Track Roller
Bottom Track Roller
Bolt
Flat Washer
Bolt
Lockwasher
15
19.
20.
21.
22.
23.
24.
Grease Fitting
Seal
Shock Assembly
Spring Assembly
Capscrew
Idler Assembly
25.
26.
27.
28.
Nut
Flat Washer
Bolt
Counterweight (660SJC)
Figure 3-1. Chassis Assembly
3121607
– JLG Lift –
3-1
SECTION 3 - CHASSIS & TURNTABLE
Service Notes
8
9
3
1
4
7
6
5
12
10
11
13
15
14
Figure 3-2. Chassis Service Notes - 1 of 2
3-2
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
1
Track tension adjustment to be made between the idler and carrier roller: 0.781 in (19.8 mm)
2
Anti-Seize Compound 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-lb, +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-lb, +10 -0 (91 Nm, +15 -0)
9
Torque to 340 ft-lb, +25 -0 (476 Nm, +35 -0)
10
Offset in Idler Spring from centerline of Idler to be oriented down.
11
Torque to 165 ft-lb, +15 -0 (231 Nm, +21 -0)
12
Apply Anti-Seize Compound to both mounting pilots Drive Motors
13
Torque to 230 ft-lb, +15 -0 (322 Nm, +21 -0)
14
Torque to 93 ft-lb, +10 -0 (130 Nm, +14 -0)
15
Torque to 53 ft-lb, +5 -0 (74 Nm, +7 -0)
Figure 3-3. Chassis Service Notes - 2 of 2
3121607
– JLG Lift –
3-3
SECTION 3 - CHASSIS & TURNTABLE
Track and Chain
10
9
5
8
4
2
6
11
7
8
3
1
1.
2.
3.
Track Assembly
Left Link
Right Link
4.
5.
6.
Bushing
Hinge Pin
Splice Bushing
7.
8.
9.
Splice Hinge Pin
Spacer
Track Cleat
10. Bolt
11. Nut
Figure 3-4. Track and Chain
3-4
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
TRACK SHOES
3.
1.
Visually check for loose or missing bolts at the start of
each operating shift.
2.
Check bolt torque approximately every 100 hours.
Torque track shoe bolts to 65 ft-lb, +6 (91 Nm, +8.4),
then tighten 1/3 turn (120°) further.
Use a portable press to push pin (5) out. Remove bushing (4).
TRACK PIN
The track pin is pressed in the right and left link of the chain. It
is also installed through bushing at each end of the link. Outside diameter (O.D.) of pin wears against inside diameter (I.D.)
of bushing with which it is making contact. Once pin reaches
allowable wear limit it may be rotated 180 degrees for
extended life.
TRACK BUSHING (BEARING)
Track bushings fit in the counterbore of each link. There is one
bushing per link set. The O.D. of the bushing contacts drive
sprocket teeth during travel and results in bushing wear at
sprocket side only. This wear and pin wear is a major factor in
looseness and damage to the chain by increasing pitch length.
Replace Track
UNCONTROLLED TRACK MOVEMENT CAN CAUSE SERIOUS INJURY. KEEP CLEAR
OF TRACK WHEN REMOVING PIN.
2.
To establish average wear measurement, choose a length of 4
sections of link assembly on top of the undercarriage in a well
tensioned zone.
When wear measurement reaches 100% limit turn pins 180°
for extended life. If this operation has been previously performed, worn parts must be replaced.
REMOVE TRACK
1.
LINKS, PIN, AND BUSHING WEAR MEASUREMENT
Use wood blocking, a come-along, or other device to
prevent track and chain assembly from falling uncontrolled to ground.
INSTALL TRACK
NOTE: Chain must be installed with pin end of links facing back of
machine at ground level.
1.
Align chain and C-clamp spacer in two places on chain.
Hammer in chain link aligning pin hole.
2.
Insert alignment pin through hole to temporarily hold
track together.
3.
Position wood blocks to frame rail for tracks to lay onto
when connecting track ends to get proper extension for
connecting end links.
Remove four bolts (10), nuts (11), and track cleat (9) from
chain assembly. Repeat with adjacent track cleat.
3121607
– JLG Lift –
3-5
SECTION 3 - CHASSIS & TURNTABLE
2.
Check for 0.781 in (19.8 mm) tension between idler &
carrier roller with level and gage. Remove special fitting.
PINS AND BUSHINGS MUST BE WELL LUBRICATED DURING ASSEMBLY.
4.
Apply anti-seize compound to pin. Line up end links.
start pin in hole by driving with a hammer.
5.
Place portable power pin press over track and pin. place
washers in press ends. Carefully press in track pin.
Rubber Track Pad Installation
6.
Re-assemble four track shoes to assembled links.
7.
Torque track shoe bolts to 65 ft-lb, +6 (91 Nm, +8.4), then
tighten 1/3 turn (120°) further.
Track tensioning
1.
3-6
Using special grease fitting tool (P/N 83813109), pump
in grease to add tension to track.
– JLG Lift –
1.
Seat rubber track pad over center rib of steel track.
2.
Apply JLG Thread Locking Compound PN 0100011 to
retaining plate bolts. Install bolts and flat washers to end
of rubber pad.
3.
Torque bolts to 70 ft-lb (97 Nm).
3121607
SECTION 3 - CHASSIS & TURNTABLE
9
7
5
6
5
4
8
3
2
3
8
1
4
9
5
6
5
7
1.
2.
3.
Guide Roller
Shaft
Plug
4.
5.
6.
Bearing
Ring
Seal
7.
8.
9.
Mounting Bracket
O-ring
Roll Pin
Figure 3-5. Bottom Track Roller Assembly
3121607
– JLG Lift –
3-7
SECTION 3 - CHASSIS & TURNTABLE
6
1
6
3
5
14
4
13
15
16
12
11
10
8
9
9
8
2
1.
2.
3.
4.
Guide Roller
Shaft
Internal Cover
Bolt
5.
6.
7.
8.
Washer
Roller Bearing
Not Used
Seal Ring
9.
10.
11.
12.
Tension Ring
Collar
Packing Ring
Seal Ring
13.
14.
15.
16.
Cover
Cover Seal
Lockwasher
Bolt
Figure 3-6. Upper Carrier Track Roller Assembly
3-8
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
TRACK ROLLER ASSEMBLY
Rollers
Rollers are “lifetime” lubricated and under normal working
conditions no further lubrication is required. Idlers should be
randomly checked while working to protect against
destruction should a seal be damaged.
ROLLER SEALS
USED SEALS WILL MOST LIKELY FAIL SHORTLY AFTER REBUILD. ALWAYS USE
NEW SEALS WHEN REASSEMBLING TRACK ROLLER.
NOTE: Mating surface where seals contact must be dry and clean;
free of dirt, nicks, and burrs.
1.
Install O-ring on roller shaft.
2.
Install seal group into roller shell seat. Remove plastic
band holding rings together.
3.
Press collar on roller shaft and lock in place with dowel.
4.
Invert roller assembly and perform steps 1 through 4.
5.
Fill roller with lube.
Install bushings in roller shell.
2.
Install collar to roller shaft.
3.
Install dowel pin through collar and shaft.
4.
Install O-ring in roller shaft.
5.
Install seal group in roller shell seal seat.
6.
Insert collar and shaft into shell until collar bottoms to
the seal group.
7.
Invert roller 180°.
8.
Complete component assembly as in steps 2 through 6.
9.
Fill Roller with lube.
BOTTOM TRACK ROLLER INSTALLATION
TRACK ROLLER DISASSEMBLY
1.
Remove lube fill plug and dump lube into a container.
2.
Press dowel pin out of collar.
3.
Remove seals and shaft.
4.
Press out bushings.
3121607
1.
– JLG Lift –
1.
Blow out roller mounting holes With air gun. Wipe
mounting surfaces clean with rag. Threads must be
clean of grease and oil.
2.
Apply JLG Thread Locking Compound PN 0100011 to
four bolts. Align roller on frame and secure with four
washers and bolts.
3.
Torque bolts to 200 ft-lb +15-0 (280 Nm, +21 -0).
4.
Use a low pressure pump with a nozzle that will fit
through idler body fill hole. Fill with SAE 30 or SAE 40 oil
at capacities for your machine.
3-9
SECTION 3 - CHASSIS & TURNTABLE
Idler Roller Assembly
The idler roller assembly is located at the front of each side frame and acts as a shock absorber for the track system. Compensation is
accomplished by a tensioning spring and hydraulic cylinder.
12
4
4
5
6
7
2
8
5
8
6
7
11
3
10
3
7
8
8
7
1
1.
2.
3.
4.
Idler
Shaft
Bearing
Roll Pin
5.
6.
7.
8.
Mounting Bracket
Seal
Seal
Seal Holder
9.
10.
11.
12.
Not Used
O-ring
Plug
Bracket
Figure 3-7. Idler Assembly
3-10
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
11
10
8
9
6
7
3
4
2
1
5
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 3-8. Spring & Shock Assembly
3121607
– JLG Lift –
3-11
SECTION 3 - CHASSIS & TURNTABLE
TRACK TENSION AND IDLER ROLLER DISASSEMBLY
IDLER ROLLER ASSEMBLY (SEE FIGURE 25)
1.
Relieve all pressure from track tensioning cylinder.
1.
Press bushings into idler shell.
2.
Carefully separate track chain and lay it on the ground.
2.
Mount a bracket on shaft.
3.
Remove recoil device group.
3.
Insert seal group into idler shell seal seat.
4.
Remove track tension group.
4.
Install O-ring on shaft.
5.
Remove two (slide brackets) support groups and idler
pin from side frame.
5.
Insert complete sub assembly in idler shell to point
where it bottoms the seal group.
6.
Remove idler roller from machine.
6.
7.
Examine all fasteners and seals for damage. Replace
damaged components.
Invert idler and assemble components as in steps 1
through 4.
7.
After loose assembly press tightly together using a vertical press.
TRACK TENSION AND IDLER ROLLER REASSEMBLY
NOTE: Seal group is assembled same as in bottom rollers.
1.
Clean, lubricate, and check all components for damage.
2.
Reassemble idler roller with support group and fork and
install into side frame.
3.
Install track tension group.
4.
Torque all fasteners to correct value.
5.
Reassemble track chain to side frame and lack master
pin and bushing as required.
IDLER ROLLER AND TRACK TENSIONER REMOVAL
AND REPLACEMENT TO SIDE FRAME
SERIOUS INJURY COULD RESULT IF THE PRESSURE IS NOT RELIEVED FROM
TENSIONER AND RECOIL SYSTEM.
6.
Pressurize tensioning cylinder to achieve the correct
track adjustment.
7.
Install cover over opening in side frame for valve used
for tensioning cylinder adjustment.
1.
To remove pressure from cylinder, carefully back off one
or two turns on the fill fitting. As soon as lube starts to
come out vent hole STOP backing off fitting.
2.
Once pressure is relieved it is safe to remove roller and
tensioner assembly.
3.
Assemble fitting and fitting seal in end of each shock
assembly. Torque to chart specifications.
IDLER ROLLER DISASSEMBLY
NOTE: Remove recoil components to access idler roller.
INSTALL SHOCK
1.
Remove one of the dowel pins that fasten the bracket to
the shaft.
2.
Remove remaining components which are now free of
shaft.
3.
Press out bushing. (Bushing can only be removed by a
vertical press with correct tooling.)
4.
If necessary, remove remaining dowel pins and bracket.
3-12
– JLG Lift –
4.
Assemble shock assembly in position. Secure with bolts,
washers, and JLG Thread Locking Compound PN
0100011. Torque to 65 ft-lb +10-0 (91 Nm, +15 -0).
5.
Using an adequate lifting device, pick up spring assembly upright onto idler assembly. Install using bolts, washers, and JLG Thread Locking Compound PN 0100011.
Torque to 165 ft-lb +15-0 (231 Nm, +21 -0).
6.
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. Use nylon sledge hammer lightly to assemble.
7.
Push idler assembly against seat. Using special adapter,
pump in grease to expand shock assembly just enough
to inspect for proper assembly.
3121607
SECTION 3 - CHASSIS & TURNTABLE
3.2 DRIVE MOTOR
13
14
36
19
11
51
46
50 48
47
15 18
17
16
59
45
6
10
9
7
5
48
52
53
38
8
56
63
36
55
42
40
62
54 51
64
35 34
35 22
21
51
2
54
55
60
43
44
47
20
56
24
4
61
48
29
27
28 29
23
49
51
36
65
41
43
30 31
26
25
5
33
6
8
7
32
15
9
10
11
14
17
13
18
16
1. Base Plate Assembly
(Items 2 -56)
2. Base Plate
3. Spool Assembly
(Items 4 - 8)
4. Spool
5. Check Valve
6. Spring
7. Plug
8. O-Ring
9. Spring Seat
10. Spring
11. Spring Seat
12. Cap Assembly
(Items 13 - 18)
13. Cap
14. O-Ring
15. Socket Head Capscrew
16. Plug
17. O-Ring
18. Setscrew
19. Relief Valve Assembly
(Items 20 - 35)
20. Relief Housing
21. Poppet
22. Poppet Seal
23. Spring Seat
24. Spring
25. Plug
26. O-Ring
27. Piston
28. O-Ring
29. Backup Ring
30. Guide Spring
31. O-Ring
32. Setscrew
33. Nut
34. O-Ring
35. Backup Ring
36. Plug
37. Valve Assembly
(Items 38 - 44)
38. Spool
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Filter
O-Ring
O-Ring
Backup Ring
Backup Ring
Snap Ring
Spring
Plug
O-Ring
Plug
Orifice
Orifice
Orifice
Plug
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
O-Ring
Check Valve
Spring
O-Ring
Not Used
Not Used
Plug
Plug
Plug
Capscrew
Spring
Pin
Pin
Figure 3-9. Crawler Drive Motor Control
3121607
– JLG Lift –
3-13
SECTION 3 - CHASSIS & TURNTABLE
2
3
6
20
19
5
4
18
17
16
9
1
15
14
13
12
11
10
8
26
27
7
25
24
23
21
22
21
22
21
1.
2.
3.
4.
5.
Flange
Piston Assembly
Spring
Oil Seal
Ball Bearing
6.
7.
8.
9.
10.
Shaft
Steel Ball
Swash Plate
Cylinder Block Assembly
Piston Assembly
11.
12.
13.
14.
15.
Plate Retainer
Retainer Holder
Pin
Cylinder Block
Spring Seat
16.
17.
18.
19.
20.
21.
Spring
Collar
Snap Ring
Valve Plate
Ball Bearing
Disc Plate
22.
23.
24.
25.
26.
27.
Friction Plate
O-Ring
O-Ring
Piston Brake
O-Ring
O-Ring
Figure 3-10. Crawler Drive Motor Assembly
3-14
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
15
16
25
17
18
20
19
21
22
4
23
26
27
28
24
3
5
6
30
31
29
9
10
11
7
12
8
1
13
14
2
3
1.
2.
3.
4.
5.
6.
Piston Motor
Floating Seal
Angular Bearing
Housing
Shim
Holder
7.
8.
9.
10.
11.
12.
Washer
Bolt
Thrust Plate
Inner race
Needle bearing
Planetary Gear
13.
14.
15.
16.
17.
18.
Thrust Plate
Bolt
Sun Gear
Snap Ring
Holder
Thrust Plate
19.
20.
21.
22.
23.
24.
Inner Race
Needle Bearing
Planetary Gear
Thrust Plate
Thrust Plate
Screw
25.
26.
27.
28.
29.
30.
31.
Drive Gear
Thrust Plate
Cover
Bolt
Plug
O-Ring
Pin
Figure 3-11. Crawler Drive - Gearbox
3121607
– JLG Lift –
3-15
SECTION 3 - CHASSIS & TURNTABLE
CYLINDER BLOCK
Disassembly
PREPARATION
1.
Drain all oil before removing motor.
2.
Clean outside of motor and Cover oil ports to prevent
contamination.
3.
Warm parts during disassembly to prevent damage.
BASE PLATE
1.
2.
3.
Place drive assembly with piston motor side up. Loosen
Socket Head Bolts evenly. Remove Flange, Spring Seat,
Spring, and Spring Seat.
Turn and pull Plunger Assembly out. If difficulty is
encountered, tap end of Plunger and insert it. Be sure
Plunger slides smoothly and then try again. Do not disassemble Plunger Assembly.
Loosen Plug and Remove Relief Valve Assembly.
1.
Pull out Cylinder Block Assembly by holding Retainer
Plate and Cylinder Block. Do not damage Piston Shoe
and Cylinder Block.
2.
Mark Piston Assembly and Cylinder Block to identify
each position. Remove Piston Assembly and Retainer
Plate from Cylinder Block.
3.
Remove Retainer Holder and Pins.
4.
Compress Spring and remove Snap Ring. Remove Collar
and Spring from Cylinder Block.
5.
Remove Swash Plate.
6.
Remove Spring from Flange. Steel Balls may come off
with Swash Plate.
7.
Remove Shaft, Ball Bearing, and Oil Seal.
GEAR BOX
DO NOT LOOSEN NUT AND SET SCREW. SETTING PRESSURE IS CHANGED BY
LOOSENING NUT AND SET SCREW.
1.
Remove Plugs and drain oil.
2.
Remove Socket Head Bolts from Cover. Tap Cover with
plastic hammer to break seal and remove Cover.
3.
Remove Thrust Plate.
4.
Remove Poppet Seat from Base Plate.
4.
Remove Drive Gear and Holder A S/A.
5.
Remove Plugs and Spring. Turn and pull Spool out. If difficulty is encountered, tap end of Spool and insert it. Be
sure Spool slides smoothly, then try again.
5.
Remove Thrust Plate and Sun Gear B.
6.
Remove Holder B S/A and Sun Gear C.
7.
Loosen Socket Head Bolts evenly and remove Ring Gear.
Pins may stick.
NOTE: Do not loosen Plugs and Orifices if it is not necessary.
6.
Loosen Socket Head Bolts evenly and pull assembly off
Case and Base Plate out of Flange. If difficulty is encountered, tap top of Base Plate and insert it, then try again.
8.
Loosen Socket Head Bolts and remove Plate. Using a
press, remove Holder C S/A with the caution not to have
the Pins stick.
7.
Position Case and Base Plate Assembly with shaft down.
Loosen Socket Head Bolts evenly and remove Base Plate.
9.
Remove Shim.
8.
Remove Valve Plate, Springs, O-Ring and Pin. Do not
damage Valve Plate.
BRAKE PISTON
1.
Blow compressed air in brake oil passage to remove
Brake Piston from Case. Brake Piston may be ejected out.
2.
Remove O-Rings from Brake Piston. Remove three Disk
Plates and two Friction Plates.
3-16
– JLG Lift –
10.
Remove Coupling.
11.
Press Flange out of Housing.
12.
Remove Floating Seal from Housing with a flat-tip screwdriver.
13.
Press Angular Bearings out of Housing.
14.
Using flat-tip screwdriver and remove another Floating
Seal from Flange.
15.
Wash parts with cleaning solvent. Apply rust preventative if parts are stored before reassembly.
3121607
SECTION 3 - CHASSIS & TURNTABLE
HYDRAULIC MOTOR PARTS REPLACEMENT CRITERIA
Item
Piston Assy (106)
Cylinder Block (104)
Valve Plate (105)
Retainer Plate (107)
Retainer Holder (108)
Swash Plate (109)
Shaft (103)
Brake Piston (125)
Disk Plate (127)
Ball Bearing (112), (113)
Piston Assy (111)
Plunger Assy (102-2)
Base Plate (102)
Spool (102-9)
Relief Valve Assy (102-7)
3121607
Inspection
Allowable Limit
(a) Deep score or roughness on shoe.
0.8a
(b) Deep score or roughness on reciprocating portion.
1.2a
(c) Large clearance between Piston and Cylinder Block.
0.060mm
(d) Play on shoe ball portion.
0.40mm
(a) Deep score or roughness on sliding portion.
0.8a
(b) Deep score or roughness inside bore.
1.6a
(c) Large clearance between Piston.
0.060mm
(d) Large clearance between Shaft spline.
38.749(pin dia.3.333)
(a) Roughness of the sliding portion or deep scoring caused by
0.8a
serious damage, seizure, and partial wear.
<0.02mm(scoring depth)
(a) Roughness of the sliding portion or deep scoring caused by
0.8a
serious damage, seizure, and partial wear.
<0.02mm(scoring depth)
(a) Roughness of the sliding portion or deep score caused by damage, seizure, and 0.8a
<0.02mm(scoring depth)
wear.
(b) Deep scoring or roughness on Steel Ball portion.
1.6a
(c) Depth of Steel Ball portion.
14.5mm
(a) Deep lip mark, roughness, or serious damage on sliding
1.6a
portion for Oil Seal.
<0.02mm(scoring depth)
(b) Excessive wear or breakage on spline
47.380(pin dia.3.000
(c) Large clearance between Cylinder Block spline hole.
30.498(pin dia.3.33)
(d) Large clearance between Coupling spline hole.
(a) Dimension
45.7mm (Height)
(b) Roughness or serious damage on sliding portion.
2.5a
(a) Dimension
3.2 (Thickness)
(b) Serious damage or peeling.
(a) Serious damage on races and Balls.
(b) Discontinuous rotation
(a) Deep score or roughness on shoe.
1.6a
(b) Deep score or roughness on reciprocating potion.
1.2a
(c) Large clearance between Piston and Flange Holder.
0.040mm
(d) Play on shoe ball portion.
1.0mm
(a) Serious damage, roughness, or deep scoring.
0.8a
(b) Large clearance between Plunger and bore.
<0.02mm(scoring depth)
0.060mm
(a) Serious damage, roughness, or deep scoring on bore.
0.8a
<0.02mm(scoring depth)
(a) Serious damage, roughness, or deep scoring.
0.8a
(b) Large clearance between Spool and bore.
0.060mm
(a) Roughness or serious damage on Free Piston sliding
<0.02mm(scoring depth)
– JLG Lift –
Parts to be Replaced
Cylinder Block Kit (B6)
Cylinder Block Kit (B6)
Valve Plate (105)
Retainer Plate (107)
Retainer Holder (108)
Swash Plate (109)
Steel Ball (110)
Shaft (103)
Brake Kit (125)
Brake Kit (127)
Ball Bearing (112), (113)
Case Kit (B7)
Base Plate Kit (B5)
Base Plate Kit (B5)
Base Plate Kit (B5)
Relief Valve Assy (B4)
3-17
SECTION 3 - CHASSIS & TURNTABLE
Assembly
Handle all parts with care to prevent damage.
21.
Apply Teflon tape to plugs. Install and tighten Plugs.
22.
Position Gear Box with piston motor side up. Degrease
thread surface of Socket Head Bolts and thread hole of
Flange.
23.
Apply Locktite 217 or equivalent on thread surface of
Socket Head bolts. Install Plates in Flange. Tighten
Socket Head Bolts.
24.
Ensure Pin is completely inserted in Coupling. Install
coupling on spline shaft Drive Gear.
Replace all seals when disassembling motor.
Clean all parts. Check for dust, damage, scratches, or other
damage before assembly. Replace all Seals and bearings.
GEAR BOX
1.
Grease Floating seals. Install one Floating Seal in Flange.
2.
Put other Floating Seal on Floating seal already set on
Flange. Ensure concentricity of Floating Seals.
3.
Press inner race of Angular Bearing in Flange.
4.
Press outer races of both Angular Bearings in Housing
from both sides.
5.
Carefully place Housing on Flange.
6.
7.
MOTOR SECTION
1.
Apply grease to Oil Seal and press into Flange. Ensure Oil
Seal is completely seated.
2.
Place two Springs in bores at bottom of Flange. Apply
grease on sliding surfaces of two Piston Assemblies and
insert in bores.
Press inner race of Angular Bearing remaining in Flange.
3.
Press top of inner race of Angular Bearing already
installed in Flange with even thrust force of 3000kgf.
While pressing, measure gap.
Press Ball Bearing on Shaft. Insert Shaft in Flange. Ensure
Shaft rotates smoothly.
4.
Press Pins in Flange so Pins project from Flange 26.5 –
27.5 mm.
Apply hydraulic fluid on two Steel Balls and spherical
hollows at bottom of Flange. Place Steel Balls in hollows
and Swash Plate in Flange.
5.
Grease Shim(s) and place on bottom surface of Holder C
S/A (203).
Place Spring Seat, Spring and Collar in Cylinder Block.
Compress Spring and install Snap Ring.
6.
10. Put Holder C S/A on Flange. Pins must be properly
inserted in Flange.
Apply grease on three Pins. Insert Pins in Cylinder Block.
Place Retainer Holder on Cylinder Block.
7.
Insert nine Piston Assemblies through flat side of
Retainer Plate.
8.
Apply hydraulic fluid in bores of Cylinder Block and on
spherical surface of Retainer Holder. Insert Piston
Assemblies in Cylinder Block.
9.
Apply hydraulic fluid on sliding surface of Swash Plate
and sliding surfaces of nine Piston Assembly shoes.
Insert Cylinder Block Assembly on Shaft.
10.
Submerge Valve Plate in hydraulic fluid before assembly.
Place Disk Plate, Friction Plate, Disk Plate, Friction Plate,
and Disk Plate in Flange (1).
11.
Fit O-Rings in grooves of Brake Piston. Apply grease on
sliding surface of Brake Piston. Insert in Flange so holes
for pins on Brake Piston and Case align.
12.
Put Springs on Brake Piston.
8.
9.
11. Apply High Strength Thread Locking Compound (JLG P/
N 0100019 to Socket Head Bolts and evenly tighten
them into flange.
12. Tap Pins on Housing so Pins project from the top surface
of the Flange by17mm.
13. Install O-Ring in Housing.
14. Put Ring Gear on Housing. Tighten Socket Head Bolts
evenly.
15. Ensure Snap Rings and are properly installed in Sun Gear
C and Sun Gear B. Put Sun Gear C in Holder C S/A, Holder
B S/A on Sun Gear C, and Sun Gear B in Holder B S/A.
16. Grease Thrust Plate and place on bottom surface of
Holder A S/A.
17. Put Holder A S/A on Sun Gear B.
18. Put Drive Gear in Sun Gears B and C. Drive Gear must be
properly engaged with planetary gears of Holder A S/A.
19. Place Thrust Plate on Drive Gear (204).
20. Degrease contact surface of Ring Gear and Cover. Apply
liquid gasket evenly and put Cover on Ring Gear. Tighten
Socket Head Bolts.
3-18
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
BASE PLATE
4.
1.
Press Bearing in Base Plate.
2.
Insert Pin in Valve Plate.
3.
Apply grease to back of Valve Plate. Place Valve Plate on
Base Plate with bronze color side up.
4.
Apply grease to O-Ring and place it on Case.
5.
Place O-Rings on Case without grease. Insert Pins in Base
Plate with tapered side up.
6.
Place Base Plate on Case. Do not allow any parts under
Base Plate to fall out. Tighten Socket Head Bolts.
7.
Insert Spool, Spring, and Spring Guide in Base Plate.
Ensure O-Rings are installed in Plugs. Tighten Plugs in
Base Plate.
8.
Install Poppet Seat at top of Relief Valve. Apply grease to
Relief Valve O-Rings. Insert Relief Valve Assembly in Base
Plate and Tighten.
9.
Insert Plunger Assembly in Base Plate. Place Spring Seat,
Spring, and another Spring Seat on each side of Plunger
Assembly. Ensure O-Ring is put in groove on Cap Assembly. Put both Caps on Base Plate. Tighten Socket Head
Bolts.
Lift drive assembly in place with adequate lifting device
and nylon straps. Level, check, and fill (if needed) oil.
Apply Anti-Seize Compound to motor mount area. Realign motor in nylon straps as needed & assemble to carbody. Torque to 230 ft-lb +15-0 (322 Nm, +21 -0).
NOTE: Sprockets are not directional.
5.
Apply Anti-Seize Compound to sprocket mounting area.
Hook to crane using strap and alignment pin. Lift up and
place on motor drive. Secure with bolts and JLG Thread
Locking Compound PN 0100011. Torque to 230 ft-lb +1.
Install Motor Assembly
1.
Clean drive motor. Wash motor mount area inside and
out using brush and solvent container. Wipe dry using
clean, dry rags.
6.
Starting with brake hose for easy access, torque three
small hoses on both sides of drive motor according to
torque chart specifications.
2.
Clean machined mounting surfaces.
7.
Torque two large hoses on drive motor according to
torque chart specifications.
3.
Get hardware for mounting drive motors and place
washers on each bolt. Apply JLG Thread Locking Compound PN 0100011.
8.
Place washers on cover plate retaining bolts and apply
JLG Thread Locking Compound PN 0100011 on each
bolt. Install cover plates and torque bolts according to
chart specifications.
3121607
– JLG Lift –
3-19
SECTION 3 - CHASSIS & TURNTABLE
Rotary Coupling
2
5
4
3
1
1.
2.
Coupling
Stabilizer
3.
4.
Support
Spacer
5.
Keeper
Figure 3-12. Rotary Coupling Installation
3-20
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
3
7
6
5
6
5
7
1
2
4
1
3
2
5
4
6
5
3
4
6
7
5
7 6
1
2
Figure 3-13. Hose Routing - 1 of 2
3121607
– JLG Lift –
3-21
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-14. Hose Routing - 2 of 2
3-22
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
1.
Assemble fittings for hoses to drive motor finger tight
until correct positioning is established.
2.
Install swivel supports with hardware and JLG Thread
Locking Compound PN 0100011. Torque to 53 ft-lb +5-0
(74 Nm, +7 -0).
3.
Lift swivel using supports previously installed, and
assemble to frame. Use JLG Thread Locking Compound
PN 0100011 on bolts. Torque to 68 ft-lb (95 Nm).
4.
Route hoses from swivel area through side frame. Make
initial connections for hoses from swivel to drive motors.
5.
Route brake, shift, and drain hoses through side frame.
Lubricate O-rings and hand tighten hoses to right-hand
drive motor fittings.
3121607
– JLG Lift –
6.
Install swivel stabilizer and secure With JLG Thread Locking Compound PN 0100011. Torque to 93 ft-lb +10-0
(130 Nm, +14 -0).
7.
Clean split post on each side of frame. Wipe off grease
from roller assembly. Apply Anti-Seize Compound. Slide
roller assembly into split post hole and secure with nut,
bolt, and JLG Thread Locking Compound PN 0100011.
Torque to 340 ft-lb +25-0 (476 Nm, +35 -0)on both sides.
3-23
SECTION 3 - CHASSIS & TURNTABLE
3.3 SWING DRIVE
20
12
2
6
1I
1H
5A
1E
4
13
5
1G
11
1J
3
1C
11
44
8
1A
1A. Output Shaft
1B. Lip Seal
1C. Bearing
1E. Bearing
1G. Housing
1H. Thrust Washer
1I. Retaining Ring
1J. Pipe Plug
2. Internal Gear
3. Carrier Assembly
4. Ring Gear
5. O-Ring
5A. O-Ring
6. Brake Housing
8. Sun Gear
11. Thrust Washer
12. Bolt
13. Dowel Pin
20. Pipe Plug
44. Internal Retaining Ring
Figure 3-15. Swing Drive Assembly
3-24
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
101
102
104
105
103
106
104
107
104
108
104
8K
109
110
8K
104
8K
112
29
28
23
32
113
115
114
116
125
117
8K
118
8K
29
6
28
22
21
30
35
6. Brake Housing
8A. Piston
8D. O-Ring
8E.Back-Up Ring
8F. O-Ring
8H. Back-up Ring
8J. Rotor Disc
8K. Stator Disc
8L. Spring
21. Bolt
22. Lockwasher
23. Pipe Plug
26. O-Ring
28. Lifting Lug
29. Bolt
30. Elbow
35. Tube
101. Bolt
102. End Cover
103. Commutator Seal
104. Ring Seal
105. Commutator and Ring Assy
106. Ring
107. Manifold
108. Rotor Set
109. Wear Plate
110. Drive Link
112. Coupling Shaft
113. Inner Bearing
114. Thrust Washer
115. Thrust Bearing
116. Inner Seal
117. Back-up Washer
118. Housing
119. Outer Bearing
120. Seal
125. Back-up Washer
Figure 3-16. Swing Motor and Brake Assembly
3121607
– JLG Lift –
3-25
SECTION 3 - CHASSIS & TURNTABLE
Gear Backlash
Set backlash to .010 - .015 in (0.254 to 0.381mm).
1.
Insert shim (JLG P/N 4071009) between pinion and bearing on the bearing high spot. The bearing high spot
should be stamped with an "X" on the surface below the
teeth and marked with yellow paint in the tooth space.
5.
Loosen jam nut.
6.
Tighten jack bolt until pinion is snug against shim and
bearing, then loosen jack bolt.
7.
Apply JLG Thread locking compound P/N 0100019 to
jack bolt threads. Torque jack bolt to 50 ft-lb (68 Nm).
8.
Tighten jam nut.
9.
Torque four mounting bolts to 340 ft-lb (461 Nm).
Shim
Jam Nut
Jack Bolt
Figure 3-17. Swing Drive Shim Placement
2.
Apply JLG Thread Locking Compound P/N 0100019 to
pivot bolt. Torque pivot bolt to 205 ft-lb (280 Nm).
3.
Remove turntable lock pin.
4.
Apply JLG Thread locking compound P/N 0100019 to
four mounting bolts. Torque mounting bolts to 30 ft-lb
(40 Nm).
Mounting Bolt
Figure 3-19. Swing Drive Jam Nut and Mounting Bolt
10.
Remove and discard swing drive shim.
Swing Drive Lubrication
Fill Swing Drive Gearbox with 43 oz (1.27L) 90w80 gear oil with
EP additives. Oil should cover the ring gear. Torque pipe plug
23 - 24 ft-lb (31 - 32.5 Nm).
Fill Plug
Pivot Bolt
Mounting Bolt
Figure 3-18. Swing Drive Pivot and Mounting Bolts
Drain Plug
Figure 3-20. Swing Drive Lubrication
3-26
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
Motor Control Valve Disassembly
Motor and Brake Disassembly
1.
Place unit on bench with motor end up.
2.
Remove Drain Plug (1P) and drain oil from gearbox.
3.
Remove Hydraulic Tubing Assembly (35).
4.
Loosen jam nuts on Elbow Fittings (30). Remove fittings
from Brake (6) and Motor Control Valve (32).
5.
Remove O-ring Plugs (23) from Motor Control Valve (32).
6.
Remove four bolts (21), washers (22), and Motor Control
Valve (32) from Motor (31).
7.
Reinstall Drain Plug (1P). Torque to 23 - 24 ft-lb (31 - 32.5
Nm).
1.
With unit resting on bench with Motor (31) end up,
remove Hex Bolts (29) and Lift Lugs (28) from Motor (31).
2.
Pull Motor (31) straight up and remove Motor (31) from
Brake Housing (6).
3.
Remove O-ring (26) between Motor (31) and Brake
Housing (6).
4.
Remove Springs (8L) from piston.
PISTON (8A) MAY MOVE QUICKLY. WEAR EYE PROTECTION.
5.
Apply less than 50 psi air to brake port to remove Brake
Piston (8A).
6.
Remove Rotors (8J) and Stators (8K) from Brake Housing
(6).
32
31
23
22
21
6
1P
6
8K
35
8J 8K
8J 8K
8J 8K
8J 8K
Figure 3-21. Main Control Valve Disassembly
8A
28
8L
29
26
31
Figure 3-22. Motor and Brake Disassembly
3121607
– JLG Lift –
3-27
SECTION 3 - CHASSIS & TURNTABLE
Main Disassembly
Hub-Shaft Disassembly
1.
Remove Sun Gear (8) with Retaining Ring (44) inside.
2.
With unit resting on Output Shaft (Pinion) (1A), remove
Bolts (12) from Brake Housing (6).
3.
Remove Brake Housing (6) from main assembly.
11.
4.
Remove O-ring (5A) from Brake Housing (6) and Ring
Gear (4).
Using retaining ring pliers, remove and discard Retaining
Ring (11) from groove in Output Shaft (1A).
12.
Remove Thrust Washer (1H).
13.
Support Housing (1G) on Output Shaft (1A) end. Press
Output Shaft (1A) out of Housing (IG).
WEAR EYE PROTECTION DURING THIS PROCEDURE.
5.
Remove Thrust Washer (11) from Brake Housing (6) and
Carrier Subassembly.
6.
Remove Ring Gear (4) from Housing (1G).
7.
Remove O-ring (5) from Ring Gear (4) and Housing (1G).
8.
Remove Carrier Subassembly.
14.
Remove Bearing Cone (IE) from Housing (IG).
9.
Remove Thrust Washer (11) between Carrier Subassembly and Internal Gear (2).
15.
Use a bearing puller to remove Bearing Cone (1D) from
Shaft (1A). Bearing Cups (1C & 1F) will remain in Housing
(1G).
10.
NOTE: Lip Seal (1B) will be pressed out of Housing (1G) by Bearing
Cone(1D) during this step.
Remove Internal Gear (2).
NOTE: If bearing replacement is necessary, Bearing Cups (1C & 1F)
can be removed with a slide hammer puller or driven out
with a punch.
44
8
20
1I
1H
1E
6
1F
11
5A
1G
4
5
1C
3F
1D
11
1B
2
13
1A
Figure 3-24. Hub-Shaft Disassembly
1A
Figure 3-23. Main Disassembly
3-28
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
Carrier Disassembly
1.
Using a 3/16" punch drive Roll Pin (3G) holding Planet
Shaft (3E) in Carrier (3A) in Planet Shaft (3E) until it bottoms.
3B
3F
3G
3C
3D
3C
3B
MAKE SURE ROLL PIN HAS BOTTOMED OR CARRIER MAY BE DAMAGED WHEN
PLANET SHAFT IS REMOVED.
2.
Remove Planet Shaft (3E) from Carrier (3A). Use a small
punch to remove Roll Pin (3G) from Planet Shaft (3E).
3.
Slide Planet Gear (3F) and two Thrust Washers (3B) out
of Carrier (3A).
4.
Remove both rows of Needle Bearings (3C) and Spacer
(3D) from bore of Planet Gear (3F).
5.
Repeat Steps 1 thru 4 for remaining Cluster Gears (3F).
3E
3A
Figure 3-25. Carrier Disassembly
3121607
– JLG Lift –
3-29
SECTION 3 - CHASSIS & TURNTABLE
Hub-Shaft Subassembly
1.
Press Bearing Cup (1C) in Housing (1G). Make sure cup
starts square with bore of Hub (1G).
2.
Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
(1G).
1I
3.
Apply grease to rubber portion of Seal (1B). Press or tap
Seal (1B) with smooth face up, in counterbore of Housing (1G) until it is flush with Housing (1G) face bore.
4.
Invert Hub (1G) and press Bearing Cup (1E) in counterbore of Housing (1G).
5.
Carefully lower Housing (1G) on Output Shaft (1A) until
Bearing Cone (1D) contacts Output Shaft (1A).
6.
Press on small end of Bearing Cone (1D), being careful
not to contact the bearing cage, until Bearing Cone (1D)
seats on Output Shaft (1A) shoulder.
7.
Start Bearing Cone (1F) on Output Shaft (1A).
8.
Press or tap Bearing Cone (1F) on Output Shaft (1A) until
it is just seated in Bearing Cup (1E), while rotating the
Housing (1G).
9.
1H
1E
1F
1G
1C
Install Bearing Spacer (1H) on Output Shaft (1A) against
Bearing Cone (1F).
1D
1B
RINGS UNDER TENSION CAN FLY OUT AND CAUSE SERIOUS INJURY. WEAR EYE
PROTECTION WHEN INSTALLING RINGS.
1A
NEVER REUSE A RETAINING RING IN REBUILD OR REPAIR.
10.
Install new Retaining Ring (1I) in groove of Output Shaft
(1A).
11.
Tap Retaining Ring (1I) with a soft metal punch to ensure
it is completely seated in groove of Output Shaft (1A).
3-30
– JLG Lift –
Figure 3-26. Hub-Shaft Subassembly
12.
Reinstall Drain Plug if not already installed (1P from Fig.
3-45). Torque to 23 - 24 ft-lb (31 - 32 Nm).
3121607
SECTION 3 - CHASSIS & TURNTABLE
Carrier Subassembly
1.
Apply a liberal coat of grease to bore of Cluster Gear
(3F). This holds Needle Rollers (3C) in place during
assembly.
2.
Install first row of Needle Rollers (3C) in bore of Cluster
Gear (3F).
3.
4.
Insert Spacer (3D) in bore of Cluster Gear (3F) on top of
Needle Rollers (3C).
Place second row of Needle Rollers (3C) in bore of Cluster Gear (3F) against Spacer(3D).
5.
Place Carrier (3A) with one roll pin hole straight up.
6.
Start Planet Shaft (3E) through hole in Carrier (3A). Using
ample grease to hold it in position, slide one Thrust
Washer (3B) over Planet Shaft (3E) with tang resting in
cast slot of Carrier (3A).
7.
With large end of Cluster Gear (3F) facing roll pin hole in
Carrier, place Cluster Gear in position in Carrier (3A).
Push Planet Shaft (3E) through Cluster Gear (3F) without
going all the way through.
8.
Slide second Thrust Washer (3B) between Cluster Gear
(3F) and Carrier (3A) with washer tang located in cast
slot of Carrier (3A). Finish sliding Planet Shaft (3E)
through Thrust Washer (3B) into Carrier (3A).
9.
Position non-chamfered side on Planet Shaft (3E) Roll
Pin hole in line with hole in Carrier (3A) using a 1/8 inch
diameter punch.
3121607
– JLG Lift –
10.
Use a 3/16" punch to align two roll pin holes. Drive roll
pin (3G) through Carrier (3A) and into Planet Shaft (3E)
until Roll Pin (3G) is flush with bottom of cast slot in Carrier (3A) outside diameter at Thrust Washer (3B) tang.
Use a 1/4" pin punch to make sure roll pin (3G) is flush in
slot.
11.
Repeat Steps 1 thru 10 for remaining Cluster Gears (3F).
3B
3F
3G
3C
3D
3C
3B
3E
3A
Figure 3-27. Carrier Subassembly
3-31
SECTION 3 - CHASSIS & TURNTABLE
Main Assembly
1.
With Hub Shaft Subassembly resting on Shaft (1A) install
Internal Gear (2). The spline of Internal Gear (2) bore will
mesh with spline of Output Shaft (1A). This will be a tight
fit.
2.
Inspect location of Internal Gear (2) on Output Shaft
(1A). A portion of Output Shaft (1A) should protrude
through Internal Gear (2) bore.
3.
Install 4 Dowel Pins (13) into counter bore holes in Hub
(1G).
4.
Install Thrust Washer (11) in counter bore of Carrier Subassembly (Small Cluster-Gear end) Use grease to hold in
place.
5.
SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.
Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place.
11.
Install Brake Housing (6). Align Pipe Plug hole (20) with
those in the Hub (1G).
12.
Install Bolts (12) through Brake Housing (6) into Hub
(1G). Torque to 23 - 27 ft-lb (31-36 Nm).
13.
With gearbox standing on pinion end, fill gearbox with
43 oz of ISO VG150 / VG220 gear oil.
14.
Install Retaining Ring (44) in groove of Sun Gear (8).
15.
Install Sun Gear (8) into mesh with Planet Gears (3F).
16.
Install Pipe Plug (20) in Cover (6). Torque to 23 to 24 ft-lb
(31 - 32 Nm).
44
8
SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.
6.
7.
8.
Place Carrier Subassembly on bench with large end of
Cluster Gears (3F) facing up with one at 12 o’clock position. Find punch marked tooth on each gear at large end
and locate at 12 o'clock (straight up) from each planet
pin. Marked tooth will be located just under Carrier on
upper two gears. Check timing through slots in carrier.
(See Carrier Subassembly)
With longer shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) cluster gears
(3F). Be sure cluster gear timing marks (punch marks)
remain in correct location during Ring Gear (4) installation. Ring Gear (4) side with an "X" or punch mark
stamped on it should be up.
While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
with Internal Gear (2). On Ring Gear (4), locate hole
marked "X" or punch marked over one of the marked
counter-bored holes (Step 5) in Hub (1G). Check timing
through slots in carrier. Rotate carrier in assembly to
check freedom of rotation.
20
6
11
5A
4
5
3F
11
2
13
NOTE: If gears do not mesh easily or Carrier Assembly does not
rotate freely, remove Carrier and Ring Gear. Check Cluster
Gear timing.
9.
10.
3-32
Install Thrust Washer (11) in counter bore on face of carrier. Use grease to hold in place.
Place O-ring (5A) into counter bore of Brake Housing (6).
Use grease to hold O-Ring in place.
– JLG Lift –
1A
Figure 3-28. Main Assembly
3121607
SECTION 3 - CHASSIS & TURNTABLE
Motor and Brake Assembly
Motor Control Valve Assembly
1.
Insert Stator (8K) (O.D. lobes) in bore of Brake Housing
(6). Alternate Rotors (8J) (I.D. splines) and Stators, ending
with a Stator (8K).
2.
Grease O-rings (8F) & (8D) and Back-up rings (8H) & (8E).
Place them in their respective grooves in Brake Housing
(6) and Piston (8A). Make sure Back-up rings are correctly
positioned.
3.
1.
NOTE: Align holes in control valve with motor ports.
Apply grease sparingly to Piston O.D. (8A) and bore of
Brake Housing (6). Insert Piston (8A) in Brake Housing
(6). Do not damage O-rings.
4.
Install Springs (8L) in Piston (8A) spring pockets.
5.
Test brake and perform roll test. Remove Brake Test
Plate.
6.
Install O-ring (26) on pilot of Motor (31). Use grease to
keep O-ring in place.
7.
Place Motor (31) in Brake pilot and line up holes. Check
timing sheet.
8.
Assemble Lift Lugs (28) on Hex Bolts (29). Assemble Hex
Bolts (29) with Lift Lugs (28) through Motor (31) and
Brake (6) against Motor flange. Torque to 80-100 ft-lb
(108-135 Nm).
Lay assembly down with motor ports facing up. Remove
two plastic plugs in the motor ports. Do not to lose Oring in each port. Assemble Motor control Valve (32) on
Motor (31) with Bolt (21) and Lock Washers (22). Torque
Bolts (21) to 23-27 ft-lb (31-36 Nm).
2.
Install Elbow Fittings (30) in Brake (6). Do not tighten
jam nuts.
3.
Install Elbow Fittings (30) in Motor Control Valve (32). Do
not tighten jam nuts.
4.
Assemble Tube (35) in Elbow Fittings (30). Torque jam
nuts to 13-15 ft-lb (17-20 Nm).
5.
Install one O-ring Plug (23) in Motor Control Valve (32).
Torque to 30-31 ft-lb (40-42 Nm).
6.
Pressure test brake, tube, and control valve connections
by applying 3000 psi (207 bar) pressure to open port in
Motor Control Valve (32) and holding for one minute.
Check for leaks at control-valve-motor interface and
tube connections. Release pressure and install remaining O-ring Plug (23) in Motor Control Valve (32). Torque
to 30-31 ft-lb (40-42 Nm).
31
O-Ring
32
23
6
8K
8J
22
8K
8J
8K
8J
6
8K
8J
21
8K
8H
1P
Brake Port
8F
8D
8E
8A
28
8L
26
Figure 3-30. Motor Control Valve Assembly
29
31
Figure 3-29. Motor and Brake Assembly
3121607
– JLG Lift –
3-33
SECTION 3 - CHASSIS & TURNTABLE
3.4 SWING BEARING
Wear Tolerance
Turntable Bearing Mounting Bolt Condition Check
NOTE: This check is designed to replace existing bearing bolt
torque checks on JLG Lifts in service. This check must be
performed after first 50 hours of machine operation and
every 600 hours of machine operation thereafter. If any
bolts are missing or loose, replace missing or loose bolts
with new bolts and torque to value specified in torque
chart after lubricating bolt threads with JLG Thread Locking Compound PN 0100019. After replacing and retorquing
bolt or bolts, recheck all bolts for looseness.
1.
SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT
IS HERE STRESSES OF LIFTING ARE CONCENTRATED, AT CENTER OF ROTATION.
BECAUSE OF THIS, PROPER MAINTENANCE OF SWING BEARING BOLTS IS A
MUST FOR SAFE OPERATION.
1.
From underside of machine, at rear center, with boom
fully elevated and fully retracted, as shown in Figure 333., Swing Bearing Tolerance Measurement Location &
Boom Placement A, using a magnetic base dial indicator,
measure and record distance between swing bearing
and turntable as shown in Figure 3-32., Swing Bearing
Tolerance Measuring Point.
2.
At the same point, with boom horizontal and fully
extended, and tower boom fully elevated as shown in Swing Bearing Tolerance Boom Placement B, using a
magnetic base dial indicator, measure and record distance between swing bearing and turntable as shown in
Figure 3-32., Swing Bearing Tolerance Measuring Point.
d. Swing turntable 90° and check some selected bolts
at new position.
3.
If difference is greater than 0.079 in. (2.00 mm), replace
swing bearing.
e. Continue rotating turntable at 90° intervals until a
sampling of bolts are checked in all quadrants.
4.
If difference is less than 0.079 in. (2.00 mm) and any of
the following conditions exist:
Check frame to bearing. Attach bolts as follows:
a. Elevate fully retracted boom to 70° (full elevation).
b. Try and insert a 0.0015" feeler gauge between bolt
head and hardened washer at position shown in Figure 3-31.
c. Make sure 0.0015" feeler gauge will not fit under
bolt head to bolt shank.
2.
Check turntable to bearing. Attach bolts as follows:
a. Metal particles in grease.
a. Elevate fully retracted boom to 70° (full elevation).
b. Increased drive power required.
b. try and insert a 0.0015" feeler gauge between bolt
head and hardened washer at positions shown in
Figure 3-31.
c. Noise.
c. Lower boom to horizontal and fully extend boom.
d. Try and insert the 0.0015" feeler gauge between bolt
head and hardened washer at position shown in Figure 3-31.
d. Rough rotation.
5.
Remove, disassemble, and inspect bearing. If bearing
inspection shows no defects, reassemble and return to
service.
Figure 3-32. Swing Bearing Tolerance Measuring Point
Figure 3-31. Swing Bearing Bolt Feeler Gauge Check
3-34
– JLG Lift –
3121607
3121607
– JLG Lift –
Figure 3-33. Swing Bearing Tolerance Measurement Location & Boom Placement
a. Boom fully elevated and fully retracted.
LEVEL SURFACE
Measuring Point
LEVEL SURFACE
b. Boom horizontal and fully extended.
Measuring Point
SECTION 3 - CHASSIS & TURNTABLE
3-35
SECTION 3 - CHASSIS & TURNTABLE
INSTALLATION
Swing Bearing Replacement
1.
REMOVAL
1.
Operate boom from Ground Control station to provide
access to frame opening or rotary coupling.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING.
2.
Attach an adequate support sling to boom and draw all
slack from sling. Prop or block boom if feasible.
3.
From inside turntable, remove mounting hardware
attaching rotary coupling retaining yoke brackets to
turntable.
JLG INDUSTRIES RECOMMENDS 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
SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
CHECK TORQUE SETTING ACCURACY OF TOOL IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED TO TIGHTEN BEARING ATTACHMENT BOLTS.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.
4.
Tag and disconnect hydraulic lines from fittings on top
of rotary coupling. Use a suitable container to retain any
residual hydraulic fluid. Immediately cap lines and ports.
5.
Attach suitable overhead lifting equipment to base of
turntable weldment.
6.
Use a suitable tool to scribe a line on swing bearing
inner race an underside of turntable. This will aid in
aligning bearing upon installation. Remove bolts and
washers which attach turntable to bearing inner race.
Discard bolts.
7.
Use lifting equipment to carefully lift complete turntable
assembly from bearing. Ensure no damage occurs to
turntable, bearing, or frame-mounted components.
8.
Carefully place turntable on a suitably supported trestle.
9.
Use a suitable tool to scribe a line on outer swing bearing race and frame. This line will aid in aligning bearing
upon installation. Remove bolts and washers which
attach outer race of bearing to frame. Discard bolts. Use
suitable lifting equipment to remove bearing from
frame, then move bearing to a clean, suitably supported
work area.
3-36
Using suitable lifting equipment, carefully lower swing
bearing in position on frame. Ensure scribed line of outer
bearing race aligns with scribed line on frame. If a new
swing bearing is used, ensure filler plug fitting is 90°
from fore and aft center line of frame.
– JLG Lift –
2.
Refer to Torque Sequence diagram as shown in Figure 334., Swing Bearing Torque Sequence. Clean residue off
new bearing bolts and apply a light coating of Thread
Locking Compound JLG P/N 0100019. Install bolts and
washers through frame and outer bearing race. Torque
bolts to 190 ft-lb (258 Nm). Remove lifting equipment
from bearing.
3.
Using suitable lifting equipment, carefully position turntable assembly above machine frame.
4.
Carefully lower turntable onto swing bearing. Ensure
scribed line of inner bearing race aligns with scribed line
on turntable. If a new swing bearing is used, ensure filler
plug fitting is 90° fore and aft center line of turntable.
5.
Clean residue off new bearing bolts and apply a light
coating of Thread Locking Compound JLG P/N 0100019.
Install bolts and washers through turntable and bearing
inner race.
3121607
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-34. Swing Bearing Torque Sequence
6.
Following Torque Sequence diagram shown in Figure 334., Swing Bearing Torque Sequence, torque bolts to 190
ft-lb (258 Nm).
Swing Bearing Torque Values
See Figure 3-34. Swing Bearing Torque Sequence.
7.
Remove lifting equipment.
1.
Outer Race - 190 ft-lb (258 Nm).
8.
Install rotary coupling retaining yoke brackets. Apply a
light coating of Thread Locking Compound, JLG P/N
0100011 to attaching bolts. Secure yoke to turntable
with mounting hardware.
2.
Inner Race - 190 ft-lb (258 Nm).
9.
Connect hydraulic lines to rotary coupling as tagged
prior to removal.
10.
At ground control station, use boom lift control to lower
boom to stowed position.
11.
Using all applicable safety precautions, activate hydraulic system and check swing system for proper and safe
operation.
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CHECK OR MISSING OR LOOSE INNER AND OUTER SWING BEARING BOLTS
AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THEREAFTER.
– JLG Lift –
3-37
SECTION 3 - CHASSIS & TURNTABLE
3.5 GENERATOR
Every 250 hours
Check drive belt tension every 250 hours of operation,.
Every 500 hours
Service generator brushes and slip rings every 500 hours of
operation. Hostile environments may require more frequent
service.
1/2 in.
(13 mm)
Figure 3-36. Generator Brushes and Slip Rings
Figure 3-35. Generator Belt Tension
Blow out inside of generator every 500 hours of service. If
operating in a hostile environment, clean monthly.
Figure 3-37. Generator Cleaning
3-38
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
Overload Protection
Inspecting Brushes, Replacing Brushes, and
Cleaning Slip Rings
STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.
Refer to Figure 3-39., Inspecting Generator Brushes, Replacing
Brushes, and Cleaning Slip Rings.
The circuit breaker protects generator windings from overload. Generator output stops if circuit breaker opens.
INSPECTING BRUSH POSITION
If circuit breaker continues to open, check for faulty equipment connected to platform receptacles.
Inspect brush alignment with slip rings. View alignment
through air vents in stator barrel. Brushes must ride completely on slip rings.
INSPECTING BRUSHES
Circuit
Breaker
Remove end panel. Inspect wires.
2.
Remove brush holder assembly. Pull brushes from holders.
3.
Replace brushes if damaged, or if brush is at or near minimum length.
CLEANING SLIP RINGS
Figure 3-38. Generator Circuit Breaker Location
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1.
– JLG Lift –
1.
Visually inspect the slip rings. Under normal use, the
rings turn dark brown.
2.
If slip rings are corroded or their surface is uneven,
remove belt to turn shaft by hand for cleaning.
3.
Clean rings with 220 grit emery paper. Remove as little
material as possible. If rings are deeply pitted and do not
clean up, consult generator factory service.
4.
Reinstall belt, brush holder assembly, and end panel.
3-39
SECTION 3 - CHASSIS & TURNTABLE
Brush Position on Slip Rings
2
3
Acceptable
Unacceptable
Note: Brushes must ride completely on slip rings.
1
1/4 in (6 mm)
or Less - Replace
2
7/16 in - 1/2 in
(11 - 12 mm ) New
3
1.
2.
3.
Brush Holder Assembly
Brushes
Slip Rings
Figure 3-39. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3-40
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
3.6 DEUTZ D2.9 L4 ENGINE
1
13
7
2
8
6
4
3
14
5
10, 11
12
15
17
37
39
38
16
36
35
34
33
18
32
19
31
30
29
26
25
24
28
20
27
23
21
1.
2.
3.
4.
5.
6.
7.
8.
Fan
Adapter
Drive Belt
Water Pump
Fuel Injector
Thermostat
Oil Fill Cap
Temperature Sender
9.
10.
11.
12.
13.
14.
15.
16.
Turbocharger
Exhaust Pipe
Spark Arrester
Pressure Sensor
Front Engine Mount
Motor Mount
Shuttle Valve
Catalytic Converter/Muffler
17.
18.
19.
20.
21.
22.
23.
24.
Rear Engine Mount
Coupling
Pump Adapter Plate
Right Track Drive Pump
Left Track Drive Pump
Gear Pump
Oil Drain Hose
Oil Drain Valve
25.
26.
27.
28.
29.
30.
31.
32.
Pump Coupler
Flywheel
Fuel Filter
Pressure Sensor
Rear Engine Mount
Oil Pan Drain Plug
Front Engine/Generator Mount
Oil Fill Cap
33.
34.
35.
36.
37.
38.
39.
Oil Cooler
Oil Filter
Belt Tensioner
Plug
Alternator
Adapter
Pulley
Figure 3-40. Deutz D2.9 L4 Engine Installation - Sheet 1 of 2
3121607
– JLG Lift –
3-41
SECTION 3 - CHASSIS & TURNTABLE
Vent
1
Return
Supply
5
2
4
3
15
7
6
To Engine
9
14
10
8
12
13
1.
2.
3.
Coolant Recovery Tank
Radiator Assembly
Air Filter Service Indicator
11
4.
5.
6.
Coolant Overflow Hose
Coolant Level Sensor
Fuel Pump
7.
8.
9.
Fuel Pre-Filter
Battery
Power Module Relay
10. Relay
11. Lanyard
12. Hitch Pin
13. Engine Tray
14. Air Filter Assembly
15. Engine Control Unit (ECU)
Figure 3-41. Deutz D2.9 L4 Engine Installation - Sheet 2 of 2
3-42
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions.
Change Engine Oil
Check Oil Level
1.
Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).
1.
Make sure machine and engine are level and switch
engine OFF before checking oil level.
2.
Make sure machine and engine are level and switch off
engine.
2.
Remove oil dipstick and wipe with clean cloth.
3.
Place oil tray under engine.
3.
Insert dipstick to the stop and remove again.
4.
Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.
MINIMUM OIL
LEVEL
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
DRAINING.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
MAXIMUM OIL
LEVEL
4.
Open oil drain valve and drain oil.
5.
Close oil drain valve.
6.
Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-49., Engine Oil Viscosity.
Figure 3-42. Deutz 2.9 T4F Dipstick Markings
5.
Replace dipstick until fully seated.
Figure 3-43. Engine Oil Viscosity
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– JLG Lift –
3-43
SECTION 3 - CHASSIS & TURNTABLE
Change Oil Filter
Change Fuel Filters
1.
Wipe area around filter to clean any dirt from area.
2.
Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off.
3.
Catch any escaping oil.
4.
Clean any dirt from filter carrier sealing surface.
5.
Lightly coat new oil filter rubber gasket with clean oil
6.
Screw in new filter by hand until gasket is flush.
7.
Hand-tighten filter another half-turn.
8.
Check oil level.
9.
Check oil pressure.
10.
3-44
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1.
Wipe area around filter to clean any dirt from area.
2.
Disconnect water sensor connector (Pre-filter Only).
3.
Remove fuel filter cartridge. Catch any escaping fuel.
4.
Clean dirt from filter carrier sealing surface.
5.
Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
6.
Screw in new filter by hand until gasket is flush. Handtighten filter another half-turn.
7.
Connect water sensor connector (Pre-filter Only).
8.
Open fuel shut-off valve.
9.
Check for leaks.
Check oil filter cartridge for leaks.
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
3.7 DEUTZ D2011 ENGINE
NOTE: Your machine may have the battery mounted on the engine side or hydraulic tank side of the platform. Refer to the following
illustrations to locate components on your specific machine.
LOCATED ON
TURNTABLE
1
RETURN
SUPPLY
VENT
2
FUEL PUMP
SUPPLIED
WITH
ENGINE
6
4
8
7
9
6
23
24
10
22
11
21
12
20
20
13
17
18
19
15
16
1.
2.
3.
4.
5.
6.
Air Filter
Fan
ECM
Dipstick
Oil Filler Cap
Oil Cooler Hose
7.
8.
9.
10.
11.
12.
Glow Plug
Injector
Exhaust Pipe
Coupling
Pump Adapter Plate
Right Track Drive Pump
13.
14.
15.
16.
17.
18.
Left Track Drive Pump
Gear Pump
Rear Engine Mounting Plate
Rear Engine Mount
Engine Mount
Right Front Engine Support
14
19.
20.
21.
22.
23.
24.
Front Engine Mounting Plate
Front Engine Mount
Starter
Muffler
Alternator
Left Front Engine/Generator Support
Figure 3-44. Deutz D2011 Engine (Battery Engine Side) Installation - 1 of 2
3121607
– JLG Lift –
3-45
SECTION 3 - CHASSIS & TURNTABLE
12
13
2
5
6
11
7
1
3
8
10
4
9
14
18
15
17
16
1.
2.
3.
4.
Oil Cooler
Radiator Mounting Plate
Radiator
Relay
5.
6.
7.
8.
Speed Sensor
Oil Filter
Fuel Filter
Oil Pressure Sensor
9.
10.
11.
12.
Throttle Actuator
Temperature Sensor
Starter
Oil Lube Pump
13. Temperature Sensor
14. Starter
15. Relay
16. Plate
17. Engine Tray
18. Battery
Figure 3-45. Deutz D2011 Engine (Battery Engine Side) Installation - 2 of 2
3-46
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
1
LOCATED ON
TURNTABLE
RETURN
SUPPLY
VENT
FUEL PUMP
SUPPLIED
WITH
ENGINE
2
6
7
3
8
4
14
9
15
10
8
13
25
11
24
12
LOCATED ON
TANK SIDE
16
22
23
17
OR
18
20
14
14
21
19
1.
2.
3.
4.
5.
6.
Air Filter
Fan
Dipstick
Oil Filler Cap
ECM
Glow Plug
7.
8.
9.
10.
11.
12.
Injector
Oil Cooler Hose
Exhaust Pipe
Thermostat
Flywheel
Coupling
13.
14.
15.
16.
17.
18.
Engine Mount
Right Front Engine Mounting Plate
Battery (Tank Side)
Pump Adapter Plate
Right Track Drive Pump
Left Track Drive Pump
19.
20.
21.
22.
23.
24.
25.
Gear Pump
Rear Engine Mounting Plates
Left Front Engine Mounting Plate
Left Front Engine/Generator Support
Starter
Muffler
Alternator
Figure 3-46. Deutz D2011 Engine (Battery Tank Side) Installation - 1 of 2
3121607
– JLG Lift –
3-47
SECTION 3 - CHASSIS & TURNTABLE
6
12
13
2
1
5
7
11
8
3
9
10
4
14
15
16
17
1.
2.
3.
4.
Oil Cooler
Radiator Mounting Plate
Radiator
Relay
5.
6.
7.
8.
Speed Sensor
Temperature Sensor
Oil Filter
Fuel Filter
9.
10.
11.
12.
Fuel Supply Pump
Oil Filler Cap
Oil Pressure Sensor
Throttle Actuator
13.
14.
15.
16.
17.
Temperature Sensor
Solenoid
Starter
Relay
Engine Tray
Figure 3-47. Deutz D2011 Engine (Battery Tank Side) Installation - 2 of 2
3-48
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions.
Changing Engine Oil
Checking Oil Level
1.
Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).
1.
Make sure machine and engine are level and switch
engine OFF before checking oil level.
2.
Make sure machine and engine are level and switch off
engine.
2.
Remove oil dipstick and wipe with clean cloth.
3.
Place oil tray under engine.
3.
Insert dipstick to the stop and remove again.
4.
Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
DRAINING.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
4.
Open oil drain valve and drain oil.
5.
Close oil drain valve.
6.
Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-49., Engine Oil Viscosity.
Figure 3-48. Deutz Dipstick Markings
5.
Replace dipstick until fully seated.
Figure 3-49. Engine Oil Viscosity
3121607
– JLG Lift –
3-49
SECTION 3 - CHASSIS & TURNTABLE
Changing Oil Filter
1.
Wipe area around filter to clean any dirt from area.
2.
Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off.
3.
Catch any escaping oil.
4.
Clean any dirt from filter carrier sealing surface.
5.
Lightly coat new oil filter rubber gasket with clean oil.
6.
Screw in new filter by hand until gasket is flush.
7.
Hand-tighten filter another half-turn.
8.
Check oil level.
9.
Check oil pressure.
10.
Check oil filter cartridge for leaks.
Replace Fuel Filter
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
3-50
– JLG Lift –
1.
Wipe area around filter to clean any dirt from area.
2.
Remove fuel filter cartridge. Catch any escaping fuel.
3.
Clean dirt from filter carrier sealing surface.
4.
Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
5.
Screw in new filter by hand until gasket is flush. Handtighten filter another half-turn.
6.
Open fuel shut-off valve.
7.
Check for leaks.
3121607
SECTION 3 - CHASSIS & TURNTABLE
Clean Fuel Strainer
3.8 SPARK ARRESTER CLEANING INSTRUCTIONS
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1.
Unscrew hexagonal nut (1).
1.
Remove cleanout plug in bottom of spark arrester (muffler).
2.
Without causing deformation (or any type of damage to
spark arrester) repeatedly tap on arrester near cleanout
plug. This may be enough to begin spark trap drainage.
3.
An industrial vacuum cleaner can do a complete job at
this point.
a. Or, IN A SAFE AREA, start engine. Alternate between
low idle and high idle for two to three minutes.
b. Or, operate engine as required by application for
two to three minutes.
4.
Install cleanout plug.
3.9 GLOW PLUGS
If glow plug option is enabled in the JLG Control System, glow
plug and indicator lamp will be energized when Power/Emergency Stop switch is pulled on if ambient air temperature is
less than 50° F (10° C) and engine coolant temperature is less
than 140° F (60° C).
2.
Remove fuel strainer cover (2).
3.
Clean fuel strainer with diesel fuel and replace as
needed.
4.
Place seal (3) in position.
5.
Install fuel strainer cover (2). Tighten screw (1).
6.
Check for leaks.
3121607
This determination occurs one second after the Power/Emergency Stop switch has been pulled on. Lamp and glow plugs
remain energized for period of time specified by setting in the
JLG Control System. Engine start is disabled during this period.
On Deutz engines, glow plugs continue (post glow) after
engine has started three times the machine digit setting.
– JLG Lift –
3-51
SECTION 3 - CHASSIS & TURNTABLE
3.10 DEUTZ EMR 2
The EMR2 consists of sensors, control unit, and actuator.
Engine-side controls and the JLG Control System are connected by separate cable harnesses to the EMR control unit.
Sensors attached to the engine provide control unit electronics with all relevant physical parameters In accordance with
information of the current engine conditions and 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.
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.
The EMR2 is equipped with safety devices and measures in the
hardware and software 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 programming over the ISO9141 interface, the EMR2 possesses a motor-specific data set which is permanently 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.
!" #!$% &'!(
!()#*!+ ,-!" #!$% &'!(
Figure 3-50. EMR 2 Engine Side Equipment
3-52
– JLG Lift –
3121607
Figure 3-51. Deutz EMR 2 Troubleshooting Flow Chart
SECTION 3 - CHASSIS & TURNTABLE
3121607
– JLG Lift –
3-53
Figure 3-52. Deutz EMR 2 Vehicle Side Connection Diagram
SECTION 3 - CHASSIS & TURNTABLE
3-54
– JLG Lift –
3121607
Figure 3-53. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
SECTION 3 - CHASSIS & TURNTABLE
3121607
– JLG Lift –
3-55
Figure 3-54. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
SECTION 3 - CHASSIS & TURNTABLE
3-56
– JLG Lift –
3121607
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-55. EMR 2 Engine Plug Pin Identification
3121607
– JLG Lift –
3-57
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-56. EMR 2 Vehicle Plug Pin Identification
3-58
– JLG Lift –
3121607
Figure 3-57. EMR2 Fault Codes - Sheet 1 of 5
SECTION 3 - CHASSIS & TURNTABLE
3121607
– JLG Lift –
3-59
Figure 3-58. EMR2 Fault Codes - Sheet 2 of 5
SECTION 3 - CHASSIS & TURNTABLE
3-60
– JLG Lift –
3121607
Figure 3-59. EMR2 Fault Codes - Sheet 3 of 5
SECTION 3 - CHASSIS & TURNTABLE
3121607
– JLG Lift –
3-61
Figure 3-60. EMR2 Fault Codes - Sheet 4 of 5
SECTION 3 - CHASSIS & TURNTABLE
3-62
– JLG Lift –
3121607
Figure 3-61. EMR2 Fault Codes - Sheet 5 of 5
SECTION 3 - CHASSIS & TURNTABLE
3121607
– JLG Lift –
3-63
SECTION 3 - CHASSIS & TURNTABLE
3.11 BIO FUEL IN DEUTZ ENGINES
APPROVED ENGINES
General
912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513
series are approved for bio-diesel from year of manufacture
1993 under compliance with basic conditions specified below.
Use of bio fuels is permitted for the compact engines made by
DEUTZ.
BASIC CONDITIONS TO BE OBSERVED
• A power loss of 5-9% in relation to diesel fuel in accordance
with EN 590 is possible due to the lower heating value.
Blocking of fuel injector is not allowed.
Distillate fuels with residue oil percentages or mixed fuels may
not be used in DEUTZ compact engines.
DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with a cetane number of at least 51. DEUTZ
engines for mobile machinery are designed for a cetane number of at least 45. When using fuels of a low cetane number, disturbing white smoke and ignition misfires are to be expected
under some circumstances.
• Lubricating oil quality must correspond to TR 0199-993002. Lubricating oil change interval must be halved in
relation to operation with diesel fuel in accordance with EN
590.
• Standstills of longer than 4 to 6 weeks must be avoided with
bio-diesel. Otherwise, engine must be started and stopped
with diesel fuel.
A cetane number of at least 40 is permissible for the US market,
therefore special engine models have been developed to
avoid starting difficulties, extreme white smoke or increased
hydrocarbon emissions (EPA specification - US EPA REGULATIONS FOR LARGE NONROAD COMPRESSION-IGNITION
ENGINES).
• Bio-diesels can be mixed with normal diesel fuel but basic
conditions described in this subsection apply for mixtures.
Mixtures with up to 5% (m/m) bio-diesel (B5) which have
recently been on sale at European fuel stations are
excepted. These fuels must be treated like normal diesel
fuels because EN 590 expressly permits adding up to 5%
(m/m) bio-diesel in accordance with EN 14214.
If white smoke is unacceptable when using a very low cetane
number, use of ignition improvers is to be recommended as a
later remedial measure.
• Approximately 30-50 hours after changing from diesel fuel to
bio-diesel, the fuel filter should be changed as a preventive
measure to avoid a drop in performance due to clogged fuel
filters. Deposited fuel ageing products are dissolved by biodiesel and transported into the fuel filter. They should not
be changed immediately, but after 30 to 50 hours because
that is the time it takes for most dirt to be dissolved.
Certification measurements for compliance with legal emission
limits are carried out with test fuels prescribed by law. These
correspond to diesel fuels in accordance with EN 590 and
ASTM D 975. No emission values are guaranteed with other
fuels described. It is the obligation of the owner to check permission for use of fuels in accordance with regional regulations.
PLANT OIL
Bio Fuel
PERMITTED BIO-DIESEL FUELS
Originally only rape seed oil methylester (RME) was sold as a
bio-diesel fuel in Europe but fatty acid methylester (FAME)
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Management Biodiesel e.V.).
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPERATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH
VISCOSITY, AND POOR EVAPORATION BEHAVIOR).
The conversion of DEUTZ engines to rape seed oil fuel operation with conversion kits and modified tanks systems of various
manufacturers is not allowed and leads to loss of warranty
rights.
The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
comply with the ASTM D6751-07a (B100) standard.
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SECTION 3 - CHASSIS & TURNTABLE
PREVENTIVE MEASURES
Biological Contamination In Fuels
• Keep storage tank clean. Perform regular cleaning of the
tank by specialist companies
SYMPTOMS
The following symptoms may indicate a fuel tank is contaminated by micro-organisms:
• Installation of fuel pre-filters with water traps, especially in
countries with frequently fluctuating fuel qualities and high
percentage of water.
• Internal tank corrosion,
• Filter blockage and associated loss of power due to gel-like
deposits on the fuel filter (especially after long standstills)
If the fuel system and storage tank have already been attacked
by micro-organisms. Biocide must be dosed according to the
manufacturer's specifications.
CAUSE
• Avoid direct exposure of the storage tank to sunlight
Micro-organisms (bacteria, yeasts, funguses) can form biosludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of water
in the air. Water does not dissolve in fuel so penetrating water
collects at bottom of the tank. Bacteria and funguses grow in the
watery phase, at phase boundary to the fuel phase, from which
they draw their nutrition. There is an increased risk especially
with bio-diesel (FAME).
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• Use smaller storage tanks with corresponding low dwell
times of the stored fuel
FUEL ADDITIVES
The use of fuel additives is not permitted. The flow improvers
mentioned above are an exception. Use of unsuitable additives
will result in loss of warranty.
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SECTION 3 - CHASSIS & TURNTABLE
NOTES:
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SECTION 4 - BOOM & PLATFORM
SECTION 4. BOOM & PLATFORM
f. Tag and disconnect hydraulic lines to slave leveling
cylinder. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.
Remove slave cylinder.
4.1 BOOM SYSTEMS
Removal
1.
Remove platform/support as follows:
a. Disconnect electrical cable from control console.
b. Remove eight bolts securing platform to platform
support and remove the platform.
c. Using an overhead crane or suitable lifting device,
strap support platform support.
d. Remove six bolts and locknuts securing support to
rotator.
e. Using a suitable brass drift and hammer, remove
rotator shaft, then remove support from rotator.
Figure 4-2. Rotator and Leveling Cylinder Locations
3.
Remove powertrack from boom as follows:
a. Disconnect wiring harness from ground control box.
Figure 4-1. Location of Components - Platform Support
2.
Remove rotator and slave level cylinder from fly boom
as follows:
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.
a. Tag and disconnect hydraulic lines to rotator. Use
suitable container for residual hydraulic fluid. Cap
hydraulic lines and ports.
b. Tag and disconnect hydraulic lines from boom to
control valve. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.
b. Remove hardware from pin #1. Remove pin #1 from
fly boom with a suitable brass drift and hammer.
c. Disconnect dual capacity indicator limit switch from
side of boom section.
c. Support rotator. Remove hardware from pin #2.
Remove pin #2 from fly boom with a suitable brass
drift and hammer. Remove rotator.
d. Remove hydraulic lines and electrical cables from
powertrack.
d. Telescope fly section out approximately 20 inches
(50.8 cm) to access slave leveling cylinder.
e. Support slave cylinder. Remove hardware from pin
#3. Remove pin #3 from fly boom with a suitable
brass drift and hammer.
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e. Using a suitable lifting equipment, adequately support powertrack weight along entire length.
f. Remove bolts #1 securing push tube on fly boom
section.
g. Remove bolts #2 securing push tube on mid boom
section.
4-1
SECTION 4 - BOOM & PLATFORM
h. With powertrack support and using all applicable
safety precautions, remove bolts #3 and #4 securing
rail to the base boom section. Remove powertrack
from boom section.
4.2 WEAR PADS
Wear pads are made of polyethylene. Pads move on polyurethane painted surfaces. No paint is removed and no lubrication is applied.
!
"
#"
Figure 4-3. Boom Powertrack Components
4.
Remove boom assembly from machine as follows:
a. Using suitable lifting equipment, adequately support boom assembly weight along entire length.
CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING
LINES TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEM.
b. Tag and disconnect hydraulic lines from telescope
cylinder. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.
PAD
c. Remove hardware securing lift cylinder rod end to
base boom section.
A
5/8"
9/16"
B, C, D
3/4"
5/8"
d. Using a suitable brass drift and hammer, remove lift
cylinder pin from base boom.
THICKNESS
OF NEW PAD
REPLACE WHEN
WORN TO:
Figure 4-4. Location and Thickness of Wear Pads
e. Remove hardware securing master cylinder rod end
to base boom section.
1.
Shim wear pads to within 1/32 in (.79 mm) tolerance
between wear pad and adjacent surface.
f. Using a suitable brass drift and hammer, remove the
master cylinder pin from the base boom.
2.
Replace wear pads when worn within 1/16 in (1.59 mm)
and 1/8 in (3.18 mm) - B, C, D of threaded insert. See
Location and Thickness Of Wear Pads.
3.
Bolt length must be changed when adjusting wear pads
and removing or adding shims.
g. Remove hardware securing push bar to turntable
upright.
WHEN REMOVING PIN FROM PUSHBAR DO NOT DROP PUSHBAR ON WIRE
ROPE ADJUSTMENT THREADS. FAILURE TO DO SO WILL DAMAGE THREADS.
h. Using a suitable brass drift and hammer, remove
push bar pin from turntable upright.
a. Longer bolts must be used when adding shims to
ensure proper thread engagement in insert.
b. Shorter bolts must be used when shims are
removed so bolt does not protrude from insert and
contact boom surface.
i. Remove hardware securing boom pivot pin to turntable upright.
j. Using a suitable brass drift and hammer, remove
pivot pin from 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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SECTION 4 - BOOM & PLATFORM
4.
4.3 BOOM DISASSEMBLY/ASSEMBLY & CABLE
REPLACEMENT
Remove spring mounting plate, spring, and proximity
switch from aft end of base section.
Boom Section Disassembly
1.
Remove hardware securing push bar to aft end of telescope cylinder. Remove pin from cylinder.
2.
Remove hardware securing cover plate on bottom front
of base boom section.
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 wire rope adjustments to bottom
front of base boom section.
Figure 4-6. Proximity Switch Assembly Disassembly
Figure 4-5. Clamping Wire Ropes
NOTE: CE specification machines go to Step 4. All other machines
go to Step 5.
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5.
Remove hardware securing wire rope adjustment block
to aft end of base boom section and remove block.
6.
Remove hardware securing telescope cylinder to aft end
of mid boom section.
WHEN REMOVING TELESCOPE CYLINDER FROM BOOM, IT MAY BE NECESSARY
TO TURN CYLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN BOOM.
MOVE CYLINDER SLOWLY OUT OF POSITION. DAMAGE TO COMPONENTS MAY
RESULT FROM FORCIBLE IMPACT WITH ASSEMBLIES.
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7.
Remove bolts securing wire rope attach bar to top of fly
boom section.
8.
Pull telescope cylinder and wire ropes partially from aft
end of base boom section. Secure cylinder with a suitable sling and lifting device at center of gravity.
4-3
SECTION 4 - BOOM & PLATFORM
NOTE: Check groove so that it may be clearly seen if gauge contour matches sheave groove contour.
4.4 WIRE ROPE
WIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER
HANDLE WIRE ROPE WITH BARE HANDS.
Each day before using machine:
1.
Raise main boom approximately horizontal.
2.
Extend and retract the boom sections.
3.
Check for delayed movement of fly section which indicates loose wire ropes.
Figure 4-9. Sheave Groove Wear
7.
Inspection
NOTE: Pictures in this paragraph are samples to show rope
replacement criteria.
1.
Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.
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.
2.
Check wire rope tension by deflecting wire ropes by
hand. Properly tensioned ropes should have little or no
movement.
Inspect ropes for broken wires, particularly valley wire
breaks and breaks at end terminations.
NOTE: Flexing a wire rope can often expose broken wires hidden
in valleys between strands.
Eight Year Inspection
1.
Mandatory wire rope and sheave replacement.
Additional inspection required if:
Figure 4-7. Wire Rope Wire Breaks
2.
Inspect ropes for corrosion.
3.
Inspect ropes for kinks or abuse.
a. Machine is exposed to hostile environment or conditions.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
NOTE: A kink is caused by pulling down a loop in a slack line during improper handling, installation, or operation.
e. Boom exposed to electrical arc. Wires may be fused
internally.
Replacement Criteria
NOTE: Sheaves and wire rope must be replaced as sets.
Figure 4-8. Wire Rope Kink
4.
5.
4-4
Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)Inspect
sheaves for condition of flanges. (See Dimension Of
Sheaves for proper dimension.)
Inspect sheaves with a groove wearout gauge for excessive wear.
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1.
Rusted or corroded wire ropes.
2.
Kinked, “bird caged”, or crushed ropes.
3.
Ropes at end of adjustment range.
4.
Sheaves failing wearout gage inspection.
5.
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.
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SECTION 4 - BOOM & PLATFORM
4.5 WIRE ROPE TENSIONING ADJUSTMENT
Wire Rope Tensioning Procedure
1.
2.
Install adjusting nuts (or remove nylon collar locknuts if
re-adjusting) to both retract and extend wire ropes.
3.
Torque retract adjusting nuts (platform end) to 15 ft-lb
(20 Nm) alternating between the two wire ropes and
keeping approximately the same amount of thread
beyond the adjusting nut.
4.
Repeat torque procedure in step #4 to extend wire ropes
(turntable end).
5.
Extend boom 2 - 3 feet using telescope function. Repeat
step #4.
6.
Retract boom 1 - 2 feet using telescope function. Do not
bottom out telescope cylinder. Repeat step #5.
7.
Extend boom approximately 2 - 3 feet again and check
torque on retract wire ropes.
8.
Retract boom without bottoming out telescope cylinder. Check torque on extend wire ropes.
Position boom in fully down and retracted position.
NOTE: Step #8 and #9 may need to be repeated to equalize the
torque on all 4 wire ropes.
Figure 4-10. Dimensions of Boom Sections
9.
DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED.
After all wire ropes are properly torqued, install nylon
collar locknuts. Remove all clamping devices and install
all covers and guards. Check boom for proper function.
DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED.
CLAMP THREADED ENDS OF WIRE ROPE TO PREVENT ROTATION.
Figure 4-11. Clamping Wire Ropes
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SECTION 4 - BOOM & PLATFORM
Figure 4-12. Boom Assembly Cutaway - Sheet 1 of 3
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SECTION 4 - BOOM & PLATFORM
Figure 4-13. Boom Assembly Cutaway - Sheet 2 of 3
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SECTION 4 - BOOM & PLATFORM
Figure 4-14. Boom Assembly Cutaway - Sheet 3 of 3
10.
Carefully remove telescope cylinder and sheave assembly. Place telescope cylinder on a suitable trestle.
Figure 4-15. Disassembly of Sheave Assembly
11.
Remove hardware securing wear pads to front of base
boom section. Remove wear pads from top, sides, and
bottom of base boom section.
12.
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.
13.
Remove hardware which secures wear pads to aft end of
mid boom section. Remove wear pads from top, sides,
and bottom of mid boom section.
14.
Remove hardware which secures sheave guards and
sheave assemblies to mid boom section. Remove sheave
assemblies from mid boom section.
15.
Remove hardware which secures wear pads to front of
mid boom section. Remove wear pads from top, sides,
and bottom of the mid boom section.
a. Remove hardware from wear pads. Remove wear
pads from cylinder.
b. Remove hardware from wire rope guard. Remove
guard from cylinder.
c. Remove hardware from sheave pin. Remove pin and
sheave from cylinder.
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SECTION 4 - BOOM & PLATFORM
16.
Remove fly boom section from mid section using an
overhead crane or suitable lifting device.
NOTE: When removing fly boom section from mid boom section,
retract wire rope must be dragged along with fly boom section.
17.
18.
Remove hardware which secures wear pads to aft end of
fly boom section. Remove wear pads from top, sides,
and bottom of fly boom section.
When removing wire rope from fly boom section, push
cable into fly boom. Route wire rope back through holes
in side of fly boom section.
Inspection
NOTE: Refer to guidelines established in Section 2 - General when
inspecting pins and bearings.
1.
Inspect all sheaves (extend and retract wire ropes and
telescope cylinder) for excessive groove wear, burrs, or
other damage. Replace sheaves as necessary.
NOTE: Use a groove gauge to check size, contour, and amount of
wear. Replace sheave if worn as shown in the following
drawing.
Figure 4-17. Dimension of Sheaves When New
Figure 4-16. Wire Rope Routing Disassembly
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SECTION 4 - BOOM & PLATFORM
2.
Inspect extend and retract wire rope sheave bearings for
wear, scoring or other damage, and ovality.
2.
Measure inside dimensions of mid section to determine
number of shims required for proper lift.
3.
Inspect extend wire rope and retract wire rope sheave
pins for scoring, tapering and ovality. Replace pins as
necessary.
3.
Install side, top, and bottom wear pads to aft end of fly
section. Shim evenly to inside measurements of mid section.
4.
Inspect telescope cylinder sheave pin for scoring, tapering and ovality. Replace pins as necessary.
4.
5.
Inspect boom pivot pin for wear, scoring, tapering and
ovality, or other damage. Replace pins as necessary.
Install retract wire ropes in aft end of fly section. Route
wire ropes through holes in side of fly boom section and
pull into slot.
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.
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
Figure 4-18. Routing Installation of Retract Wire Ropes
5.
NOTE: Install same number and thickness of shims removed during disassembly when installing fly section wear pads.
1.
Install side, top, and bottom wear pads to aft end of mid
section. Shim evenly to mid section inside measurements.
Measure inside dimensions of base and mid sections to
determine number of shims required for proper lift.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE BOOM SLIDING TRAJECTORIES
ARE CLEAR OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS.
6.
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Shim insides of boom sections for a total of 1/16 inch
(0.062) clearance (if action is centered, there will be 1/32
inch clearance on each side).
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SECTION 4 - BOOM & PLATFORM
Figure 4-19. Boom Powertrack Installation
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SECTION 4 - BOOM & PLATFORM
7.
Slide fly boom section into mid boom section. Shim
boom, if necessary, for a total of 1/16 inch (0.062) clearance.
8.
Install wear pads in forward position of the mid boom
section. Shim boom, if necessary, for a total of 2/10 inch
(0.20) clearance.
9.
Properly position retraction wire rope sheaves assemblies at aft end of mid boom section. Ensure all sheaveto-mounting block attachment holes align. Install
sheave pins and secure them with mounting hardware.
Position retract wire ropes onto sheaves.
10.
Install sheave guards to aft end of mid boom section
and secure with mounting hardware.
11.
Slide mid boom section into base boom section. Allow
retraction wire ropes to trail between 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 base boom
section. Shim boom, if necessary, for a total of 2/10 inch
(0.20) clearance.
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.
14.
Install wire rope threaded ends thru attachment holes in
bottom of base boom section. Loosely install nuts and
jam nuts on threaded ends of wire ropes.
15.
16.
Route extend wire ropes around extend sheave and
secure wire ropes to the telescope cylinder.
17.
Install extend wire rope mounting blocks to threaded
ends of wire ropes. Loosely install nuts and jam nuts on
threaded ends of wire ropes.
NOTE: Do not twist or cross wire ropes during installation.
NOTE: For non CE specification machines, skip step 18 and proceed to step 19.
18.
Install extend wire rope mounting blocks, proximity
mounting plate and spring to threaded ends of wire
ropes. Loosely install nuts and jam nuts on threaded
ends of wire ropes. Refer to Figure 4-20., Proximity
Switch Installation.
19.
Secure sling and lifting device at telescope cylinder’s
approximate center of gravity, and lift cylinder to aft end
of boom assembly.
WHEN INSERTING TELESCOPE CYLINDER IN BOOM, IT MAY BE NECESSARY TO
TURN CYLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN BOOM. CARE
MUST BE TAKEN TO MOVE CYLINDER SLOWLY INTO POSITION. DAMAGE TO
COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH ASSEMBLIES.
Align telescope cylinder barrel-to-sheave attachment
point. Install extend sheave pin through telescope cylinder barrel and sheave assembly; secure pin with mounting hardware.
20.
Align cylinder with slots at aft end of mid boom section,
then secure cylinder with mounting hardware.
21.
Align holes in aft end of fly boom section with holes in
wire rope mounting block. Secure with mounting hardware.
Figure 4-20. Proximity Switch Installation
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SECTION 4 - BOOM & PLATFORM
22.
Align holes in aft end of mid boom section with holes in
wire rope mounting block. Secure with mounting hardware.
Installation
1.
Using a suitable lifting device, position boom assembly
on turntable so pivot holes in both boom and turntable
are aligned.
2.
Install boom pivot pin. Ensure 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, Ensure 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.
6.
Connect all wiring to ground control box.
b. Install powertrack to rail with mounting hardware.
7.
Connect all hydraulic lines running along side of boom
assembly.
c. Attach push tube bracket to side of mid boom section with mounting hardware.
8.
Using all applicable safety precautions, operate lifting
device to position boom lift cylinder so holes in cylinder
rod end and boom structure are aligned. Insert lift cylinder pin. Ensure location of hole in pin is aligned with
attach point on boom.
9.
Align holes in boom structure with hole in master cylinder. Insert master cylinder pin. Ensuring hole in pin is
aligned with attach point on boom.
10.
Adjust retract and extend cables to proper torque. Refer
to paragraph 2-6, boom cable torque procedures.
f. Carefully feed hoses and electrical cables through
aft end of powertrack rail, powertrack, and push
tube.
11.
Using all applicable safety precautions, operate machine
systems and raise and extend boom fully. Note extension cycle performance.
g. Ensure all hoses and cables are properly routed
through powertrack rail, powertrack, and push tube.
Tighten or install all clamping or securing apparatus
to hoses or cables, as necessary.
12.
Retract and lower boom. Note retraction cycle performance.
NOTE: Boom wire ropes must be torqued after installation of
boom assembly.
23.
Align holes in rod end of telescope cylinder with holes in
push bar. Install push bar pin and secure with mounting
hardware.
23.
Install hydraulic lines and electrical cables, and harnessing powertrack components as follows:
a. Align holes in powertrack rail with attachment holes
in side of base boom section. Secure rail with
mounting hardware.
NOTE: Do not over tighten attach bolt on push tube bracket. It
should pivot freely.
d. Install slide block and wear pads to powertrack rail
with mounting hardware.
e. Install powertrack to push tube with mounting
hardware.
h. Install powertrack cover and push tube rods with
mounting hardware.
Figure 4-21. Boom Powertrack Assembly
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SECTION 4 - BOOM & PLATFORM
4.6 ARTICULATING JIB BOOM
Disassembly
Removal
1.
For platform/support removal see platform/support
removal diagram. See Section 4-1., Location of Components - Platform Support.
2.
Position articulating jib boom level with ground.
3.
Remove mounting hardware from slave leveling cylinder pin #1. Using a suitable brass drift and hammer,
remove cylinder pin from articulating jib boom.
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 pins from rotator support.
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: Refer to Section 2 - General, when inspecting pins and
bearings.
Figure 4-22. Articulating Jib Boom Components
4.
4-14
Remove mounting hardware from articulating jib boom
pivot pin #2. Using a suitable brass drift and hammer,
remove pivot pin from boom assembly.
– JLG Lift –
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.
3.
Inspect inner diameter of articulating fly boom pivot
bearings for scoring, distortion, wear, or other damage.
Replace bearings as necessary.
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.
5.
Inspect inner diameter of rotator attach point bearings
for scoring, distortion, wear, or other damage. Replace
bearing as necessary.
6.
Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.
7.
Inspect structural units of articulating jib boom assembly for bending, cracking, separation of welds, or other
damage. Replace boom sections as necessary.
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SECTION 4 - BOOM & PLATFORM
Assembly
4.8 BOOM CLEANLINESS GUIDELINES
NOTE: For location of components See Section 4-22., Articulating
Jib Boom Components.
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.
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.
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.
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. Secure with mounting hardware.
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. Secure with
mounting hardware.
7.
Align 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. Secure with mounting hardware.
The following are guidelines for internal boom cleanliness for
machines used in excessively dirty environments.
1.
JLG recommends use of JLG Hostile Environment Package to keep internal portions of a boom cleaner and
help prevent dirt and debris from entering the boom.
This package reduces the amount of contamination
which can enter the boom, but does not eliminate the
need for more frequent inspections and maintenance
when used in these types of environments.
2.
JLG recommends you follow all guidelines for servicing
your equipment in accordance with instruction in the
JLG Service & Maintenance Manual for your machine.
Periodic maintenance and inspection is vital to proper
operation of the machine. Frequency of service and
maintenance must be increased as environment, severity, and frequency of usage requires.
3.
Debris and contamination inside the boom can cause
premature failure of components and should be
removed. Methods to remove debris should always be
done using all applicable safety precautions outlined in
the JLG Operation & Safety Manual and the JLG Service
& Maintenance Manuals.
4.
The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
toward the nearest exiting point from the boom. Make
sure that all debris is removed before operating the
machine.
5.
If pressurized air cannot dislodge debris, then water
with mild solvents applied with a pressure washer can
be used. Wash debris toward the nearest exiting point
from the boom. Make sure all debris is removed, no
“puddling” of water has occurred, and boom internal
components are dry before operating machine. Make
sure you comply with all federal and local laws for disposing of wash water and debris.
6.
If pressurized air or washing boom does not dislodge
and remove debris, disassemble boom following
instructions outlined in the JLG Service & Maintenance
Manual to remove debris.
4.7 LIMIT SWITCHES AND CAM VALVE ADJUSTMENT
Adjust switches and cam valve as shown in Figure 4-23., Horizontal Limit and Dual Capacity Limit Switches Adjustments
and Figure 4-24., Transport Switch Adjustments - CE Machines
Only.
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4-15
SECTION 4 - BOOM & PLATFORM
Figure 4-23. Horizontal Limit and Dual Capacity Limit Switches Adjustments
4-16
– JLG Lift –
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SECTION 4 - BOOM & PLATFORM
Figure 4-24. Transport Switch Adjustments - CE Machines Only
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4-17
SECTION 4 - BOOM & PLATFORM
4.9 ROTARY ACTUATOR
Required Tools
Theory of Operation
The L20 Series rotary actuator is a simple mechanism that uses
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation.
Each actuator is composed of a housing with integrated gear
teeth (01) and only two moving parts: the central shaft with
integrated bearing tube and mounting flange (02), and the
annular piston sleeve (03). Helical spline teeth machined on
the shaft engage matching splines on the piston inside diameter. The piston outside diameter carries a second set of opposite direction splines which engage with matching splines in
the housing.
As hydraulic pressure is applied, piston is displaced axially
within the housing - similar to operation of a hydraulic cylinder - while splines cause shaft to rotate. When control valve is
closed, oil is trapped inside the actuator, preventing piston
movement and locking the shaft in position. The shaft is sup-
1.
Flashlight - Examine timing marks, component failure,
and overall condition.
2.
Felt Marker - Match mark timing marks and outline troubled areas.
3.
Allen wrench - Remove port plugs and set screws.
4.
Box knife - removal of seals.
5.
Seal tool - assembly and disassembly of seals and wear
guides.
6.
Pry bar - End cap removal and manual rotation of shaft.
7.
Rubber mallet- Removal and installation of shaft and
piston sleeve assembly.
8.
Nylon drift - Piston sleeve installation.
9.
End cap dowel pins - removal and installation of end cap
(sold with Helac seal kit).
The seal tool is a customized standard flat head screwdriver. To
make this tool, heat flat end with a torch. Secure heated end of
screwdriver in a vice and bend to a slight radius. Once radius is
achieved, round off all sharp edges using a grinder. There may
be some slight modifications for your personal preference.
Bars indicate starting positions
of piston and shaft. Arrows indicate direction they will rotate.
The housing with integral ring
gear remains stationary.
As fluid pressure is applied, the
piston is displaced axially while
helical gearing causes the piston
and shaft to rotate simultaneously. The double helix design
compounds rotation: shaft rotation is about twice of the piston.
ported radially by the large upper radial bearing and lower
radial bearing. Axially, the shaft is separated from the housing
by upper and lower thrust washers. End cap is adjusted for
axial clearance and locked in position by set screws or pins.
4-18
– JLG Lift –
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SECTION 4 - BOOM & PLATFORM
PARTS
1. Housing
2. Shaft
3. Piston Sleeve
4. End Cap
HARDWARE
103.1. Screw
103.2 . Washer
106.1. Port Plug
106.2. Port Plug
109 . Lock Pin
113. Capscrew
SEALS
200. T-Seal
202. T-Seal
204. O-ring
205. Cup Seal
207. Backup Ring
304.1. Wiper Seal
BEARINGS
302. Wear Guide
304. Thrust Washer
ACCESSORIES
400. Stop Tube
420.1 Bushing
420.2 Bushing
421.1 Bushing
Figure 4-25. Rotary Actuator - Exploded View
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4-19
SECTION 4 - BOOM & PLATFORM
PARTS
1. Housing
2. Shaft
3. Piston Sleeve
4. End Cap
HARDWARE
103.1. Screw
103.2 . Washer
106.1. Port Plug
106.2. Port Plug
109 . Lock Pin
113. Capscrew
SEALS
200. T-Seal
202. T-Seal
204. O-ring
205. Cup Seal
207. Backup Ring
304.1. Wiper Seal
BEARINGS
302. Wear Guide
304. Thrust Washer
ACCESSORIES
400. Stop Tube
420.1 Bushing
420.2 Bushing
421.1 Bushing
Figure 4-26. Rotary Actuator - Assembly Drawing
4-20
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SECTION 4 - BOOM & PLATFORM
Disassembly
1.
Remove capscrews (113) over end cap lock pins (109).
2.
Using a 1/8” (3.18mm) drill bit, drill a hole in center of
each lock pin approximately 3/16" (4.76mm) deep.
3.
Remove lock pins using an ”Easy Out” (Size #2 shown. If
pin will not come out, use 5/16" drill bit 1/2" (12.7mm)
deep to drill out entire pin.
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4.
Remove end cap (4) using tools provided with Helac seal
kit.
5.
Using a metal bar or similar tool, unscrew end cap (4) by
turning it counter clockwise.
6.
Remove end cap (4) and set aside for later inspection.
4-21
SECTION 4 - BOOM & PLATFORM
7.
Remove stop tube if installed.
8.
Actuator has timing marks for proper engagement.
4-22
– JLG Lift –
9.
Before removing shaft, (2), use a felt marker to clearly
indicate timing marks between shaft and piston. This
simplifies timing during assembly.
10.
Remove shaft (2). It may be necessary to strike threaded
end of shaft with a rubber mallet.
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SECTION 4 - BOOM & PLATFORM
11.
Before removing piston (3), mark housing (1) ring gear in
relation to piston O.D. gear. There should be timing
marks on housing (1) ring gear, piston (3), and shaft (2).
13.
At the point when piston gear teeth come out of
engagement with housing gear teeth, mark piston and
housing with a marker as shown.
12.
To remove piston (3), use a rubber mallet and plastic
mandrel so piston is not damaged.
14.
Remove O-ring (204) and backup ring (207) from end
cap (4) and set aside for inspection.
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4-23
SECTION 4 - BOOM & PLATFORM
15.
Remove wear guides (302) from end cap (4) and shaft
(2).
17.
Remove thrust washers (304) from end cap (4) and shaft
(2).
16.
To remove main pressure seals (205), cut them with a
sharp razor blade. Do not to damage seal groove.
18.
Remove wiper seal (304.1) from end cap (4) and shaft (2).
19.
Remove piston O.D. seal (202).
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SECTION 4 - BOOM & PLATFORM
20.
Remove piston I.D. seal (200).
2.
Inspect thrust washers (304) for rough or worn edges
and surfaces. Measure thickness is within specifications
(Not less than 0.092” or 2.34 mm).
3.
Inspect wear guide condition and measure thickness
(not less than 0.123” or 3.12 mm).
Inspection
1.
Clean all parts in a solvent tank and dry with compressed air before inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal
grooves, bearing grooves, thrust surfaces, rod surface,
housing bore, and gear teeth.
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4-25
SECTION 4 - BOOM & PLATFORM
Assembly
1.
Gather all components and tools to one location. Use
cut away drawing to reference seal orientations.
2.
Install thrust washer (304) on shaft (2) and end cap (4).
4-26
– JLG Lift –
3.
Install wiper seal (304.1/green 0-ring) in groove on shaft
(2) and end cap (4) - around outside edge of thrust
washer (304).
4.
Use a seal tool install main pressure seal (205) on shaft
(2) and end cap (4). Use seal tool in a circular motion.
5.
Install wear guide (302) on end cap (4) and shaft (2).
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SECTION 4 - BOOM & PLATFORM
6.
7.
Install inner T-seal (200) in piston (3) using a circular
motion. Install outer T-seal (202) by stretching it around
the groove in a circular motion. Each T-seal has two
back-up rings (see drawing for orientation).
Beginning with inner seal (200) insert one end of b/u
ring in lower groove and feed the rest in using a circular
motion. Make sure wedged ends overlap correctly.
8.
Insert piston (3) in housing (1) as shown, until outer piston seal (202) touches inside housing bore.
9.
Looking from angle shown, rotate piston (3) until marks
you put on piston and housing (1) during disassembly
line up as shown. Using a rubber mallet, tap piston in
housing to point where gear teeth meet.
Repeat for outer seal (202).
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4-27
SECTION 4 - BOOM & PLATFORM
10.
Looking from opposite end of housing (1) when timing
marks line up, tap piston (3) in until gear teeth mesh
together. Tap piston in housing until it bottoms out.
13.
Install 2 bolts in threaded holes in flange. Using a bar,
rotate shaft clockwise until wear guides are seated in
housing bore.
11.
Install shaft (2) in piston (3). Do not damage seals. Do
not engage piston gear teeth.
14.
Install stop tube on shaft end. Stop tube is an available
option to limit actuator rotation.
15.
Coat threads on end of shaft with anti-seize grease to
prevent galling.
12.
4-28
Looking from view shown, use existing timing marks to
line up gear teeth on shaft (2) with gear teeth on inside
of piston (3). Tap flange end of shaft with rubber mallet
until gear teeth engage.
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SECTION 4 - BOOM & PLATFORM
16.
Install 0-ring (204) and back-up ring (207) in inner seal
groove on end cap (4).
17.
Thread end cap (4) on shaft (2) end. Ensure wear guide
stays in place on end cap as it is threaded in housing (1).
18.
19.
Place lock pins (109) provided in Helac seal kit in holes
with dimple side up. Using a punch, tap lock pins to bottom of hole.
20.
Insert set screws (113) over lock pins. Tighten to 25 in-lb
(2.825 Nm).
Tighten end cap (4). Ensure holes for lock pins line up.
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4-29
SECTION 4 - BOOM & PLATFORM
Installing Counterbalance Valve
3.
Bolts that come with valve are Grade 8 bolts. Install new
bolts with a new valve. Apply Loctite #242 to shanks of
the three bolts at time of installation.
4.
Torque 1/4-inch bolts 110-120 in-lb (12.4-13.5 Nm). Do
not torque over 125 in-lb (14.1 Nm). Torque 5/16-inch
bolts to 140 in-lb (15.8 Nm). Do not torque over 145 in-lb
(16.3 Nm).
Refer to Figure 4-27., Rotator Counterbalance Valve.
1.
Make sure surface of actuator is clean and free of any
contamination and debris, including old Loctite.
2.
Make sure new valve has the O-rings in counterbores of
valve to seal it to the actuator housing.
Figure 4-27. Rotator Counterbalance Valve
4-30
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SECTION 4 - BOOM & PLATFORM
Testing Actuator
1.
If equipment is available, test actuator on a hydraulic test
bench. Breakaway pressure — the pressure at which the shaft
begins to rotate — should be approximately 400 psi (28 bar).
Cycle actuator at least 25 times at 3000 psi (210 bar) pressure.
After 25 rotations, increase pressure to 4500 psi (315 bar).
Check for leaks and cracks. Perform test again at end of rotation in the opposite direction.
Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two
bleed nipples. Secure with hose clamps. Place vinyl
tubes in a clean 5-gallon container to collect purged oil.
2.
Oil can be returned to reservoir after procedure is completed.
Testing Actuator for Internal LeakS
If actuator is equipped with a counterbalance valve, plug valve
ports, connect hydraulic lines to housing ports. Bleed all air
from actuator (see Installation and Bleeding). Rotate shaft to
end of rotation at 3000 psi (210 bar) and maintain pressure.
Remove hydraulic line from non-pressurized side.
Continuous oil flow from open housing port indicates internal
leakage across the piston. Replace line and rotate shaft to end
of rotation in opposite direction. Repeat test procedure outlined above for other port. If there is an internal leak, disassemble, inspect, and repair.
Installation and Bleeding
AFTER INSTALLING ACTUATOR, IT IS IMPORTANT THAT ALL SAFETY DEVICES
SUCH AS TIE RODS OR SAFETY CABLES ARE PROPERLY REATTACHED.
Figure 4-28. Actuator Bleed Ports
To purge air from hydraulic lines, connect them together to
create a closed loop and pump hydraulic fluid through them.
Review hydraulic schematic to determine which hydraulic
lines to connect. The linear feet and inside diameter of hydraulic supply lines together with pump capacity determine
amount of pumping time required to fully purge the hydraulic
system.
Bleeding may be necessary if excessive backlash is exhibited
after actuator is connected to hydraulic system. The following
steps are recommended when a minimum of two gal (8L) is
purged.
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3.
With an operator in the platform, open both bleed nipples 1/4 turn. Hydraulically rotate platform to end of
rotation (clockwise or counterclockwise), and maintain
hydraulic pressure. Oil with small air bubbles will be
seen flowing through the tubes. Allow 1/2 gallon of fluid
to be purged from actuator.
4.
Keep fittings open and rotate platform in opposite
direction to end position. Maintain hydraulic pressure
until an additional 1/4 gallon of fluid is pumped into the
container.
5.
Repeat steps 2 & 3. After last 1/2 gallon is purged, close
both bleed nipples before rotating away from end position.
4-31
SECTION 4 - BOOM & PLATFORM
Table 4-1. Troubleshooting
Troubleshooting
Problem
1.
Shaft rotates slowly or not at all
Cause
Solution
a. Insufficient torque output
a. Verify correct operating pressure. Do not exceed OEM’s
pressure specifications. Load may be above maximum
capacity of the actuator.
b. Low rate of fluid flow
b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.
c. Control or counterbalance valve has internal leak
c. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate actuator through housing ports (do
not exceed OEM’s operating pressure). Valve must be
replaced if a steady flow of fluid is seen coming from valve
ports.
d. Piston and/or shaft seal leak
d. Remove plug and housing’s valve ports. Operate actuator
through housing ports. Conduct internal leakage test.
e. Corrosion build-up on the thrust surfaces
e. Rebuild actuator. Remove all rust then polish. Replacement parts may be needed.
f. Rebuild actuator. Use fluid compatible with all seals and
f. Swollen seals and composite bearings caused by incom- bearings.
patible hydraulic fluid
2.
Operation is erratic or not responsive
a. Air in actuator
a. Purge air from actuator. See bleeding procedures.
3.
Shaft will not fully rotate
a. Twisted or chipped gear teeth
a. Check for gear binding. Actuator may not be able to be
rebuilt and may need to be replaced. Damage could be a
result of overload or shock.
b. Port fittings are obstructing the piston
b. Check thread length of port fittings. Fittings should during stroke not reach inside housing bore.
a. Control or counterbalance valve has internal leak
a. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate actuator through housing ports (do
not exceed OEM’s operating pressure). Valve must be
replaced if a steady flow of fluid is seen coming from valve
ports.
b. Piston and/or shaft seal leak
b. Remove plug and housing’s valve ports. Operate actuator
through housing ports. Conduct internal leakage test.
4.
Selected position cannot be maintained
c. Purge air from actuator. See bleeding procedures
c. Air in actuator
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SECTION 4 - BOOM & PLATFORM
4.10 FOOT SWITCH ADJUSTMENT
4.11 PLATFORM
Adjust foot switch to operate functions when pedal is at center
of travel. Adjust if switch operates within last 1/2 in. (6.35 mm)
of top or bottom travel.
Platform Support Torque Settings
NOTE: If any rotator bolts are replaced, re-torque all rotator bolts.
ELECTRIC SHOCK OR UNCONTROLLED MACHINE MOVEMENT CAN CAUSE
DEATH OR SERIOUS INJURY. DISCONNECT INPUT POWER BEFORE PERFORMING INSTALLATION OR MAINTENANCE.
NOTE: For models with two switches, both switches can be independently adjusted.
1.
Remove four socket head cap screws and cover from
foot switch assembly.
2.
To increase travel before switch is activated, turn Adjustment Screw clockwise.
3.
To decrease travel before switch is activated, turn
Adjustment Screw counter-clockwise.
!
!
"#$%&"'()*
&&
Figure 4-30. Platform Support Torque Values
Replace Platform Sections
The platform is made up of five sections: floor, right side, left
side, back (console box mounting.), and gate. Sections are
secured with Huck magna grip fastener and collars.
1.
Support Huck collar with a suitable support.
2.
Using a hammer and chisel, remove collar from fastener.
Figure 4-29. Foot Switch Adjustment
4.
Install cover and secure with four socket head caps
crews. Torque to 18-22 in-lb (2-3 Nm).
Figure 4-31. Platform Section Replacement
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– JLG Lift –
3.
Replace Huck fasteners with 1/4 x 20 NC x 2 1/4" grade 5
bolts, flat washers, and locknuts when installing new
section of platform.
4.
Replace rivets with 1/4 x 20 NC x 2 “grade 5 bolts, flat
washers, and locknuts when installing a new gate to
platform.
4-33
SECTION 4 - BOOM & PLATFORM
2.
4.12 POWERTRACK MAINTENANCE
Repeat step 1 and remove screw from other side of
track. Remove bar/poly roller from powertrack.
Remove Link
NOTE: Hoses shown in powertrack are for example only. Actual
hose and cable arrangements are different.
1.
4-34
Clamp bar and poly roller tightly so they do not spin
when removing screw. With a small ¼” ratchet and a T20 Torx bit, remove 8-32 x 0.500 screw from one side.
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SECTION 4 - BOOM & PLATFORM
5.
REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT
DAMAGE.
3.
To remove a link, rivets holding links together must be
removed. Use a right-angle pneumatic die grinder with
a ¼” ball double cut bur attachment.
4.
insert tool into rolled over end of rivet. Grind out middle
of rivet until rolled over part of rivet falls off. Repeat for
all rivets to be removed.
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After grinding it may be necessary to use a center punch
with a hammer to remove rivet.
NOTE: It may be necessary to loosen fixed end brackets from
machine to move track section enough to disconnect links.
– JLG Lift –
4-35
SECTION 4 - BOOM & PLATFORM
6.
4-36
Insert flat head screwdriver between links. Twist and pull
links apart.
– JLG Lift –
7.
Remove link from other section of powertrack using
screwdriver.
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SECTION 4 - BOOM & PLATFORM
Install New Link
1.
2.
Spread half-shear (female) end of new link and slide cutout end of track section into it. Use screwdriver if necessary.
3.
Round half-shears will not fit properly in cut-outs after
new link is installed .
Squeeze cut-out end of new link into half-shear (female)
end of track section.
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4-37
SECTION 4 - BOOM & PLATFORM
4.
5.
4-38
Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will
rotate into cut-outs.
6.
Push pin through center hole. Slide washer on pin.
7.
Install snap ring in groove on pin. Repeat pin installation
steps for all center holes with rivets removed.
Parts shown below connect new link to powertrack.
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SECTION 4 - BOOM & PLATFORM
NOTE: Make sure snap rings are seated in pin groove and closed
properly.
Correct
1.
2.
Pull up on other end of round bar. Slide new poly roller
on bar.
Incorrect
Install new 8-32 x 0.500 self-threading Torx head screw
in end of new aluminum round bar. Torque to 18-20 inlb (2-2.25 Nm).
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4-39
SECTION 4 - BOOM & PLATFORM
3.
Install new 8-32 x 0.500 self threading screw on other
side. Torque to 18-20 in-lb (2-2.25 Nm).
Replace Fixed End Brackets
REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT
DAMAGE.
1.
Remove rivets as shown in link removal instructions..
NOTE: When tightening screws make sure screw head is seated
against link with no space in between link and underside of
screw head.
4-40
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SECTION 4 - BOOM & PLATFORM
2.
Parts used: Bracket Center Pin and Center Pin Snap Ring.
3.
Take new bracket and install bracket center pin and
snap ring. Repeat on other bracket if replacing it.
Replace Moving End Brackets
REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE.
1.
Remove existing pins and center rivet. Remove rivet as
shown in link removal instructions on page 4-20. Repeat
on other bracket if replaced.
NOTE: Ensure snap rings are seated in pin groove and closed
properly.
Correct
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– JLG Lift –
4-41
SECTION 4 - BOOM & PLATFORM
2.
NOTE: Ensure snap rings are seated in pin groove and closed
properly.
Install center pin with snap ring in new bracket.
Correct
3.
4-42
Install radius pins and snap rings in original locations.
Repeat with other moving end if replaced.
– JLG Lift –
1.
Incorrect
Make sure both brackets rotate correctly.
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SECTION 5 - HYDRAULICS
SECTION 5. HYDRAULICS
5.1 O-RING LUBRICATION
2.
Hold fitting over hydraulic oil container and brush an
even film of oil around entire O-ring in fitting. Make sure
O-ring is completely saturated.
3.
Turn fitting over and repeat previous step to O-ring on
other side of fitting. Make sure entire O-ring is coated
with hydraulic oil.
When assembling connectors, all fittings with O-rings must be
lubricated with hydraulic oil before assembly. There are four
methods of lubricating O-rings:
1. Cup and Brush
2. Dip
3. Spray
4. Brush-On
Cup and Brush
Tools needed:
• Small container for hydraulic oil
• Small paint brush
1.
Hold fitting in one hand and dip brush into container
with other hand. Remove excess hydraulic oil from
brush so an even film of oil is applied to O-ring.
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5-1
SECTION 5 - HYDRAULICS
Dip
Spray
NOTE: This method works best with Face Seal O-rings, but will
work for all O-ring fitting types.
This method requires a pump or trigger spray bottle.
Tools needed:
• Small leak proof container
1.
Fill spray bottle with hydraulic oil.
2.
Hold fitting over suitable catch can.
3.
Spray entire O-ring surface with medium coat of oil.
• Sponge cut to fit inside container
• Small amount of hydraulic oil to saturate sponge.
1.
Place sponge inside container and add hydraulic oil to
sponge until fully saturated.
2.
Dip fitting into sponge using firm pressure.
Brush-On
This method requires a sealed bottle brush.
3.
After lifting fitting, a small droplet should form and drip
from bottom of fitting. This indicates an even coating of
oil.
1.
Fill bottle with hydraulic oil.
2.
Using slight pressure to body of spray bottle, invert bottle so brush end faces down.
3.
Brush an even coat of hydraulic oil on entire O-ring.
NOTE: O-ring boss-type fittings require more pressure to immerse
more of fitting into saturated sponge. This also causes
more oil to be dispersed from sponge.
5-2
– JLG Lift –
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SECTION 5 - HYDRAULICS
5.2 CYLINDERS - THEORY OF OPERATION
Cylinders Without Counterbalance Valves - Master
Cylinder and Steer Cylinder
Systems With Double Acting Cylinders
Systems with double acting cylinders are the Slave Level, Master Level, Lift, Telescope, Articulating Jib Boom Lift, Axle Lockout, and Steer. 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 piston
side of cylinder) forces the piston to travel toward the rod end
of the barrel, extending the cylinder rod (piston attached to
rod). When oil flow is stopped, movement of rod stops. By
directing oil to the rod side of the cylinder, the piston is forced
in the opposite direction and the cylinder rod retracts.
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
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, repair cylinder.
5.
With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.
6.
Activate engine and retract cylinder. Check extend port
for leakage.
7.
If extend port leakage is less than 6-8 drops per minute,
carefully reconnect hose to extend port, then activate
cylinder through one complete cycle and check for
leaks. If leakage continues at a rate of 6-8 drops per minute or more, repair cylinder.
Systems With 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 control valve.
5.3 CYLINDER CHECKING PROCEDURE
NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is
suspected.
Boom at Horizontal
Figure 5-1. Boom Positioning and Support, Cylinder Repair
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– JLG Lift –
5-3
SECTION 5 - HYDRAULICS
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves
(Upper Lift Cylinder)
(Articulating Jib Boom Lift, and Slave), Slave Level, Lower Lift,
Upright level, Main Telescope and Tower Telescope)
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
1.
Using all applicable safety precautions, activate hydraulic system.
WHEN WORKING ON MAIN LIFT CYLINDER, RAISE BOOM TO HORIZONTAL AND
PLACE A BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN
BOOM. DO NOT WORK ON CYLINDER WITHOUT A SUITABLE PROP IN PLACE.
2.
5-4
Shut down hydraulic system and allow machine to sit for
10-15 minutes. If machine is equipped with 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 hydraulic line pressure. 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 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, counterbalance valve is defective and must
be replaced.
4.
To check piston seals, carefully remove 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, piston
seals are defective and must be replaced.
5.
If no repairs are necessary or when repairs have been
made, replace counterbalance valve and 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.
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
1.
Using all applicable safety precautions, activate hydraulic system.
IF WORKING ON TOWER BOOM LIFT CYLINDER, RAISE TOWER BOOM HALFWAY, FULLY ELEVATE MAIN BOOM WITH TELESCOPE C YLINDER FULLY
RETRACTED. ATTACH AN OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT,
LEAVING APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR SLING FOR
TEST PURPOSES. IF WORKING ON THE UPRIGHT LEVEL, RAISE TOWER BOOM
HALFWAY, THEN RAISE MAIN BOOM TO HORIZONTAL AND POSITION A SUITABLE BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW MAIN BOOM. IF
WORKING ON PLATFORM LEVEL CYLINDER, STROKE PLATFORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS AT A 45 DEGREES ANGLE.
– JLG Lift –
2.
Shut down hydraulic system and allow machine to sit for
10-15 minutes. If machine is equipped with 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 hydraulic line pressure.
3.
Carefully remove hydraulic hoses from appropriate cylinder port block. Catch initial weeping of hydraulic fluid
in a suitable container. After 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,
counterbalance valve is defective and must be replaced.
4.
To check piston seals, carefully remove counterbalance
valve from 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, 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.
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 5 - HYDRAULICS
5.4 CYLINDER REMOVAL AND INSTALLATION
Main Boom Telescope Cylinder Installation
Main Boom Telescope Cylinder Removal
1.
Place machine on a flat and level surface, with main
boom in the horizontal position.
2.
Shut down engine. Support main boom basket end with
a prop. (See Figure 5-1., Boom Positioning and Support,
Cylinder Repair).
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 on threaded
end of cables.
DO NOT TO TWIST OR CROSS CABLES DURING INSTALLATION.
3.
Secure sling and lifting device at telescope cylinder’s
center of gravity. Lift cylinder to aft end of boom assembly.
4.
Install extend cable mounting blocks to threaded ends
of cables. Loosely install nuts and jam nuts on threaded
ends of cables.
CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING
LINES TO PREVENT ENTRY OF CONTAMINANTS INTO THE SYSTEM.
3.
Tag and disconnect hydraulic lines to telescope cylinder.
Use a suitable container to retain residual hydraulic fluid.
Cap hydraulic lines and ports.
4.
Remove hardware securing cover plate on bottom of
base boom section and remove cover.
DO NOT ALLOW CABLE TO ROTATE. THIS MAY DAMAGE THE CABLE.
5.
6.
7.
8.
9.
WHEN INSERTING TELESCOPE CYLINDER INTO BOOM, IT MAY BE NECESSARY
TO TURN C YLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN THE
BOOM. MOVE CYLINDER SLOWLY INTO POSITION OR DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
5.
Carefully install telescope cylinder barrel end support
into slots in mid boom and secure with blocks and bolts.
Use Loctite #242 on bolts.
6.
Remove hardware securing push bar to turntable and
telescope cylinder.
Align holes in aft end of fly boom section with holes in
cable mounting block. Secure with mounting hardware.
7.
Using a suitable brass drift, carefully drive push bar pins
from telescope cylinder rod and turntable.
Align holes in aft end of base boom section with holes in
cable mounting block. Secure with mounting hardware.
8.
Remove cylinder port plugs and hydraulic line caps. Correctly attach lines to cylinder ports.
Remove hardware securing cable adjustment block to
aft end of the base boom section and remove block.
9.
Align holes in rod end of telescope cylinder with holes in
push bar. Install push bar pin and secure with mounting
hardware.
10.
Align holes in push bar with holes in turntable. Install
push bar pin and secure with mounting hardware.
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.
(See Section 4 - Boom & Platform).
Remove hardware securing telescope cylinder to aft end
of mid boom section.
WHEN REMOVING TELESCOPE CYLINDER FROM BOOM, IT MAY BE NECESSARY
AT SOME POINT TO TURN CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED IN THE BOOM. MOVE CYLINDER SLOWLY INTO POSITION OR
DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE
ASSEMBLIES.
10.
Remove bolts securing cable attach bar to top of fly
boom section.
11.
Pull telescope cylinder and cables partially from aft end
of base boom section. Secure cylinder with a suitable
sling and lifting device at center of gravity.
12.
Carefully remove telescope cylinder and sheave assembly. Place telescope cylinder on a suitable trestle.
3121607
NOTE: Boom cables must be torqued after telescope cylinder installation. (See Section 4.1, Boom Rope Torquing Procedures)
– JLG Lift –
5-5
SECTION 5 - HYDRAULICS
5.5 CYLINDER REPAIR
Main Boom Lift Cylinder Removal
1.
Place machine on a flat and level surface. Start engine
and place main boom in horizontal position. Shut down
engine and prop boom. (See Figure 5-1., Boom Positioning and Support, Cylinder Repair)
2.
Remove hardware retaining cylinder rod attach pin to
boom. Using a suitable brass drift, drive out cylinder rod
pin.
3.
Using auxiliary power, retract the lift cylinder rod completely.
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.
NOTE: Following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific
cylinder are noted.
Disassembly
CYLINDER DISASSEMBLYSHOULD BE PERFORMED ON A CLEAN WORK SURFACE
IN A DIRT FREE WORK AREA TO PREVENT CONTAMINATION.
1.
DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.
Operate hydraulic power source and extend the cylinder. Shut down and disconnect power source. Adequately support cylinder rod, if applicable.
3.
If applicable, remove cartridge-type holding valve and
fittings from cylinder port block. Discard O-rings.
Main Boom Lift Cylinder Installation
5-6
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 barrel end attach pin
through mounting holes in lift cylinder and turntable.
Secure in place with pin retaining hardware.
3.
Remove cylinder port plugs and hydraulic line caps and
correctly attach lines to cylinder ports.
4.
Using auxiliary power, extend cylinder rod until attach
pin hole aligns with those in the boom. Using a suitable
soft mallet, drive cylinder rod attach pin through the
boom and lift cylinder. Secure pin in place with attaching hardware.
5.
Remove boom prop and overhead crane. Activate
hydraulic system.
6.
Using all applicable safety precautions, operate boom
functions. Check for correct operation and hydraulic
leaks. Secure as necessary.
7.
Check fluid level of hydraulic tank. Adjust as necessary.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
Cylinder Locations
3
4
600 SJC Only
2
1
4
Item
1
2
3
4
5
Cylinder
Main Lift
Master
Telescope
Platform Level (Slave)
Jib Lift
Figure 5-2. Hydraulic Cylinder Locations
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– JLG Lift –
5-7
SECTION 5 - HYDRAULICS
5.
Main Lift Cylinder
Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).
DISASSEMBLY
NOTE: Refer to Figure 5-6.
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
Figure 5-4. Marking Cylinder for Alignment
3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.
Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6.
Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7.
Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-3. Cylinder Barrel Support
Figure 5-5. Cylinder Rod Support
5-8
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
1.
1a.
2.
2a.
3.
4.
Barrel
Composite Bushing
Rod
Composite Bushing
Head
Piston
5.
6.
7.
8.
9.
10.
Tapered Bushing
Spacer
Cartridge Valve
O-Ring Plug
5/16"-11x2 Bolt
O-Ring Plug
11.
12.
13.
14.
15.
16.
Lock Ring
Hydrolock Seal
O-Ring
Back-Up Ring
Wear Ring
O-Ring
17.
18.
19.
20.
21.
22.
Back-Up Ring
Rod Seal
Wiper
Locking Compound
Locking Primer
Ring Washer
23. Not Used
24. Socket Head Screw
25. O-Ring Plug
Figure 5-6. Main Lift Cylinder Assembly
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– JLG Lift –
5-9
SECTION 5 - HYDRAULICS
8.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
7.
Inspect threaded portion of piston for damage. Dress
threads as necessary.
9.
Loosen and remove nut attaching piston to rod. Remove
piston.
8.
Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
10.
Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.
9.
11.
Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.
10.
Inspect threaded portion of head for damage. Dress
threads as necessary.
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,
damage, 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.
12.
Remove tapered bushing from piston.
13.
Screw piston counter-clockwise by hand and remove
from cylinder rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-7. Tapered Bushing Removal
14.
Remove and discard piston O-rings, seal rings, and
backup rings.
15.
Remove piston spacer, if applicable, from rod.
16.
Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
d. Press composite bushing into barrel or rod bushing
with correct size arbor.
Cleaning and Inspection
1.
Clean parts thoroughly with approved cleaning solvent.
2.
Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-8. Composite Bushing 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.
Inspect threaded portion of barrel for damage. Dress
threads as necessary.
16.
Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
17.
If applicable, inspect piston rings for cracks or other
damage. Replace as 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.
6.
5-10
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
Assembly
NOTE:
Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
1.
Use seal tool to install new rod seal into applicable cylinder head gland groove.
Figure 5-11. Wiper Seal Installation
3.
Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-9. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.
Figure 5-12. Head Seal Kit Installation
Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.
4.
Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5.
Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.
Figure 5-10. Poly-Pak Piston Seal Installation
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– JLG Lift –
5-11
SECTION 5 - HYDRAULICS
6.
If applicable, place new O-ring and back-up rings in
inner piston diameter groove.
11.
Remove cylinder rod from holding fixture.
12.
Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13.
Position cylinder barrel in a suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.
Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.
15.
Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
16.
Secure cylinder head gland using washer ring and
socket head bolts.
Figure 5-13. Piston Seal Kit Installation
7.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
8.
Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.
Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.
Install bolts in tapered bushing using loctite #242
Figure 5-15. Rod Assembly Installation
Figure 5-14. Tapered Bushing Installation
5-12
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
5.
Master Cylinder
Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).
DISASSEMBLY
NOTE: Refer to Figure 5-19. Master Cylinder.
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.
Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
3.
If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.
Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.
Figure 5-17. Marking Cylinder for Alignment
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6.
Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7.
Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-16. Cylinder Barrel Support
Figure 5-18. Cylinder Rod Support
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– JLG Lift –
5-13
SECTION 5 - HYDRAULICS
1.
1a.
2.
2a.
3.
Barrel
Composite Bushing
Rod
Composite Bushing
Piston
4.
5.
6.
7.
8.
Head
Tapered Bushing
Spacer
Capscrew
Ring Washer
9.
10.
11.
12.
13.
Locking Compound
Locking Primer
Seal
Lock Ring
O-Ring
14.
15.
16.
17.
18.
Back-Up Ring
Wear Ring
O-Ring
Back-Up Ring
Rod Seal
19. Wiper
20. Not Used
21. Capscrew
Figure 5-19. Master Cylinder Assembly
5-14
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
8.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
7.
Inspect threaded portion of piston for damage. Dress
threads as necessary.
9.
Loosen and remove nut attaching piston to rod. Remove
piston.
8.
Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
10.
Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.
9.
11.
Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.
10.
Inspect threaded portion of head for damage. Dress
threads as necessary.
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,
damage, 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.
12.
Remove tapered bushing from piston.
13.
Screw piston counter-clockwise by hand and remove
from cylinder rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-20. Tapered Bushing Removal
14.
Remove and discard piston O-rings, seal rings, and
backup rings.
15.
Remove piston spacer, if applicable, from rod.
16.
Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
d. Press composite bushing into barrel or rod bushing
with correct size arbor.
Cleaning and Inspection
1.
Clean parts thoroughly with approved cleaning solvent.
2.
Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-21. Composite Bushing 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.
Inspect threaded portion of barrel for damage. Dress
threads as necessary.
16.
Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
17.
If applicable, inspect piston rings for cracks or other
damage. Replace as 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.
6.
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– JLG Lift –
5-15
SECTION 5 - HYDRAULICS
Assembly
NOTE:
Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
1.
Use seal tool to install new rod seal into applicable cylinder head gland groove.
Figure 5-24. Wiper Seal Installation
3.
Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-22. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.
Figure 5-25. Head Seal Kit Installation
Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.
4.
Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5.
Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.
Figure 5-23. Poly-Pak Piston Seal Installation
5-16
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
6.
If applicable, place new O-ring and back-up rings in
inner piston diameter groove.
11.
Remove cylinder rod from holding fixture.
12.
Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13.
Position cylinder barrel in a suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.
Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.
15.
Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
16.
Secure cylinder head gland using washer ring and
socket head bolts.
Figure 5-26. Piston Seal Kit Installation
7.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
8.
Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.
Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.
Install bolts in tapered bushing using loctite #242
Figure 5-28. Rod Assembly Installation
Figure 5-27. Tapered Bushing Installation
3121607
– JLG Lift –
5-17
SECTION 5 - HYDRAULICS
5.
Telescope Cylinder
Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.
Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.
Figure 5-30. Marking Cylinder for Alignment
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6.
Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7.
Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-29. Cylinder Barrel Support
Figure 5-31. Cylinder Rod Support
5-18
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
1.
2.
3.
4.
5.
Barrel
Rod
Head
Piston
Tapered Bushing
6.
7.
8.
9.
10.
Spacer
Valve Assembly
O-Ring Plug
Capscrew
Ring Washer
11.
12.
13.
14.
15.
Capscrew
Capscrew
Wiper
Rod Seal
O-Ring
16.
17.
18.
19.
20.
Back-Up Ring
Wear Ring
O-Ring
Back-Up Ring
T-Seal
21.
22.
23.
24.
25.
Wear Ring
Locking Compound
Locking primer
Not Used
Bolt
Figure 5-32. Telescope Cylinder Assembly
3121607
– JLG Lift –
5-19
SECTION 5 - HYDRAULICS
8.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
7.
Inspect threaded portion of piston for damage. Dress
threads as necessary.
9.
Loosen and remove nut attaching piston to rod. Remove
piston.
8.
Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
10.
Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.
9.
11.
Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.
10.
Inspect threaded portion of head for damage. Dress
threads as necessary.
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,
damage, 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.
12.
Remove tapered bushing from piston.
13.
Screw piston counter-clockwise by hand and remove
from cylinder rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-33. Tapered Bushing Removal
14.
Remove and discard piston O-rings, seal rings, and
backup rings.
15.
Remove piston spacer, if applicable, from rod.
16.
Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
d. Press composite bushing into barrel or rod bushing
with correct size arbor.
Cleaning and Inspection
1.
Clean parts thoroughly with approved cleaning solvent.
2.
Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-34. Composite Bushing 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.
Inspect threaded portion of barrel for damage. Dress
threads as necessary.
16.
Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
17.
If applicable, inspect piston rings for cracks or other
damage. Replace as 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.
6.
5-20
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
Assembly
NOTE:
Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
1.
Use seal tool to install new rod seal into applicable cylinder head gland groove.
Figure 5-37. Wiper Seal Installation
3.
Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-35. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.
Figure 5-38. Head Seal Kit Installation
Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.
4.
Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5.
Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.
Figure 5-36. Poly-Pak Piston Seal Installation
3121607
– JLG Lift –
5-21
SECTION 5 - HYDRAULICS
6.
If applicable, place new O-ring and back-up rings in
inner piston diameter groove.
11.
Remove cylinder rod from holding fixture.
12.
Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13.
Position cylinder barrel in a suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.
Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.
15.
Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
16.
Secure cylinder head gland using washer ring and
socket head bolts.
Figure 5-39. Piston Seal Kit Installation
7.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
8.
Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.
Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.
Install bolts in tapered bushing using loctite #242
Figure 5-41. Rod Assembly Installation
Figure 5-40. Tapered Bushing Installation
5-22
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
5.
Platform Level (Slave) Cylinder
Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.
Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
3.
If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.
Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.
Figure 5-43. Marking Cylinder for Alignment
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6.
Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7.
Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-42. Cylinder Barrel Support
Figure 5-44. Cylinder Rod Support
3121607
– JLG Lift –
5-23
SECTION 5 - HYDRAULICS
1.
1a.
2.
2a.
3.
4.
Barrel
Composite Bushing
Rod
Composite Bushing
Piston
Head
5.
6.
7.
8.
9.
10.
Tapered Bushing
Spacer
Cartridge Valve
O-Ring Plug
Capscrew
Ring Washer
11.
12.
13.
14.
15.
16.
Locking Compound
Locking Primer
Seal
Ring Lock
O-Ring
Back-Up Ring
17.
18.
19.
20.
21.
Wear Ring
O-Ring
Back-Up Ring
Rod Seal
Wiper
22.
23.
24.
25.
Not Used
Cartridge Valve
O-Ring Plug
Bolt
Figure 5-45. Platform Level (Slave) Cylinder Assembly
5-24
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
8.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
7.
Inspect threaded portion of piston for damage. Dress
threads as necessary.
9.
Loosen and remove nut attaching piston to rod. Remove
piston.
8.
Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
10.
Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.
9.
11.
Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.
10.
Inspect threaded portion of head for damage. Dress
threads as necessary.
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,
damage, 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.
12.
Remove tapered bushing from piston.
13.
Screw piston counter-clockwise by hand and remove
from cylinder rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-46. Tapered Bushing Removal
14.
Remove and discard piston O-rings, seal rings, and
backup rings.
15.
Remove piston spacer, if applicable, from rod.
16.
Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
d. Press composite bushing into barrel or rod bushing
with correct size arbor.
Cleaning and Inspection
1.
Clean parts thoroughly with approved cleaning solvent.
2.
Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-47. Composite Bushing 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.
Inspect threaded portion of barrel for damage. Dress
threads as necessary.
16.
Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
17.
If applicable, inspect piston rings for cracks or other
damage. Replace as 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.
6.
3121607
– JLG Lift –
5-25
SECTION 5 - HYDRAULICS
Assembly
NOTE:
Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
1.
Use seal tool to install new rod seal into applicable cylinder head gland groove.
Figure 5-50. Wiper Seal Installation
3.
Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-48. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.
Figure 5-51. Head Seal Kit Installation
Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.
4.
Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5.
Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.
Figure 5-49. Poly-Pak Piston Seal Installation
5-26
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
6.
If applicable, place new O-ring and back-up rings in
inner piston diameter groove.
11.
Remove cylinder rod from holding fixture.
12.
Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13.
Position cylinder barrel in a suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.
Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.
15.
Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
16.
Secure cylinder head gland using washer ring and
socket head bolts.
Figure 5-52. Piston Seal Kit Installation
7.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
8.
Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.
Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.
Install bolts in tapered bushing using loctite #242
Figure 5-54. Rod Assembly Installation
Figure 5-53. Tapered Bushing Installation
3121607
– JLG Lift –
5-27
SECTION 5 - HYDRAULICS
5.
Jib Lift Cylinder (SJC Only)
Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).
DISASSEMBLY
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.
Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.
Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.
Figure 5-56. Marking Cylinder for Alignment
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6.
Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7.
Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-55. Cylinder Barrel Support
Figure 5-57. Cylinder Rod Support
5-28
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
1.
1a.
2.
3.
4.
Barrel
Bushing
Head
Ring Washer
Capscrew
5.
5a.
6.
7.
8.
Rod
Bushing
Cartridge Valve
Not Used
O-Ring Plug
9.
10.
11.
12.
13.
O-Ring Plug
Piston
Tapered Bushing
Spacer
Not Used
14.
15.
16.
17.
18.
Seal
Lock Ring
O-Ring
Back-Up Ring
Rod Seal
19.
20.
21.
22.
23.
Wiper
Wear Ring
Wiper
Wear Ring
Locking Compound
24. Locking Primer
25. Not Used
26. Bolt
Figure 5-58. Jib Lift Cylinder Assembly(660SJC)
3121607
– JLG Lift –
5-29
SECTION 5 - HYDRAULICS
8.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
7.
Inspect threaded portion of piston for damage. Dress
threads as necessary.
9.
Loosen and remove nut attaching piston to rod. Remove
piston.
8.
Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
10.
Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.
9.
11.
Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.
10.
Inspect threaded portion of head for damage. Dress
threads as necessary.
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,
damage, 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.
12.
Remove tapered bushing from piston.
13.
Screw piston counter-clockwise by hand and remove
from cylinder rod.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-59. Tapered Bushing Removal
14.
Remove and discard piston O-rings, seal rings, and
backup rings.
15.
Remove piston spacer, if applicable, from rod.
16.
Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
d. Press composite bushing into barrel or rod bushing
with correct size arbor.
Cleaning and Inspection
1.
Clean parts thoroughly with approved cleaning solvent.
2.
Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
Figure 5-60. Composite Bushing 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.
Inspect threaded portion of barrel for damage. Dress
threads as necessary.
16.
Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
17.
If applicable, inspect piston rings for cracks or other
damage. Replace as 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.
6.
5-30
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
Assembly
NOTE:
Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before
assembly.
1.
Use seal tool to install new rod seal into applicable cylinder head gland groove.
Figure 5-63. Wiper Seal Installation
3.
Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-61. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.
Figure 5-64. Head Seal Kit Installation
Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.
4.
Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5.
Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.
Figure 5-62. Poly-Pak Piston Seal Installation
3121607
– JLG Lift –
5-31
SECTION 5 - HYDRAULICS
6.
If applicable, place new O-ring and back-up rings in
inner piston diameter groove.
11.
Remove cylinder rod from holding fixture.
12.
Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13.
Position cylinder barrel in a suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.
Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.
15.
Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
16.
Secure cylinder head gland using washer ring and
socket head bolts.
Figure 5-65. Piston Seal Kit Installation
7.
Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.
8.
Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.
Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.
Install bolts in tapered bushing using loctite #242
Figure 5-67. Rod Assembly Installation
Figure 5-66. Tapered Bushing Installation
5-32
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
5.6 HYDRAULIC PUMP (GEAR)
7.
Remove pump from vise and place on clean work bench.
Remove four hex head bolts and spacers if applicable.
8.
Lift and remove end cover.
9.
Carefully remove gear housing and place on work
bench. Make sure rear bearing block remains on drive
and idler shafts.
Disassembly
NOTE: The following general instructions also apply to multiple
section gear pumps. The only extra parts are the coupling
between drive shafts and center distance plate which
divides the two pump sections. This repair procedure also
applies to ”W” series Gear Motors.
1.
Always work in a clean work area when repairing
hydraulic products. Plug ports and wash exterior of
pump with approved cleaning solvent.
2.
Remove port plugs and drain oil from pump.
3.
Use a permanent marker pen to mark a line across
mounting flange, gear housing and end cover. This will
assure proper reassembly and rotation of pump.
4.
Remove key from drive shaft if applicable.
5.
Clamp mounting flange in a protected jaw vise with
pump shaft facing down.
6.
Loosen four metric hex head bolts.
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SECTION 5 - HYDRAULICS
10.
Remove rear bearing block from drive and idler shafts.
13.
Remove front bearing block.
11.
Remove idler shaft from bearing block.
14.
Turn mounting flange over, with shaft seal up. Remove
retaining ring with snap ring pliers.
12.
Remove drive shaft from mounting flange.
15.
Remove oil seal from mounting flange. Do not mar or
scratch seal bore.
16.
Remove dowel pins from gear housing. Do not lose pins.
17.
Remove and discard seals from both bearing blocks.
NOTE: Shaft seal will be replaced.
5-34
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SECTION 5 - HYDRAULICS
Inspect Parts For Wear
1.
2.
3.
4.
Inspect gear face for scoring or excessive wear. If face
edge of gear teeth are sharp, they will mill into the bearing blocks. If wear has occurred, parts are unusable.
5.
Inspect bearing blocks for excessive wear or scoring on
surfaces in contact with gears. Inspect bearings for
excessive wear or scoring.
6.
Inspect area inside gear housing. A clean ”wipe” on
inside surface of intake side is normal. There should not
be excessive wear, deep scratches, or gouges.
Clean and dry all parts thoroughly before inspection. It
is not necessary to inspect seals. They will be placed as
new items.
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.
Inspect drive gear shaft and idler gear shafts at bearing
points and seal area for rough surfaces and excessive wear.
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5-35
SECTION 5 - HYDRAULICS
General Information
2.
Install retaining ring in groove in seal bore of mounting
flange.
3.
Place front and back bearing blocks on a clean surface
with E-seal grooves facing up. Apply a light coating of
petroleum jelly in the grooves. Coat E-seal and backup
with petroleum jelly. This helps keep seals in place during reassembly
4.
Place E-seals, flat side out, into grooves in both bearing
blocks. Carefully place backup ring, flat side out, in
groove made by E-seal and groove in bearing block.
(Note: W900 series pump - In center of backup ring and Eseal there is a notch. Make sure notches line up so backup
ring will set flush with E-seal). Backup ring in W1500
pump is symmetrical.
FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR
NO FLOW AT RATED PRESSURE. RELATIONSHIP OF MOUNTING FLANGE, BEARING BLOCKS, AND GEAR HOUSING MUST BE CORRECT.
Reverse Shaft Rotation of Pump
NOTE: Pump is not bi-rotational. Use the following procedure if
shaft rotation direction is changed.
Reverse shaft rotation of ”W” series gear pump by rotating, as
a group, two bearing blocks and gear housing 180° in relationship to remaining parts of pump. This places pressure port
opposite from original position.
Assembly
NOTE: Install new seals when reassembling pump or motor. Go to
page 8 for kit part numbers for W-600, W-900, and W-1500
pumps and motors.
1.
5-36
Install new shaft seal in mounting flange with part number side facing out. Press seal into seal bore until seal
reaches bottom of bore. Use uniform pressure to prevent seal misalignment or damage.
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3121607
SECTION 5 - HYDRAULICS
5.
Place mounting flange, with shaft seal side down, on a
clean flat surface.
10.
Place rear bearing block over drive and idler gear shafts
with seal side up and open end of E-seal
facing intake side of pump.
6.
Apply a light coating of petroleum jelly to exposed face
of front bearing block.
11.
Install two dowel pins in mounting flange holes or two
long dowel pins through gear housing if pump is a multiple section pump.
7.
Insert drive end of drive shaft through bearing block
with seal side down and open side of E-seal pointing to
intake side of pump.
12.
Apply a light coating of petroleum jelly in grooves on
both sides of gear housing. Coat new O-rings and install
in grooves.
8.
Install seal sleeve over drive shaft. Carefully slide drive
shaft through shaft seal. Remove seal sleeve from shaft.
9.
Install idler gear shaft in remaining position in bearing
block. Apply a light coat of clean oil to face of drive and
idler gears.
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5-37
SECTION 5 - HYDRAULICS
13.
Gently slide gear housing over rear bearing block
assembly. Slide housing down until it engages dowel
pins. Press firmly in place with hands, do not force or use
any tool. Check intake port in housing is on same side as
open end of E-seal, and marked lines on mounting
flange and gear housing are aligned.
15.
Install four spacers (if applicable) and hex head bolts
through bolt holes in end cover. Hand tighten.
16.
Place mounting flange of pump in protected jawed vise
and alternately torque bolts to torque chart specifications. All torque figures are for ”dry torque” bolts.
NOTE: Rear bearing block surface should be slightly below gear
housing face. If bearing block is higher than rear face of
gear housing, E-seal or O-ring have shifted out of groove.
Remove gear housing and check for proper seal installation.
Table 5-1.Hydraulic Pump Bolt Torque Chart
14.
5-38
Install two remaining dowel pins in rear of gear housing,
if applicable. Place end cover over back of pump.
Torque Values,
Black Oxide
End Cover
Torque Values,
Zinc Plated End
Cover
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
Pump Series
Thread Size
W-600
17.
Remove pump from vise.
18.
Place a small amount of clean oil in pump inlet and
rotate drive shaft away from inlet one revolution. If drive
shaft binds, disassemble pump and check for assembly
problems. Reassemble pump.
– JLG Lift –
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SECTION 5 - HYDRAULICS
Placing Pump Back Into Service
1.
5.7 VARIABLE PUMP
If shop test stand is available, use the following procedure for testing rebuilt pumps:
a. Mount pump on test stand. Make sure proper level
of clean oil is available in 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 pressure measured and monitored at various hydraulic circuit points. The
Series 42 pump has several locations at which to take these
measurements. The following outlines show gauge port locations, and gauge and fitting size for each port.
Table 5-2. Recommended Gauge Size
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.
2.
If shop test stand is not available, use the following procedure for testing rebuilt pumps:
a. For engine driven pumps, mount pump on equipment and run pump at 1/2 engine speed at zero
pressure for three minutes.
Gauge
Port
Name
d. Stop engine and check pump for external leaks.
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
M4 & M5
Servo
1000
60
9/16-18 ORF
L1 & L2
Case
500
35
1-1/16-12 ORF
S
Charge Pump
Inlet Vacuum
30 in. Hg Vac.
1
1-1/16-12 ORF
b. Operate control valve and build pressure intermittently for three minutes.
c. Increase engine speed to full throttle and build
pressure intermittently for three minutes.
Pressure
Measured
NFPE Control
The 3-position FNR control, and electric and hydraulic nonfeedback proportional (NFPE and NFPH) controls are nonfeedback type controls. FNR and NFPE controls consist of
pump housing mounted modules. Hydraulic input for NFPH is
received through ports on top of pump [9/16–18 SAE O-ring
fitting].
Non-feedback controls are factory set. Control modules can be
removed to clean ports and change O-rings.
FNR and NFPE orifice plugs are located inside the servo piston
covers. NFPH orifice plugs are located in the NFPH ports. Orifice plugs may be cleaned or replaced.
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5-39
SECTION 5 - HYDRAULICS
SHIM ADJUSTABLE STYLE
Remove and Install FNR and NFPE Modules
1.
Clean pump and module housings.
2.
Remove four screws retaining module to pump housing (4
mm Int. Hex). Remove module from 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. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).
Remove and Install 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.
2.
Remove orifice plug (1/8" Int. Hex).
3.
Examine orifice and port for cleanliness.
4.
Install orifice plug. Torque to 1.5 - 2.5 ft-lb (2.0-3.4 Nm).
1.
2.
3.
Plug
O-Ring
Shims
4.
5.
Spring T-Seal
Poppet
Figure 5-68. Shim Adjustable Charge Relief Valve
Components
Charge Relief Valve
Charge relief valve may be removed for cleaning and installation of new O-rings. Pressure setting may be changed for different charge flows depending on charge pump size and
pump speed.
1.
Remove shim adjustable charge relief valve plug (1" Hex)
from pump housing. Remove O-ring from plug.
2.
Remove spring and poppet from housing.
3.
Do not alter shims which may be installed between
spring and valve plug, or interchange parts with another
valve. Inspect poppet and mating seat in housing for
damage or foreign material.
4.
If desired, change charge relief valve setting. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in).
Effective setting will vary.
Factory setting is set relative to case pressure at 1800 rpm.
Actual charge pressure varies at different speeds.
To confirm charge relief valve setting, measure charge
pressure (port M3) with pump in stroke. Charge pressure
should level off when relief setting is reached.
5-40
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3121607
SECTION 5 - HYDRAULICS
1.
System Pressure Gauge Port M2
7.
Case Drain Port L2
2.
System Pressure Port B
8.
Servo Pressure Gauge Port L4
3.
System Pressure Port A
9.
Case Drain Port L1
4.
System Pressure Gauge Port M1
10.
Case Drain Port L1 (non-feedback)
5.
Servo Pressure Gauge Port M5
11.
Charge Pressure Gauge
6.
Case Drain Port L2 (non-feedback)
12.
Charge Pump Inlet Port S
Figure 5-69. Gauge Port Locations
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5-41
SECTION 5 - HYDRAULICS
Torque
#
Plug/
Fitting
lb. ft.
Nm
1
Servo Gauge Port M4
N/A
N/A
2
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
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 5-70. Plugs/Fittings Size & Torque
5-42
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3121607
SECTION 5 - HYDRAULICS
5.
Install new O-ring on valve plug. Reinstall poppet,
spring, and plug (with shims and O-ring) into pump
housing. Torque to 40-100 ft-lb (55-135 Nm).
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 5-72. Shaft Seal Components
Figure 5-71. Screw Adjustable Charge Relief Valve
Components
A lip type shaft seal is used in Series 42 pumps. Seal and shaft
can be replaced without major unit disassembly. Replacement
generally requires removing pump from machine.
1.
Mark plug, lock nut, and housing to maintain original
adjustment before removing screw adjustable relief valve
plug. Loosen lock nut (1-1/16" Hex) and remove plug (8
mm Int. Hex). Remove O-ring from plug.
2.
Remove spring and poppet from housing.
3.
Inspect poppet and mating seat in housing for damage
or foreign material.
4.
Install new O-ring on valve plug. Reinstall poppet and
spring. Reinstall plug and lock nut. Torque to 34 - 42 ft-lb
(47-57 Nm), aligning marks made at disassembly.
5.
Check and adjust charge pressure if necessary. For screw
adjustable “anti-stall” charge relief valves, an approximate rule of thumb is 2.8 bar/quarter turn (40 psi/quarter turn).
6.
Measure charge pressure (port M3) with pump in stroke.
Charge pressure should level off when relief setting is
reached.
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 5-73. Installation of Shaft Seal
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SECTION 5 - HYDRAULICS
1.
Position pump with shaft facing up.
NOTE: If unit is positioned horizontally when shaft is removed, cylinder block could move out of place, making shaft installation difficult.
2.
Remove retaining ring from housing.
3.
Pull out seal carrier assembly.
4.
Remove O-ring from seal carrier. To install a new shaft
only, go to step 8.
5.
Place seal carrier in an arbor press with shaft bearing
side down and press out old seal. An appropriately sized
pipe spacer or socket wrench can be used as a press
tool. Seal is not reusable.
6.
Inspect seal carrier and new seal for damage. Inspect
sealing area on shaft for rust, wear, or contamination.
Polish sealing area on shaft if necessary.
7.
Press new seal in shaft bearing side of seal carrier. Seal
lip must face outside of pump. Do not damage seal. Outside diameter of seal may be coated with a sealant (e.g.
Loctite High Performance Sealant #59231) before installation. This helps prevent leaks caused by damage to
seal bore in seal carrier. If shaft is not being replaced go
to step 11.
8.
Remove shaft and roller bearing assembly from pump or
motor.
9. Remove retaining ring from roller bearing assembly with
snap ring pliers. Remove roller bearing assembly.
10.
Place roller bearing assembly on new shaft and secure
with retaining ring.
11. Wrap spline or key end of shaft with thin plastic to prevent damage to seal lip during installation. Lubricate
inside diameter of shaft seal with petroleum jelly.
12.
13.
Place O-ring on shaft bearing and lubricate with petroleum jelly.
Slide seal carrier assembly over shaft and into housing
bore. Press against O-ring. Hold inward pressure against
shaft to compress cylinder block spring while pressing seal
carrier into place.
14. Install retaining ring.
5-44
1. Key
2. Shaft Assembly
3. Retaining Ring
4. Roller Bearing
5. Shaft
Figure 5-74. Shaft Components
Hydraulic Pump W/Hayes Pump Drive Coupling
Lubrication
Coat pump and drive coupling splines with Lithium Soap
Base Grease (TEXACO CODE 1912 OR EQUIVALENT)
whenever pump or pump drive coupling is removed. Coupling is greased prior to assembly.
– JLG Lift –
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SECTION 5 - HYDRAULICS
Charge Pump
NOTE: Disassemble charge pump to inspect and clean, or change
auxiliary shaft drive coupling.
1.
Remove auxiliary pump if necessary.
2.
Remove screws retaining charge pump cover to pump
housing (Torx T). Seven screws are used with “no pad” or
SAE “A” auxiliary mounting pad charge pump cover, and
six screws are used with SAE “B” auxiliary mounting pad
charge pump cover. Remove charge pump cover, gasket, and cover locating pins.
3.
Remove gerotor cover assembly from charge pump
cover or back of pump housing. Remove gerotor cover
O-rings. Two O-rings are used on gerotor cover of all
pumps.
4.
Remove gerotor assembly from gerotor cover or pump
housing.
5.
Remove gerotor drive pin and drive coupling. Remove
gerotor cover locating pin from pump housing.
6.
Inspect each part if they are to be reused. If either gerotor
assembly parts needs to be replaced, they must both be
replaced. Always replace O-rings and charge pump cover
gasket. Inspect journal bearing in gerotor cover for excessive wear.
7.
Lubricate gerotor assembly with clean hydraulic oil
before assembly.
8.
Install gerotor drive pin into hole in drive coupling.
Apply grease or petroleum jelly to keep in place.
9.
Install drive coupling on pump shaft with smaller outside diameter facing away from shaft.
10.
Install gerotor assembly onto coupling.
11.
Install gerotor cover locating pin into pump housing.
Install gerotor cover assembly over gerotor. Locating pin
must engage slot in gerotor cover.
NOTE: Charge pump rotation is determined by location of gerotor
recess and pressure balance hole in gerotor cover. Different
gerotor covers are used for clockwise and counterclockwise
rotation pumps.
1.
Cover Retaining Screw
6.
Gerotor Cover Locating Pin
2.
O-Ring
7.
Charge Pump Cover
Locating Pin
Install new pressure balance O-rings to gerotor cover
and retain with petroleum jelly or grease.
3.
Gerotor Cover
4.
Gerotor Assembly
8.
Gerotor Drive Pin
13.
Install charge pump cover locating pins and new charge
pump cover gasket.
5.
Drive Coupling
9.
Gasket
14.
Install charge pump cover. Cover must engage gerotor
cover and locating pins. Install charge pump cover
screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm).
15.
Reinstall auxiliary pump if necessary.
12.
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Figure 5-75. Charge Pump Components
5-45
SECTION 5 - HYDRAULICS
NOTE:
5.8 HYDRAULIC COMPONENT START-UP
The goal at hydrostatic system start up is to preserve the
designed life span of the system. Use the following start-up
procedure when a new pump or motor is installed or a system
is restarted after a pump or motor has been removed and reinstalled.
It may be easier to fill housing before installing the case drain
line. Component (especially motor) location may prevent case
drain port access after installation.
NOTE: Oil used to fill component housing must be clean. Store fill
container properly to prevent contamination.
Install 1000 psi (60 bar) pressure gauge in charge pressure
gauge port to monitor charge pressure during start-up.
THE FOLLOWING PROCEDURE MAY REQUIRE MACHINE TO BE DISABLED
(WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.)
WHILE PERFORMING PROCEDURE. TO PREVENT INJURY. TAKE NECESSARY
SAFETY PRECAUTIONS BEFORE MOVING VEHICLE/MACHINE.
Inspect pumps or motors for damage that may have been
incurred during shipping and handling before installation.
Make sure all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean before filling with fluid.
Fill reservoir with recommended hydraulic fluid. This fluid
should be passed through a 10 micron (nominal, no bypass)
filter before entering reservoir. Using contaminated fluid can
damage components and may cause unexpected vehicle/
machine movement.
INSPECT ALL PUMPS OR MOTORS FOR DAMAGE AND CONTAMINATION IF ANY
PUMP OR MOTOR IS REPLACED DUE TO INTERNAL DAMAGE. FLUSH AND
REPLACE ALL HYDRAULIC SYSTEM FLUID OR DAMAGE TO ENTIRE SYSTEM MAY
RESULT.
Inlet line from reservoir to pump must be filled prior to startup. Check inlet line for properly tightened fittings, restrictions,
and air leaks.
NOTE: Reservoir is usually above pump inlet. Pressure head created by higher oil level helps keep inlet pressures within
acceptable range and prevent high vacuum levels. However, air may be trapped due to hose routing or low reservoir locations. Bleed air by loosening hose at fitting closest
to pump. When oil begins to flow, line is full and air has
been purged. Tighten fitting to specified torque. If tank
needs to be pressurized to start oil flow, take a vacuum
reading at pump inlet during operation to verify pump is
not trying to draw an inlet vacuum higher than its capability.
Fill pump and motor housing with clean hydraulic fluid before
start up. Fill housing by pouring filtered oil in upper case drain
port.
NOTE:
5-46
Use highest possible case drain port. This ensures housing contains as much oil as possible and offers the greatest amount of
lubrication to internal components.
It is recommended external control input signal, (electrical
connections for EDC), be disconnected at pump control until
after initial start-up. This ensures pump remains in its neutral
position.
DO NOT START ENGINE UNLESS PUMP IS IN NEUTRAL POSITION (0° SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN
CASE PUMP IS ACTUATED DURING INITIAL START-UP.
”Jog” or slowly rotate engine until charge pressure starts to
rise. Start engine and run at lowest possible RPM until charge
pressure is established. Excess air should be bled from system
lines as close to motors as possible.
NOTE: With engine on low idle loosen, do not remove, system lines
at motor(s). Continue to run engine at low idle and tighten
system lines as soon as oil is observed to leak from them.
When oil is observed to ”leak” at motor, line is full and air is
purged. Tighten system hoses to specified torque.
Once charge pressure is 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 cause.
INADEQUATE CHARGE PRESSURE WILL AFFECT OPERATOR'S ABILITY TO CONTROL MACHINE.
Shut down engine and connect external control input signal.
Reconnect machine function(s), if disconnected earlier. Start
engine, checking pump remains in neutral. With engine at normal operating RPM, slowly check 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.
Machine is ready for operation.
– JLG Lift –
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SECTION 5 - HYDRAULICS
5.9 PRESSURE SETTING PROCEDURES
Platform Level Up
NOTE: Pressure is trapped at port M3 and must be released before
installing pressure gauge.
COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS.
JLG INDUSTRIES, INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE
HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES
PRIOR TO CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALIBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF
SPECIFIED PRESSURES.
Main Relief
1.
Install pressure gauge at quick disconnect on port MP
on main valve.
2.
With aid of an assistant, activate telescope in.
3.
While monitoring pressure gauge, adjust main relief to
3000 PSI (206.85 Bar). Turn adjuster clockwise to
increase pressure or counterclockwise to decrease pressure.
Install pressure gauge at quick disconnect in port MP on
main valve.
2.
With aid of an assistant, activate lift down.
3.
While monitoring pressure gauge, adjust lift down relief
to 1500 PSI (103 Bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
2.
Lock the turntable using the turntable lock.
3.
With the aid of an assistant, activate swing left or right
4.
While monitoring pressure gauge, adjust swing relief to
1700 PSI (117 Bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
3121607
With aid of an assistant, activate level up.
3.
While monitoring pressure gauge, adjust level up relief
to 2800 PSI (193 Bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
1.
Activate level up to end of stroke to release pressure.
Install pressure gauge at quick disconnect on port M4.
2.
With the aid of an assistant, activate level down.
3.
While monitoring pressure gauge, adjust the level up
relief to 1800 PSI (124 Bar). Turn the adjuster clockwise
to increase pressure or counterclockwise to decrease
pressure.
Jib Up
NOTE: Left and right swing pressures are set with one adjustment.
Install pressure gauge at quick disconnect on port MP
on main valve.
2.
NOTE: Pressure is trapped at port M4 and must be released before
installing pressure gauge.
Swing
1.
Activate level down to end of stroke to release pressure.
Install pressure gauge at quick disconnect on port M3
on main valve after releasing pressure.
Platform Level Down
Lift Down
1.
1.
1.
Install pressure gauge in M port on jib block.
2.
With aid of an assistant, activate jib up.
3.
While monitoring pressure gauge, adjust jib up relief to
1500 PSI (103 Bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
Jib Down
– JLG Lift –
1.
Install pressure gauge on the M port on jib block.
2.
With aid of an assistant, activate jib down.
3.
While monitoring pressure gauge, adjust jib down relief
to 1200 PSI (82 Bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
5-47
SECTION 5 - HYDRAULICS
*18-20 ft-lb in-lb (24.5-27 Nm)
**25-27 ft-lb (34-37 Nm)
***4-5 ft-lb (6.5-9.5 Nm)
60 in-lb (7 Nm)
16*
21*
17*
15*
20
19
18*
1***
12A
13*
12
3*
19A
11
2**
9*
7*
10
6*
5*
4A
8*
4
26*
1.
Solenoid Operated 2-Way valve
10.
Platform Rotate Directional Control Valve
19.
Upper Lift Directional Control Valve
2.
Pressure Control Load Sense Cartridge
3.
Main Relief Direct Operated Relief Valve
11.
Upper Telescope Directional Control Valve
20.
Swing Directional Control Valve
12.
Flow Control Directional Control Valve
21.
Direct Operated Relief Valve
4.
Platform Level Directional Control Valve
13.
Load Shuttle Valve
22.
Not Used
5.
Platform Level Check Valve
14.
Load Shuttle Valve
23.
Not Used
6.
Platform Level Check Valve
15.
Load Shuttle Valve
24.
Not Used
7.
Platform Level Relief Valve
16.
Load Shuttle Valve
25.
Not Used
8.
Direct Operated Relief Valve
17.
Load Shuttle Valve
26.
Directional Control Valve (Lower Lift)
9.
Pressure Compensated Flow Control (Fixed 0.2 GPM)
18.
Direct Operated Relief Valve
Figure 5-76. Location of Components - Main Control Valve
5-48
– JLG Lift –
3121607
SECTION 5 - HYDRAULICS
2**
1*
4*
3*
1..
Flow Control Cartridge
2.1.
*60 in-lb (7 Nm)
**18-20 ft-lb (25-27 Nm)
Directional Control Valve Assembly
3.
Relief Cartridge
4.
Relief Cartridge
Figure 5-77. Articulating Jib Valve
3121607
– JLG Lift –
5-49
SECTION 5 - HYDRAULICS
NOTES:
5-50
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
SECTION 6. JLG CONTROL SYSTEM
speed, and max.-speed for all boom, drive, and steering functions.
6.1 INTRODUCTION
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY
TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION,
INCLUDING OPTIONS.
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF
PRESSURE-WASHING IS USED 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) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND 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
Upper lift, swing, and drive are controlled by individual joysticks. Steering is controlled by a rocker switch built in the top
of the drive joystick. To activate Drive, Lift, and Swing; pull up
the slide lock on the joystick and move the handle in the
desired direction.
The control system provides 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 in 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 with a custom designed,
direct connect hand held analyzer or wireless adapter using an
app on your Android or iPhone/iPad device. The analyzer or
wireless output displays two lines of information at a time, by
scrolling through the program.
Each module has a label with JLG part number and a serial number
containing a date code.
!
"
#
$
%
#
!
!
"
#
Figure 6-1. Hand-Held Analyzer (WANALYZER Controls and Display Similar)
3121607
– JLG Lift –
6-1
SECTION 6 - JLG CONTROL SYSTEM
&"(
)*
#
!"
#
!"
$
-./0
$
#
%&
#'
+,
Figure 6-2. Controller Block Diagram
6-2
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Connect JLG Control System Analyzer
1.
Using Analyzer
Connect four pin end of cable supplied with hand-held
or wireless analyzer to controller module on platform
box or at controller module inside ground control box.
Connect other end of cable to analyzer.
NOTE: Cable has a keyed four pin connector at each end. It cannot
be connected backwards.
1.
Power up Control System by turning lower key to platform or ground position and pulling both emergency
stop buttons out.
Analyzer displays the following with machine power on and
analyzer connected properly:
Figure 6-3. Analyzer Platform Connector
MENU:
HELP:PRESS ENTER
Move between top level menu items using
RIGHT
and LEFT
arrow keys. To select a dis-
played menu item, press ENTER
. To cancel a selected
Figure 6-4. Analyzer Ground Control Box Connector
NOTE: Follow instructions provided with Wireless Analyzer (WANALYZER) kit. JLG Analyzer application must be downloaded
and installed to your smartphone or tablet device.
menu item press ESC
. Scroll using right and left arrow
keys to select a different menu item.
Top level menus:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
3121607
– JLG Lift –
6-3
SECTION 6 - JLG CONTROL SYSTEM
If ENTER
is selected at the HELP: PRESS ENTER display,
and a fault is present, the analyzer display scrolls the fault
across the screen. If no fault is detected, the display shows:
HELP: EVERYTHING OK. If powered up at the ground station,
the display shows: GROUND OK.
If ENTER
Pressing ENTER
with any of the above displayed menus,
displays 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
is pressed again, display shows the following:
menu item by pressing the ESCAPE
key.
Changing Access Level
When 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 access level, the correct password must be
entered. To enter password, scroll to ACCESS LEVEL menu. For
example:
LOGGED HELP
1: POWER CYCLE (0/0)
Analyzer displays last system fault if any are present. Use right
and left arrow keys to scroll through fault logs and view last 25
faults. Press ESC
two times to return to MENU screen.
POWER CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu items
may be offered: for example:
ACCESS LEVEL:
CODE 00000
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
6-4
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Adjust Parameters
Press ENTER
to select the ACCESS LEVEL menu.
Using the UP
or DOWN
digit of the password, 3.
Once you have gained access to level 1, and a personality item
arrow keys, enter first
is selected, press the UP
adjust its value, for example:
or DOWN
arrow keys to
Then using the RIGHT
arrow key, position cursor 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.
When correct password is displayed, press ENTER
. The
access level displays the following if password was entered
correctly:
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 at maximum value or decrease if the
DOWN
arrow is pressed at minimum value for any personality. If value does not change when pressing up and down
arrows, check access level is at access level 1.
MENU:
ACCESS LEVEL 1
Repeat above steps if correct access level is not displayed or
you can not adjust personality settings.
3121607
– JLG Lift –
6-5
SECTION 6 - JLG CONTROL SYSTEM
There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
Machine Setup
When a machine digit item is selected, press UP
DOWN
ELEVATION CUTBACK
or
arrow keys to adjust its value, for example:
CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFORMANCE OF YOUR MACHINE.
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF
PRESSURE-WASHING IS USED 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) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME
PERIODS TO AVOID HEAVY SATURATION.
Level Vehicle Description
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults for the recommended
factory settings.
NOTE: Password 33271 allows access to level 1 to change
machine personality settings.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2. ENTER
cle is current.
6-6
– JLG Lift –
confirms vehi-
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-1. Analyzer Abbreviations
Table 6-1. Analyzer Abbreviations
ABBREVIATION
ACCEL
ACT
A/D
AMB.
ANG
AUX
BCS
BM
BLAM
BR
BSK
CAL
CL
CM
CNTL
CNTRL
C/O
CONT(S)
COOR
CRK PT
CRP
CUT
CYL
DECEL
D
DN
DWN
DEG.
DOS
DRV
E
E&T
ELEV
ENG
EXT
F
FL
FNT
FOR
FWD
FSW
FUNC
G
GND
GRN
GM
H
HW
HWFS
I
JOY
L
LB
3121607
MEANING
ACCELERATE
ACTIVE
ANALOG DIGITAL CONVERTER COUNT
AMBIENT
ANGLE
AUXILIARY
BOOM CONTROL SYSTEM
BOOM LENGTH ANGLE MODULE
BOOM LENGTH ANGLE MODULE
BROKEN
BASKET
CALIBRATION
CLOSED
CHASSIS MODULE
CONTROL
CONTROL
CUT OUT
CONTRACTOR(S)
COORDINATED
CRACK POINT
CREEP
CUTOUT
CYLINDER
DECELERATE
DOWN
DOWN
DOWN
DEGREE
DRIVE ORIENTATION SYSTEM
DRIVE
ERROR
ELEVATED & TILTED
ELEVATION
ENGINE
EXTEND
FRONT
FLOW
FRONT
FORWARD
FORWARD
FOOT SWITCH
FUNCTION
GROUND
GROUND
GREEN
GROUND MODULE
HOURS
HARDWARE
HARDWARE FAILSAFE
IN or CURRENT
JOYSTICK
LEFT
POUND
– JLG Lift –
ABBREVIATION
LEN
LIM
LT
LVL
M
MIN
MAX
M
MN
NO
NC
O
O/C
OP
O/R
O//R
OSC
OVRD
P
P
PCV
PLAT
PLT
PM
POT
PRES
PRS
PT
R
REV
RET
ROT.
RT
S/C
SEL
SN
SPD
STOW
STOWD
SW
TELE
TEMP
TORQ.
TRN
T/T
T
TURNTBL
TWR
U
V
VER
VLV
WIT
YEL
MEANING
LENGTH
LIMIT
LEFT
LEVEL
MINUTES
MINIMUM
MAXIMUM
MAIN
MAIN
NORMALLY OPEN or NO
NORMALLY CLOSED
OUT
OPEN CIRCUIT
OPEN
OVERRIDE or OUTRIGGER
OVERRIDE
OSCILLATING
OVERRIDE
PLATFORM
PRESSURE
PROPORTIONAL CONTROL VALVE
PLATFORM
PLATFORM
PLATFORM MODULE
POTENTIOMETER
PRESSURE
PRESSURE
POINT
REAR or RIGHT
REVERSE or REVISION
RETRACT
ROTATE
RIGHT
SHORT CIRCUIT
SELECTOR
SERIAL NUMBER
SPEED
STOWED
STOWED
SWITCH or SOFTWARE
TELESCOPE
TEMPERATURE
TORQUE
TRANSPORT
TURNTABLE
TOWER
TURNTABLE
TOWER
UPPER or UP
VOLT
VERSION
VALVE
WITNESS
YELLOW
6-7
SECTION 6 - JLG CONTROL SYSTEM
MENU:
HELP:PRESS ENTER
HELP:
(001)
EVERYTHING OK
LOG:(xxx)
x:xxxxxxxxxxx
MENU:
DIAGNOSTICS
TO
MENU:
SYSTEM TEST
DIAGNOSTICS:
DRIVE/STEER
DIAGNOSTICS:
BOOM FUNCTIONS
JOYSTICK DRIVE:
FORWARD XXX%
JOYSTICK LIFT:
MAIN UP XXX%
JOYSTICK STEER:
LEFT XXX%
LIFT OUTPUT:
MAIN UP XXX%
DRIVE OUTPUT:
FORWARD XXX%
LIFT UP
COMMANDED:XXXXMA
TO
DIAGNOSTICS:
ENGINE
DRIVE FORWARD:
COMMANDED:XXXXMA
BRAKES STATUS:
LOCKED
LIFT DOWN
COMMANDED:XXXXMA
DRIVE REVERSE:
COMMANDED:XXXXMA
CREEP:
SWITCH: CLOSED
LIFT OUTPUT
ACTUAL:XXXXMA
DRIVE OUTPUT:
ACTUAL: XXXXMA
CREEP MODE:
OFF
JOYSTICK SWING:
LEFT XXX%
STEER OUTPUT:
LEFT XXX%
2-SPEED:
SWITCH: OPEN
SWING OUTPUT:
LEFT XXX%
LEFT TRACK
OUTPUT: FWD XXX%
2-SPEED VALVE
OUTPUT: OFF
SWING LEFT
COMMANDED:XXXXMA
STEER TYPE:
NORMAL
HIGH ENGINE
SWITCH: OPEN
SWING RIGHT
COMMANDED:XXXXMA
RIGHT TRACK
ACTUAL: XXXXMA
DRIVE MODE:
MID ENGINE
SWING OUTPUT
ACTUAL:XXXXMA
LEFT TRACK FWD
COMMANDED:XXXXMA
DRV. ORIENTATION
FEATURE:DISABLED
PLATFORM LEVEL:
UP XXX%
FLOW VALVE
COMMANDED:XXXXMA
LEFT TRACK REV
COMMANDED:XXXXMA
DRV. ORIENTATION
SWITCH: OPEN
PLATFORM ROTATE:
LEFT XXX%
FLOW VALVE
ACTUAL:XXXXMA
LEFT TRACK
ACTUAL: XXXXMA
DRV. ORIENTATION
OVERRIDE: OPEN
MAIN TELESCOPE:
IN XXX%
PLATFORM CONTROL
VALVE: OFF
RIGHT TRACK
OUTPUT: FWD XXX%
DRV. ORIENTATION
STATUS:CONFIRMED
TOWER TELESCOPE:
IN XXX%
FUNCTION SPEED:
PUMP POT XXX%
RIGHT TRACK FWD
COMMANDED:XXXXMA
DRIVE CONTROL:
NORMAL
TOWER LIFT:
UP XXX%
CREEP
SWITCH: CLOSED
RIGHT TRACK REV
COMMANDED:XXXXMA
CRIBBING MODE:
DISABLED
JIB LIFT:
UP XXX%
CREEP MODE:
OFF
Figure 6-5. Analyzer Software Version 6.8 - Sheet 1 of 6
6-8
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
From
DIAGNOSTICS:
BOOM FUNCTIONS
DIAGNOSTICS:
ENGINE
DIAGNOSTICS:
SYSTEM
DIAGNOSTICS:
UMS
START SEQUENCE:
NOT ACTIVE
GROUND MODULE:
BATTERY: XX.XV
CHASSIS TILT
ANGLE: XX.X
BATTERY VOLTAGE:
XX.XV
PLATFORM MODULE:
BATTERY: XX.XV
UMS TO TURNTABLE
ANGLE: XX.X
COOLANT
TEMPERATURE:XXXF
AMBIENT
TEMPERATURE:XXXF
UMS INCLINATION
ANGLE: XX.X
ELECTRIC FAN
OUTPUT: OFF
PLATFORM SELECT
KEYSWITCH: OPEN
CHASSIS TILT
X-AXIS: XX.X
ELECTRIC FUEL
PUMP OUTPUT: OFF
GROUND SELECT
KEYSWITCH: OPEN
CHASSIS TILT
Y-AXIS: XX.X
ENGINE OIL
PRESSURE:XXX PSI
STATION CONTROL:
GROUND
AUXILIARY POWER
SWITCH: OPEN
FUEL SELECTION
SWITCH: GAS
FOOTSWITCH INPUT
GROUND: OPEN
HORN
SWITCH: OPEN
FUEL SELECTION
STATUS: GAS
FOOTSWITCH INPUT
PLATFORM: OPEN
RETURN HYDRAULIC
FILTER: OPEN
AMBIENT
TEMPERATURE:XXXF
TRANSPORT
SWITCHES: OPEN
CHARGE PUMP
FILTER: OPEN
FUEL LEVEL
SENSOR: OK
TRANSPORT MODE:
OUT OF TRANSPORT
SOFT TOUCH LIMIT
SWITCH: OPEN
STARTER
CRANK TIME: XX S
END OF STROKE
PROXIMITY:CLOSED
STOUCH OR SKYGRD
RELAYS: OPEN
ENGINE SPEED
ACTUAL: XXXX RPM
TOWER LIFT
PROXIMITY:CLOSED
ST/SG OVERRIDE
OVERRIDE: OPEN
ENGINE SPEED
TARGET: XXXX RPM
TOWER TELESCOPE
PROXIMITY:CLOSED
GENSET.WELDER
SWITCH: OPEN
TOWER POSITION:
RETRACTED
LIGHTS
SWITCH: OPEN
CABLE BREAK
SWITCH: CLOSED
PLATFORM TILT1
ANGLE: XX.X
CREEP
SWITCH: CLOSED
PLATFORM TILT2
ANGLE: XX.X
CREEP MODE:
OFF
PLATFORM TILT1
VOLTAGE: XX MV
CHASSIS TILT:
XX.X DEGREES
PLATFORM TILT2
VOLTAGE: XX MV
TO
DIAGNOSTICS:
LOAD
UMS STATUS:
NORMAL
Figure 6-6. Analyzer Software Version 6.8 - Sheet 2 of 6
3121607
– JLG Lift –
6-9
SECTION 6 - JLG CONTROL SYSTEM
FROM
DIAGNOSTICS:
UMS
DIAGNOSTICS:
LOAD
DIAGNOSTICS:
CAN STATISTICS
DIAGNOSTICS:
1
CALIBRATION DATA
DIAGNOSTICS:
DATALOG
DIAGNOSTICS:
VERSIONS
CAPACITY LENGTH
SWITCH: CLOSED
CAN STATISTICS
RX/SEC: X
CALIBRATION DATA 1
LOAD ZERO:
DATALOG:
ON: XXXh XXm
GROUND MODULE
SOFTWARE: XX.XX
CAPACITY ANGLE
SWITCH: CLOSED
CAN STATISTICS
TX/SEC: X
CALIBRATION DATA 1
LOAD 500LB:
DATALOG:
ENGINE: XXXh XXm
GROUND MODULE
COST. DATA:XX.XX
PERCENT OF MAX
LOAD: XXX%
CAN STATISTICS
BUS OFF: X
CALIBRATION DATA 1
PLATFORM UP:
DATALOG:
DRIVE: XXXh XXm
GROUND MODULE
HARDWARE: REV XX
PLATFORM LOAD
STATE: OK
CAN STATISTICS
PASSIVE: X
CALIBRATION DATA 1
1
PLATFORM DN:
DATALOG:
LIFT: XXXh XXm
GROUND MODULE
S/N: XXXXXX
DATALOG:
SWING: XXXh XXm
PLATFORM MODULE
SOFTWARE: XX.XX
DATALOG:
TELE: XXXh XXm
PLATFORM MODULE
HARDWARE: REV XX
DATALOG:
MAX TEMP: XXXF
PLATFORM MODULE
S/N: XXXXXX
DATALOG:
MIN TEMP: XXXF
PROPULSION MOD
SOFTWARE: XX.XX
DATALOG:
MAX VOLTS: XX.XV
TCU MODULE
SOFTWARE: XX.XX
DATALOG:
RENTAL: XXXh XXm
TCU MODULE
HARDWARE: REV XX
CAN STATISTICS
MSG ERROR: XXXX
CLEAR RENTAL:
1
YES:ENTER,NO:ESC
DATALOG:
ERASE RENTAL?
1
TCU MODULE
S/N: XXXXXX
GATEWAY MODULE
SOFTWARE: XX.XX
GATEWAY MODULE
HARDWARE: REV XX
ANALYZER:
ANALYZER XX.XX
Figure 6-7. Analyzer Software Version 6.8 - Sheet 3 of 6
6-10
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
FROM
MENU:
DIAGNOSTICS
MENU:
SYSTEM TEST
SYSTEM TEST:
ACTIVATE?
MENU:
ACCESS LEVEL
ACCESS LEVEL:
CODE XXXXXX
MENU:
PERSONALITIES
PERSONALITIES:
DRIVE
PERSONALITIES:
STEER
PERSONALITIES:
LEFT TRACK
PERSONALITIES:
RIGHT TRACK
DRIVE:
ACCEL X.XS
STEER:
MAX SPEED XXX%
LEFT TRACK:
ACCEL X.XS
RIGHT TRACK:
ACCEL X.XS
DRIVE:
DECEL X.XS
LEFT TRACK:
DECEL X.XS
RIGHT TRACK:
DECEL X.XS
DRIVE:
MIN FORWARD XXX%
LEFT TRACK:
MIN FORWARD XXX%
RIGHT TRACK:
MIN FORWARD XXX%
DRIVE:
MAX FORWARD XXX%
LEFT TRACK:
MAX FORWARD XXX%
RIGHT TRACK:
MAX FORWARD XXX%
DRIVE:
MIN REVERSE XXX%
LEFT TRACK:
MIN REVERSE XXX%
RIGHT TRACK:
MIN REVERSE XXX%
DRIVE:
MAX REVERSE XXX%
LEFT TRACK:
MAX REVERSE XXX%
RIGHT TRACK:
MAX REVERSE XXX%
DRIVE:
ELEV. MAX XXX%
LEFT TRACK:
ELEV F MAX XXX%
RIGHT TRACK:
ELEV F MAX XXX%
DRIVE:
CREEP MAX XXX%
LEFT TRACK:
ELEV R MAX XXX%
RIGHT TRACK:
ELEV R MAX XXX%
LEFT TRACK:
CREEP F MAX XXX%
RIGHT TRACK:
CREEP F MAX XXX%
LEFT TRACK:
CREEP R MAX XXX%
RIGHT TRACK:
CREEP R MAX XXX%
TO
MENU:
MACHINE SETUP
TO
PERSONALITIES:
MAIN LIFT
TRACK COUNTER
ROTATE MAX XXX%
Figure 6-8. Analyzer Software Version 6.8 - Sheet 4 of 6
3121607
– JLG Lift –
6-11
SECTION 6 - JLG CONTROL SYSTEM
FROM
PERSONALITIES:
RIGHT TRACK
PERSONALITIES:
MAIN LIFT
PERSONALITIES:
SWING
PERSONALITIES:
TOWER LIFT
PERSONALITIES:
MAIN TELESCOPE
PERSONALITIES:
TOWER TELESCOPE
MAIN LIFT:
ACCEL X.XS
SWING:
ACCEL X.XS
TOWER LIFT:
ACCEL X.XS
MAIN TELESCOPE:
ACCEL X.XS
TOWER TELESCOPE:
ACCEL X.XS
MAIN LIFT:
DECEL X.XS
SWING:
DECEL X.XS
TOWER LIFT:
DECEL X.XS
MAIN TELESCOPE:
DECEL X.XS
TOWER TELESCOPE:
DECEL X.XS
MAIN LIFT:
MIN UP XXX%
SWING:
MIN LEFT XXX%
TOWER LIFT:
MIN UP XXX%
MAIN TELESCOPE:
MIN IN XXX%
TOWER TELESCOPE:
MIN IN XXX%
MAIN LIFT:
MAX UP XXX%
SWING:
MAX LEFT XXX%
TOWER LIFT:
MAX UP XXX%
MAIN TELESCOPE:
MAX IN XXX%
TOWER TELESCOPE:
MAX IN XXX%
MAIN LIFT:
CREEP UP XXX%
SWING:
CREEP LEFT XXX%
TOWER LIFT:
MIN DOWN XXX%
MAIN TELESCOPE:
MIN OUT XXX%
TOWER TELESCOPE:
MIN OUT XXX%
MAIN LIFT:
MIN DOWN XXX%
SWING:
MIN RIGHT XXX%
TOWER LIFT:
MAX DOWN XXX%
MAIN TELESCOPE:
MAX OUT XXX%
TOWER TELESCOPE:
MAX OUT XXX%
MAIN LIFT:
MAX DOWN XXX%
SWING:
MAX RIGHT XXX%
MAIN LIFT:
CREEP DOWN XXX%
SWING:
CREEP RIGHT XXX%
PERSONALITIES:
PLATFORM LEVEL
PERSONALITIES:
PLATFORM ROTATE
PERSONALITIES:
JIB LIFT
PERSONALITIES:
GROUND MODE
PERSONALITIES:
GEN SET/WELDER
PLATFORM LEVEL:
ACCEL X.XS
PLATFORM ROTATE:
ACCEL X.XS
JIB LIFT:
ACCEL X.XS
GROUND MODE:
MAIN UP: XXX%
GEN SET/WELDER:
ENGINE XXXX RPM
PLATFORM LEVEL:
DECEL X.XS
PLATFORM ROTATE:
DECEL X.XS
JIB LIFT:
DECEL X.XS
GROUND MODE:
MAIN DOWN: XXX%
PLATFORM LEVEL:
MIN IN XXX%
PLATFORM ROTATE:
MIN LEFT XXX%
JIB LIFT:
MIN UP XXX%
GROUND MODE:
SWING: XXX%
PLATFORM LEVEL:
MAX IN XXX%
PLATFORM ROTATE:
MAX LEFT XXX%
JIB LIFT:
MAX UP XXX%
GROUND MODE:
PLT LEVEL: XXX%
PLATFORM LEVEL:
MIN OUT XXX%
PLATFORM ROTATE:
MIN RIGHT XXX%
JIB LIFT:
MIN DOWN XXX%
GROUND MODE:
PLT ROTATE: XXX%
PLATFORM LEVEL:
MAX OUT XXX%
PLATFORM ROTATE:
MAX RIGHT XXX%
JIB LIFT:
MAX DOWN XXX%
GROUND MODE:
MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB LIFT: XXX%
GROUND MODE:
JIB SWING: XXX%
Figure 6-9. Analyzer Software Version 6.8 - Sheet 5 of 6
6-12
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
FROM
MENU:
PERSONALITIES
MENU:
MACHINE SETUP
MENU:
CALIBRATIONS
1
MODEL NUMBER:
600S
MARKET:
CE
ENGINE:
PERKINS ECM
FLYWHEEL TEETH:
133 TEETH
GLOW PLUG:
IN-CYLINDER
STARTER LOCKOUT:
DISABLED
ENGINE SHUTDOWN:
ENABLED
TILT:
5 DEGREES
JIB:
NO
4 WHEEL STEER:
NO
STOUCH/SKYGUARD:
NO
GEN SET/WELDER:
NO
GEN SET CUTOUT:
MOTION ENABLED
H & T LIGHTS:
NO
CABLE SWITCH:
NO
LOAD SYSTEM:
NO
LOAD SENSOR:
4 UNDER PLATFORM
FUNCTION CUTOUT:
NO
GROUND ALARM:
MOTION
DRIVE:
4WD
TEMPERATURE:
FAHRENHEIT
LEVELING MODE:
ALL FUNCTIONS
DRIVE CONTROL:
ENHANCED
BOOM CONTROL:
NORMAL
CLEARSKY:
NO
CRIBBING OPTION:
NO
FUEL TANK SIZE:
31 GALLON
ALARM / HORN:
SEPARATE
CALIBRATIONS:
TILT SENSOR
1
CALIBRATIONS:
UMS SENSOR
1
CALIBRATIONS:
FORD ENGINE
1
CALIBRATIONS:
LOAD SENSOR
1
CALIBRATIONS:
DEUTZ SETUP
1
TILT SENSOR:
CALIBRATE?
1
UMS SENSOR:
CALIBRATE?
1
FORD ENGINE:
DISABLE RS-485?
1
LOAD SENSOR:
CALIBRATE?
1
DEUTZ SETUP
SETUP X
1
UMS SENSOR:
RAW: XX.X
1
CALIBRATIONS:
LEVEL UP CRKPT
1
1
CALIBRATIONS:
LEVEL DOWN CRKPT
CALIBRATIONS:
PROP MODULE
1
PROP MODULE:
J1-7 MIN: XXX
1
PROP MODULE:
J1-7 MAX: XXX
1
1
PROP MODULE:
DEADBAND: XXXXX
PROP MODULE:
J1-8 MIN: XXX
1
PROP MODULE:
FF NUM: XXXXX
1
PROP MODULE:
J1-8 MAX: XXX
1
PROP MODULE:
FF DEN: XXXXX
1
PROP MODULE:
J1-9 MIN: XXX
1
PROP MODULE:
I NUM: XXXXX
1
PROP MODULE:
J1-9 MAX: XXX
1
PROP MODULE:
I DEN: XXXXX
1
PROP MODULE:
J1-10 MIN: XXX
1
PROP MODULE:
NEG ERR: XXXXX
1
PROP MODULE:
J1-10 MAX: XXX
1
PROP MODULE:
GAIN FLAG: XXXXX
1
CALIBRATIONS:
PLAT. LEVELING
1
Figure 6-10. Analyzer Software Version 6.8 - Sheet 6 of 6
3121607
– JLG Lift –
6-13
SECTION 6 - JLG CONTROL SYSTEM
NOTE: Personality settings can be adjusted within the adjustment
range for optimum machine performance.
6.2 MACHINE PERSONALITY SETTINGS
Table 6-2. 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
0.7
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
6-14
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-2. 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
3121607
– JLG Lift –
6-15
SECTION 6 - JLG CONTROL SYSTEM
Table 6-2. 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 for optimum machine performance.
4150365B
6-16
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
None
Priority
No flash code is indicated for the following help messages. They are intended to
hint at a possible problem if 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 creep switch is open.
RUNNING AT CREEP – TILTED
AND ABOVE ELEVATION
All boom function speeds are limited to creep because vehicle is tilted and
above elevation.
RUNNING AT CUTBACK – ABOVE
ELEVATION
Drive speed is limited to “ELEVATED MAX” because 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 platform 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.
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
3121607
Description
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.
STEER LOCKED – SELECTED
BEFORE FOOTSWITCH
Steer was selected before and during footswitch closure.
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 Q-Prox
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.
– JLG Lift –
2
3
6-17
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
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
Flash code 2/3 indicates problems with boom function selection.
Priority
3
LIFT/SWING LOCKED – JOYSTICK Platform upper lift or swing was selected before and during footswitch closure.
MOVED BEFORE FOOTSWITCH
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 –
A platform boom function (lower lift, telescope, basket level, basket rotate, jib)
SELECTED BEFORE FOOTSWITCH was selected before key switch or footswitch closure.
6-18
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 the Q-Prox 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 voltage is less
than centertap voltage minus half the center tap voltage minus 0.3 volts. If centertap is at high end of the range, these faults will be triggered below 1.05 volts.
If centertap is at 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 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 voltage is more
than centertap voltage plus half the centertap voltage plus 0.3 volts. If centertap is at high end of the range, these faults will be triggered above 4.35 volts. If
centertap is at low end of the range, these faults will be triggered above 3.8
volts.
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. 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 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 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 start switch is
closed.
Priority
FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/4
Flash code 2/4 indicates steering digital inputs are faulty.
NOT REQUIRED
2/5
Flash code 2/5 indicates 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
ELEVATION
Drive is selected while above elevation and drive cutout is configured to 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.
MODEL CHANGED – HYDRAULICS SUSPENDED – CYCLE EMS
User changed model number using the analyzer. User must cycle power before
hydraulics system will be active again.
2/7
Flash code 2/7 indicates 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
4
11
5
Hydraulic return filter clogged
CHARGE PUMP FILTER BYPASSED Charge pump filter clogged
3/1
Flash code 3/1 indicates a contactor did not close when energized.
NOT REQUIRED
3/2
Flash code 3/2 indicates 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 analog feedback reads too
high and the output is commanded off. Short to ground is detected when analog feedback reads low and the output is commanded on. Short to battery is
detected when analog feedback reads Vbat and the output is commanded off.
Not reported during 2 second power-up.
6
ALTERNATOR/ECM POWER
SHORT TO GROUND
HOUR METER SHORT TO
GROUND
HOUR METER SHORT TO
BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT
3121607
– JLG Lift –
6-19
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
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
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
6-20
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
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 Only occurs on machines with electronic leveling systems.
GROUND
BASKET UP OVERRIDE OPEN
CIRCUIT
Only occurs on machines with electronic leveling systems.
BASKET UP OVERRIDE SHORT TO Only occurs on machines with electronic leveling systems.
BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO
BATTERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN
CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN OVERRIDE
SHORT TO GROUND
Only occurs on machines with electronic leveling systems.
BASKET DOWN OVERRIDE OPEN Only occurs on machines with electronic leveling systems.
CIRCUIT
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
3121607
– JLG Lift –
6-21
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
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
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
6-22
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
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.
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.
3/4
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 analog feedback reads too high and the output is commanded off. Short
to ground is detected when analog feedback reads low and the output is commanded on. Short to battery is detected when 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
3121607
– JLG Lift –
6-23
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description
Priority
JIB DOWN SHORT TO
BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
6-24
PLATFORM CONTROL VALVE
SHORT TO BATTERY
Only occurs on machines with electronic basket leveling
PLATFORM CONTROL VALVE
SHORT TO GROUND
Only occurs on machines with electronic basket leveling
PLATFORM CONTROL VALVE
OPEN CIRCUIT
Only occurs on machines with electronic basket leveling
3/5
Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED
4/2
Flash code 4/2 indicates 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.
HIGH ENGINE TEMP
Occurs when engine temperature is above 117° Celsius for Ford engines, and
above 130° Celsius for Deutz engines.
AIR FILTER BYPASSED
Air filter clogged
NO ALTERNATOR OUTPUT
Engine has been running for 15 seconds or more and battery voltage is still
below 12.5 volts.
LOW OIL PRESSURE
If a Deutz engine is installed, 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 oil pressure sensor is reading above
6.6 volts.
OIL PRESSURE SHORT TO
GROUND
If a Deutz engine is installed, this indicates 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 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 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 fuel sensor is reading above 4.3 volts.
– JLG Lift –
9
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
FUEL SENSOR SHORT TO
GROUND
4/4
Description
Indicates fuel sensor is reading below 0.2 volts.
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 – 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:
Priority
7
8
10
Ground module or platform module is not receiving CAN messages. This is
probably due to wiring problems between the platform and ground modules.
7/7
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
GROUND MODULE FAILURE:
HWFS CODE 1
Ground module V(Low) FET has failed
GROUND SENSOR REF
VOLTAGE OUT OF RANGE
These faults occur when the seven volt reference voltage used for 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.
11
CHASSIS TILT SENSOR NOT GAIN Indicates that chassis tilt sensor calibration information has been lost. Machine
CALIBRATED
will indicate it is tilted at all times. This calibration data is programmed into the
unit at the factory.
CHASSIS TILT SENSOR GAIN OUT Indicates chassis tilt sensor calibration is corrupted.
OF RANGE
3121607
– JLG Lift –
6-25
SECTION 6 - JLG CONTROL SYSTEM
Table 6-4. Help Message/Fault Listing
HELP MESSAGE
FAULT
OK
DRIVING AT CREEP - TILTED
FSW OPEN
RUNNING AT CREEP - CREEP SWITCH OPEN
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
RUNNING AT CUTBACK - ABOVE ELEVATION
TILT SENSOR OUT OF RANGE
LOAD SENSOR READING UNDER WEIGHT
FSW FAULTY
KEYSWITCH FAULTY
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
FSW INTERLOCK TRIPPED
STEER LOCKED - SELECTED BEFORE FOOTSWITCH
STEER SWITCHES FAULTY
D/S JOY. QPROX BAD
L/S JOY. QPROX BAD
D/S JOY. OUT OF RANGE LOW
D/S JOY. OUT OF RANGE HIGH
L/S JOY. OUT OF RANGE LOW
L/S JOY. OUT OF RANGE HIGH
D/S JOY. CENTER TAP BAD
L/S JOY. CENTER TAP BAD
WAITING FOR FSW TO BE OPEN
PUMP POT FAULTY
PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH
PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH
FOOTSWITCH SELECTED BEFORE START
BOOM PREVENTED - DRIVE SELECTED
DRIVE PREVENTED - ABOVE ELEVATION
DRIVE PREVENTED - TILTED & ABOVE ELEVATION
DRIVE PREVENTED - BOOM SELECTED
FORD ECM POWER SHORT TO GROUND
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
6-26
0
0
0
0
0
0
0
0
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
– JLG Lift –
0
0
0
0
0
0
0
0
1
1
2
2
2
2
2
3
2
2
3
3
2
3
2
3
3
3
3
3
5
5
5
5
3
3
3
3
3
3
3
3
3
3
3
3
3
FAULT REMOVAL
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-4. Help Message/Fault Listing
HELP MESSAGE
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
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO BATTERY
TWO SPEED SHORT TO GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO BATTERY
ALARM SHORT TO GROUND
ALARM OPEN CIRCUIT
ALARM SHORT TO BATTERY
GENERATOR SHORT TO GROUND
GENERATOR OPEN CIRCUIT
GENERATOR SHORT TO BATTERY
HEAD TAIL LIGHT SHORT TO GROUND
HEAD TAIL LIGHT OPEN CIRCUIT
HEAD TAIL LIGHT SHORT TO BATTERY
HOUR METER SHORT TO GROUND
HOUR METER SHORT TO BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY
BASKET DOWN SHORT TO GROUND
BASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET LEFT SHORT TO GROUND
BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO BATTERY
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
3121607
FAULT
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
– JLG Lift –
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
FAULT REMOVAL
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
6-27
SECTION 6 - JLG CONTROL SYSTEM
Table 6-4. Help Message/Fault Listing
HELP MESSAGE
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
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
FUEL SENSOR SHORT TO BATTERY
FUEL SENSOR SHORT TO GROUND
OIL PRESSURE SHORT TO BATTERY
OIL PRESSURE SHORT TO GROUND
COOLANT TEMPERATURE SHORT TO GROUND
FORD FAULT CODE 12
FORD FAULT CODE 13
FORD FAULT CODE 14
FORD FAULT CODE 15
FORD FAULT CODE 21
FORD FAULT CODE 22
FORD FAULT CODE 23
FORD FAULT CODE 24
FORD FAULT CODE 25
FORD FAULT CODE 26
FORD FAULT CODE 31
FORD FAULT CODE 32
FORD FAULT CODE 33
FORD FAULT CODE 34
FORD FAULT CODE 35
FORD FAULT CODE 36
6-28
FAULT
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
– JLG Lift –
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
FAULT REMOVAL
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-4. Help Message/Fault Listing
HELP MESSAGE
FORD FAULT CODE 41
FORD FAULT CODE 42
FORD FAULT CODE 43
FORD FAULT CODE 44
FORD FAULT CODE 45
FORD FAULT CODE 46
FORD FAULT CODE 51
FORD FAULT CODE 52
FORD FAULT CODE 53
FORD FAULT CODE 54
FORD FAULT CODE 55
FORD FAULT CODE 56
FORD FAULT CODE 57
FORD FAULT CODE 61
FORD FAULT CODE 62
FORD FAULT CODE 63
FORD FAULT CODE 64
FORD FAULT CODE UNKNOWN
RETURN FILTER BYPASSED
CHARGE PUMP FILTER BYPASSED
BATTERY LOW
BATTERY TOO HIGH - SYSTEM SHUT DOWN
BATTERY TOO LOW - SYSTEM SHUT DOWN
SPEED SENSOR READING INVALID SPEED
SPEED INPUT LOST
ENGINE TEMP HIGH
AIR FILTER BYPASSED
NO ALTERNATOR OUTPUT
OIL PRESSURE LOW
485 COMMUNICATIONS LOST
CAN BUS FAILURE
LOAD SENSOR NOT CALIBRATED
TILT SENSOR NOT CALIBRATED
EEPROM FAILURE - CHECK ALL SETTINGS
PLATFORM MODULE FAILURE: HWFS CODE 1
GROUND MODULE FAILURE: HWFS CODE 1
3121607
FAULT
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
2
2
4
4
4
5
5
4
4
4
4
4
6
9
9
9
9
9
– JLG Lift –
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
8
8
4
4
4
5
5
3
3
3
3
3
6
9
9
9
9
9
FAULT REMOVAL
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT
CLEARS WHEN FAULT IS REMOVED
CLEARS WHEN FAULT IS REMOVED
6-29
SECTION 6 - JLG CONTROL SYSTEM
Table 6-5. Machine Configuration Programming Information
Configuration Digit
Number
Description
Default
Number
NOTE: Machine configuration must be completed before any personality settings can be changed. Changing personality settings first and then changing the model number of the machine configuration will cause personality settings to return to
default
MODEL NUMBER:
1
6
600SC
1
MARKET:
2
0
1
2
3
4
5
ANSI USA
ANSI EXPORT
CSA
CE
AUSTRALIA
JAPAN
0
ENGINE:
3
12
16
DEUTZ ECM: Deutz Engine Control Module (Tier 2 and 3)
DEUTZ ECM T4F: Deutz Engine Control Module (Tier 4 Final)
14
GLOW PLUG:
5
0
1
2
NO GLOW PLUGS: No glow plugs installed.
AIR INTAKE: Glow plugs installed in the air intake on the manifold.
IN-CYLINDER: Glow plugs installed in each cylinder.
2
STARTER LOCKOUT:
6
0
DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
0
1
ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished.
0
RESTART: Engine allowed to be restarted multiple times when very low
fuel level is reached.
1
ONE RESTART: Engine allowed to be restarted once for 2 minutes when very
low fuel level is reached.
2
ENGINE STOP: Engine not able to restart when very low fuel level is reached.
FUEL CUTOUT:
7
0
*This menu item is only visible if non dual fuel engines are selected.
ENGINE SHUTDOWN:
8
6-30
0
DISABLED: No engine shutdown.
1
ENABLED: Shutdown engine when coolant temperature is greater than
110°C or oil pressure is less than 8 PSI.
– JLG Lift –
1
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-5. Machine Configuration Programming Information
Configuration Digit
TILT:
9
Number
Description
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
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:
10
0
1
NO: No Jib installed.
YES: Jib installed which has up and down movements only.
0
STOUCH/SKYGUARD:
0
1
2
3
NO: No soft touch or SkyGuard system installed.
SOFT TOUCH: Soft touch only installed.
SKYGUARD: SkyGuard only installed.
BOTH (CUTOUT) - Soft touch and SkyGuard installed.
0
GEN SET/WELDER:
13
0
1
NO: No generator installed.
BELT DRIVE: Belt driven setup
0
GEN SET CUTOUT:
14*
0
1
MOTION ENABLED: Motion enabled when generator is ON.
MOTION CUTOUT: Motion cutout in platform mode only.
0
12
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS:
15
3121607
0
1
NO: No head and tail lights installed.
YES: Head and tail lights installed.
– JLG Lift –
0
6-31
SECTION 6 - JLG CONTROL SYSTEM
Table 6-5. Machine Configuration Programming Information
Configuration Digit
CABLE SWITCH:
16*
Number
0
1
Description
NO: No broken cable switch installed.
YES: Broken cable switch installed.
Default
Number
0
* Certain market selections will alter default setting.
LOAD SYSTEM:
17*
0
NO: No load sensor installed.
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
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
LOAD SENSOR:
18*
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.
1
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
FUNCTION CUTOUT:
19*
0
1
2
3
NO: No drive cutout.
BOOM CUTOUT: Boom function cutout while driving above elevation.
DRIVE CUTOUT: Drive cutout above elevation.
DRIVE CUT E&T: Drive cutout above elevation and tilted.
0
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
GROUND ALARM:
20*
0
1
2
3
NO: No ground alarm installed.
DRIVE: Travel alarm sounds when the drive function is active (Option).
DESCENT: Descent alarm sounds when lift down is active (Option).
MOTION: Motion alarm sounds when any function is active (Option).
3
* Certain market selections will alter default setting.
6-32
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-5. Machine Configuration Programming Information
Configuration Digit
DISPLAY UNITS:
22*
Number
0
1
Description
IMPERIAL: DEG F, PSI, LBS
METRIC: DEG C, KPA, KGS.
Default
Number
0
* Certain market selections will alter default setting.
DRIVE CONTROL:
24
0
1
2
NORMAL: Drive coils are energized from the Ground Module.
PROPULSION: Drive coils are energized from the Propulsion Module.
ENHANCED: Drive coils are energized from the Ground Module and the
ground side of the drive coils are brought back to current feedback returns.
2
BOOM CONTROL:
26
0
NORMAL: Boom control coils are energized from the Ground Module.
0
1
ENHANCED: Boom control coils are energized from the Ground Module and
the ground side of the drive coils are brought back to current feedback
returns.
FUNCTION SPEED
KNOB:
27
0
1
YES: Machine is equipped with Function Speed Knob.
NO: Machine is equipped with Operation Speed Knob.
0
CLEARSKY:
28
0
1
NO: ClearSky (Telematics )system option is disabled.
YES: ClearSky (Telematics) system is enabled
0
CRIBBING OPTION:
29
0
1
NO: Cribbing Option is disabled.
YES: Cribbing Option is enabled.
0
FUEL TANK SIZE:
30
0
1
31 Gallon tank.
52 Gallon tank.
0
ALARM/HORN:
31
0
1
SEPERATE: Separate alarm and horn.
COMBINED: combination alarm/horn.
0
ALERT BEACON
32
0
1
OFF FOR CREEP: Alert beacon will not flash in Creep.
20 FPS FOR CREEP: Alert beacon will flash at 20 FPS while in Creep.
0
4150364 G
3121607
– JLG Lift –
6-33
SECTION 6 - JLG CONTROL SYSTEM
6.3 MACHINE ORIENTATION WHEN SETTING
FUNCTION SPEEDS
Test Notes
LIFT UP: from platform control, lowest elevation up to maximum elevation, boom retracted, jib retracted.
LIFT DOWN: from platform control, maximum elevation down
to minimum elevation, boom retracted, jib retracted.
JIB LIFT UP: from platform control, lowest jib elevation up to
maximum jib elevation, boom retracted, jib retracted.
JIB LIFT DOWN: from platform control, maximum jib elevation
down to minimum jib elevation, boom retracted, jib retracted.
1.
Personality settings can be adjusted anywhere within
the adjustment range for optimum machine performance.
2.
Stop watch should start when function is activated - not
controller or switch.
3.
Unless noted, measure function speeds from platform.
4.
Platform speed knob must be at full speed (fully clockwise).
5.
Perform tests with oil temperature above 100° F (38° C).
SWING RIGHT(Max): 360°, from platform control, boom
approximately 45° elevation, boom retracted, jib retracted.
SWING LEFT(Max): 360°, from platform control, boom
approximately 45° elevation, boom retracted, jib retracted.
TELESCOPE OUT: from platform control, boom 20°, 500 lb
(226 kg) capacity selected.
TELESCOPE IN: from platform control, boom 20°, 500 lb (226
kg) capacity selected.
JIB TELESCOPE IN: from platform control, boom horizontal, jib
horizontal, 500 lb (226 kg) capacity selected.
JIB TELESCOPE OUT: from platform control, boom horizontal,
jib horizontal, 500 lb (226 kg) capacity selected.
DRIVE FORWARD (Max): high speed - low torque setting,
drive 200 ft (61 m) front wheels to front wheels. Timed after
machine has obtained maximum speed.
DRIVE REVERSE (Max): high speed - low torque setting, drive
200 ft (61 m) front wheels to front wheels Timed after machine
has obtained maximum speed.
DRIVE FORWARD (Creep Max): high torque - low speed setting, platform speed knob at full creep
DRIVE REVERSE (Creep Max): high torque - low speed setting, platform speed knob at full creep
DRIVE FORWARD (Elevated Max - Boom Beyond Transport): high speed - low torque setting, platform speed knob
out of creep, Lift boom above transport, drive forward 50 ft (15
m).
DRIVE REVERSE (Elevated Max - Boom Beyond Transport):
high speed - low torque setting, platform speed knob out of
creep, Lift boom above transport, drive backward 50 ft (15 m).
6-34
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)
6.4 CANBUS COMMUNICATIONS
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform and Ground Modules providing bi-directional communications.
Two-wire: One wire (red) is driven high (5v) and the other low
(black) (0v) to send a signal. Both wires ”float” (2.5v) when no
signal is being sent.
Differential: Any electrical line noise can affect the high or the
low wires but never both, so communications is not corrupted.
Serial Link: Messages are being sent bit by bit along the wires;
the high bus speed allow all modules to be constantly
updated around 20 times per second. Typical traffic is 300 500 messages per second.
A complete CANbus circuit is approximately 60 ohms, which
can be verified at the ”T” fitting inside the ground station. Individual circuits are approximately 120 ohms.
Platform Level: The GROUND MODULE stores default values
and handles interlocks. The PLATFORM MODULE reads sensors
mounted on the platform assembly and controls Level Up /
Down valves to maintain setpoint sent from the GROUND
MODULE.
Steer: The GROUND MODULE stores crack points, and sends
desired drive direction, steering mode, and axle extend/retract
commands. The PLATFORM MODULE reports steering switch
position to the GROUND MODULE.
Drive: The GROUND MODULE stores crack points and sends
commands for each drive pump. (Command is computed from
drive joystick input, interlocks, wheel angle, etc).
Lift, Tele, & Swing: The GROUND MODULE stores default values, and handles interlocks and calibration information. Lift,
Telescope, and Swing commands depend on interlocks
through out the machine. Boom angle, length, and swing are
controlled by the GROUND MODULE
The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
module. The PLATFORM MODULE handles sub-tasks. All characterized information (values) are stored in the ground module (i.e., Personalities or Calibrations).
3121607
– JLG Lift –
6-35
SECTION 6 - JLG CONTROL SYSTEM
.
Table 6-6. Fault Code List
DTC
6-36
Text
001
EVERYTHING OK
0010
RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION
0011
FSW OPEN
0012
RUNNING AT CREEP - CREEP SWITCH OPEN
0013
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
0014
CHASSIS TILT SENSOR OUT OF RANGE
0030
RUNNING AT CREEP - PLATFORM STOWED
0031
FUEL LEVEL LOW - ENGINE SHUTDOWN
211
POWER CYCLE
212
KEYSWITCH FAULTY
213
FSW FAULTY
224
FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED
225
FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED
227
STEER SWITCHES FAULTY
2211
FSW INTERLOCK TRIPPED
2212
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
2213
STEER LOCKED - SELECTED BEFORE FOOTSWITCH
2216
D/S JOY. OUT OF RANGE HIGH
2217
D/S JOY. CENTER TAP BAD
2219
L/S JOY. OUT OF RANGE HIGH
2220
L/S JOY. CENTER TAP BAD
2221
LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
2222
WAITING FOR FSW TO BE OPEN
2223
FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE
2224
FOOTSWITCH SELECTED BEFORE START
2247
FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMANENTLY SELECTED
2248
FUNCTION PROBLEM - PLATFORM ROTATE RIGHT PERMANENTLY SELECTED
2249
FUNCTION PROBLEM - JIB LIFT UP PERMANENTLY SELECTED
2250
FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED
2251
FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED
2252
FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTED
2257
FUNCTION PROBLEM - TOWER LIFT UP PERMANENTLY SELECTED
2258
FUNCTION PROBLEM - TOWER LIFT DOWN PERMANENTLY SELECTED
2262
FUNCTION PROBLEM - PLATFORM LEVEL UP PERMANENTLY SELECTED
2263
FUNCTION PROBLEM - PLATFORM LEVEL DOWN PERMANENTLY SELECTED
234
FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
235
FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER
236
FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH
237
START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH
2310
FUNCTION PROBLEM - GROUND ENABLE PERMANENTLY SELECTED
2370
FUNCTION PROBLEM - JIB LIFT UP PERMANENTLY SELECTED
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-6. Fault Code List
DTC
3121607
Text
2371
FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED
2372
FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED
2373
FUNCTION PROBLEM - SWING RIGHT PERMANENTLY SELECTED
23104
BOOM TRANSPORT SWITCH DISAGREEMENT
23105
FUNCTION PROBLEM - TOWER LIFT UP PERMANENTLY SELECTED
23106
FUNCTION PROBLEM - TOWER LIFT DOWN PERMANENTLY SELECTED
23107
FUNCTION PROBLEM - LIFT UP PERMANENTLY SELECTED
23108
FUNCTION PROBLEM - LIFT DOWN PERMANENTLY SELECTED
23109
FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED
23110
FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTED
23111
FUNCTION PROBLEM - PLATFORM LEVEL UP PERMANENTLY SELECTED
23112
FUNCTION PROBLEM - PLATFORM LEVEL DOWN PERMANENTLY SELECTED
23113
FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMANENTLY SELECTED
23114
FUNCTION PROBLEM - PLATFORM ROTATE RIGHT PERMANENTLY SELECTED
259
MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS
2513
GENERATOR MOTION CUTOUT ACTIVE
2514
BOOM PREVENTED - DRIVE SELECTED
2516
DRIVE PREVENTED - ABOVE ELEVATION
2517
DRIVE PREVENTED - TILTED & ABOVE ELEVATION
2518
DRIVE PREVENTED - BOOM SELECTED
331
BRAKE - SHORT TO BATTERY
332
BRAKE - OPEN CIRCUIT
334
LIFT UP VALVE - OPEN CIRCUIT
335
LIFT DOWN VALVE - SHORT TO BATTERY
336
LIFT DOWN VALVE - OPEN CIRCUIT
3311
GROUND ALARM - SHORT TO BATTERY
3352
LP LOCK - SHORT TO GROUND
3353
LP LOCK - OPEN CIRCUIT
3354
LP LOCK - SHORT TO BATTERY
3355
LP START ASSIST - SHORT TO GROUND
3356
LP START ASSIST - OPEN CIRCUIT
3357
LP START ASSIST - SHORT TO BATTERY
3358
MAIN DUMP VALVE - SHORT TO GROUND
3359
MAIN DUMP VALVE - OPEN CIRCUIT
3360
MAIN DUMP VALVE - SHORT TO BATTERY
3361
BRAKE - SHORT TO GROUND
3362
START SOLENOID - SHORT TO GROUND
3363
START SOLENOID - OPEN CIRCUIT
3364
START SOLENOID - SHORT TO BATTERY
3365
STEER DUMP VALVE - SHORT TO GROUND
3366
STEER DUMP VALVE - OPEN CIRCUIT
3367
STEER DUMP VALVE - SHORT TO BATTERY
3373
GEN SET/WELDER - SHORT TO GROUND
– JLG Lift –
6-37
SECTION 6 - JLG CONTROL SYSTEM
Table 6-6. Fault Code List
DTC
6-38
Text
3374
GEN SET/WELDER - OPEN CIRCUIT
3375
GEN SET/WELDER - SHORT TO BATTERY
3376
HEAD TAIL LIGHT - SHORT TO GROUND
3377
HEAD TAIL LIGHT - OPEN CIRCUIT
3378
HEAD TAIL LIGHT - SHORT TO BATTERY
3379
HOUR METER - SHORT TO GROUND
3382
PLATFORM LEVEL UP VALVE - SHORT TO GROUND
3383
PLATFORM LEVEL UP VALVE - OPEN CIRCUIT
3384
PLATFORM LEVEL UP VALVE - SHORT TO BATTERY
3388
PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND
3389
PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT
3390
PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
3394
PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND
3395
PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT
3396
PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY
3397
PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND
3398
PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT
3399
PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY
33100
JIB LIFT UP VALVE - SHORT TO GROUND
33101
JIB LIFT UP VALVE - OPEN CIRCUIT
33102
JIB LIFT UP VALVE - SHORT TO BATTERY
33103
JIB LIFT DOWN VALVE - SHORT TO GROUND
33104
JIB LIFT DOWN VALVE - OPEN CIRCUIT
33105
JIB LIFT DOWN VALVE - SHORT TO BATTERY
33106
TOWER LIFT UP VALVE - SHORT TO GROUND
33107
TOWER LIFT UP VALVE - OPEN CIRCUIT
33109
TOWER LIFT DOWN VALVE - SHORT TO GROUND
33110
TOWER LIFT DOWN VALVE - OPEN CIRCUIT
33118
SWING RIGHT VALVE - SHORT TO GROUND
33119
SWING RIGHT VALVE - OPEN CIRCUIT
33120
TELESCOPE IN VALVE - SHORT TO BATTERY
33122
SWING LEFT VALVE - SHORT TO GROUND
33123
TELESCOPE OUT VALVE - SHORT TO BATTERY
33130
THROTTLE ACTUATOR - SHORT TO GROUND
33131
THROTTLE ACTUATOR - OPEN CIRCUIT
33132
THROTTLE ACTUATOR - SHORT TO BATTERY
33182
LIFT VALVES - SHORT TO BATTERY
33186
TELESCOPE OUT VALVE - OPEN CIRCUIT
33188
TELESCOPE OUT VALVE - SHORT TO GROUND
33189
TELESCOPE IN VALVE - OPEN CIRCUIT
33190
TELESCOPE IN VALVE - SHORT TO GROUND
33279
GLOWPLUG - OPEN CIRCUIT
33280
GLOWPLUG - SHORT TO BATTERY
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-6. Fault Code List
DTC
3121607
Text
33281
GLOWPLUG - SHORT TO GROUND
33287
LIFT - CURRENT FEEDBACK READING TOO LOW
33295
SWING LEFT VALVE - OPEN CIRCUIT
33314
FLOW CONTROL VALVE - OPEN CIRCUIT
33315
FLOW CONTROL VALVE - SHORT TO BATTERY
33316
FLOW CONTROL VALVE - SHORT TO GROUND
33317
DRIVE FORWARD VALVE - OPEN CIRCUIT
33318
DRIVE FORWARD VALVE - SHORT TO BATTERY
33319
DRIVE FORWARD VALVE - SHORT TO GROUND
33320
DRIVE REVERSE VALVE - OPEN CIRCUIT
33322
DRIVE REVERSE VALVE - SHORT TO GROUND
33331
DRIVE - CURRENT FEEDBACK READING TOO LOW
33406
LIFT UP VALVE - SHORT TO GROUND
33410
DRIVE - CURRENT FEEDBACK READING LOST
33412
SWING VALVES - SHORT TO BATTERY
33413
TOWER LIFT - CURRENT FEEDBACK READING TOO LOW
33414
SWING - CURRENT FEEDBACK READING TOO LOW
33415
FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO LOW
33416
TOWER LIFT - CURRENT FEEDBACK READING LOST
33417
LIFT - CURRENT FEEDBACK READING LOST
33418
SWING - CURRENT FEEDBACK READING LOST
33419
FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST
33420
TRACTION LOCK VALVE - SHORT TO BATTERY
33421
TRACTION LOCK VALVE - OPEN CIRCUIT
33422
TRACTION LOCK VALVE - SHORT TO GROUND
33423
OSCILLATING AXLE VALVES - SHORT TO BATTERY
33424
OSCILLATING AXLE VALVES - SHORT TO GROUND
33425
TOWER LIFT VALVES - SHORT TO BATTERY
342
PLATFORM LEVEL UP VALVE - SHORT TO BATTERY
343
PLATFORM LEVEL UP VALVE - SHORT TO GROUND
345
PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT
346
PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
347
PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND
349
PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT
3410
PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY
3411
PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND
3412
PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT
3413
PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY
3414
PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND
3415
JIB LIFT UP VALVE - OPEN CIRCUIT
3416
JIB LIFT UP VALVE - SHORT TO BATTERY
3417
JIB LIFT UP VALVE - SHORT TO GROUND
3418
JIB LIFT DOWN VALVE - OPEN CIRCUIT
– JLG Lift –
6-39
SECTION 6 - JLG CONTROL SYSTEM
Table 6-6. Fault Code List
DTC
6-40
Text
3419
JIB LIFT DOWN VALVE - SHORT TO BATTERY
3420
JIB LIFT DOWN VALVE - SHORT TO GROUND
431
FUEL SENSOR - SHORT TO BATTERY
432
FUEL SENSOR - SHORT TO GROUND
433
OIL PRESSURE - SHORT TO BATTERY
434
OIL PRESSURE - SHORT TO GROUND
435
COOLANT TEMPERATURE - SHORT TO GROUND
437
ENGINE TROUBLE CODE
438
HIGH ENGINE TEMP
4310
NO ALTERNATOR OUTPUT
4311
LOW OIL PRESSURE
4313
THROTTLE ACTUATOR FAILURE
4314
WRONG ENGINE SELECTED - ECM DETECTED
4322
LOSS OF ENGINE SPEED SENSOR
4323
SPEED SENSOR READING INVALID SPEED
4326
FUEL ACTUATOR - SHORT TO GROUND
4327
FUEL ACTUATOR - OPEN CIRCUIT
4328
FUEL ACTUATOR - SHORT TO BATTERY
4329
FUEL ACTUATOR - CURRENT FEEDBACK READING TOO LOW
4330
FUEL ACTUATOR - CURRENT FEEDBACK READING LOST
441
BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
442
BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
443
LSS BATTERY VOLTAGE TOO HIGH
444
LSS BATTERY VOLTAGE TOO LOW
445
BATTERY VOLTAGE LOW
662
CANBUS FAILURE - PLATFORM MODULE
663
CANBUS FAILURE - LOAD SENSING SYSTEM MODULE
666
CANBUS FAILURE - ENGINE CONTROLLER
6613
CANBUS FAILURE - EXCESSIVE CANBUS ERRORS
6622
CANBUS FAILURE - TCU MODULE
6629
CANBUS FAILURE - TELEMATICS CANBUS LOADING TOO HIGH
681
REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP
813
CHASSIS TILT SENSOR NOT CALIBRATED
814
CHASSIS TILT SENSOR OUT OF RANGE
815
CHASSIS TILT SENSOR DISAGREEMENT
821
LSS CELL #1 ERROR
822
LSS CELL #2 ERROR
823
LSS CELL #3 ERROR
824
LSS CELL #4 ERROR
825
LSS HAS NOT BEEN CALIBRATED
826
RUNNING AT CREEP - PLATFORM OVERLOADED
827
DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED
828
LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Table 6-6. Fault Code List
DTC
3121607
Text
8211
LSS READING UNDER WEIGHT
8639
FRONT LEFT STEER VALVE - OPEN CIRCUIT
8640
FRONT LEFT STEER VALVE - SHORT TO BATTERY
8641
FRONT LEFT STEER VALVE - SHORT TO GROUND
8642
FRONT RIGHT STEER VALVE - OPEN CIRCUIT
8643
FRONT RIGHT STEER VALVE - SHORT TO BATTERY
8644
FRONT RIGHT STEER VALVE - SHORT TO GROUND
8669
OSCILLATING AXLE SWITCH DISAGREEMENT
991
LSS WATCHDOG RESET
992
LSS EEPROM ERROR
993
LSS INTERNAL ERROR - PIN EXCITATION
994
LSS INTERNAL ERROR - DRDY MISSING FROM A/D
998
EEPROM FAILURE - CHECK ALL SETTINGS
9910
FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION
IMPROPER
9911
FUNCTIONS LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER
9915
CHASSIS TILT SENSOR NOT GAIN CALIBRATED
9919
GROUND SENSOR REF VOLTAGE OUT OF RANGE
9920
PLATFORM SENSOR REF VOLTAGE OUT OF RANGE
9921
GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY
9922
PLATFORM MODULE FAILURE - HWFS CODE 1
9924
FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
9927
GROUND MODULE CONSTANT DATA UPDATE REQUIRED
9944
CURRENT FEEDBACK GAINS OUT OF RANGE
9945
CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT
9949
MACHINE CONFIGURATION OUT OF RANGE - CHECK ALL SETTINGS
9977
LSS CORRUPT EEPROM
9979
FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER
9986
GROUND MODULE VLOW FET FAILURE
– JLG Lift –
6-41
SECTION 6 - 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.
GEN SET / WELDER
ENGINE SHUTDOWN
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
0
0
1
0
1
ANSI EXPORT
6
1
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
0
0
1
0
1
CSA
6
2
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
0
0
1
0
1
CE
6
3
12
0
1
2
0
1
0
1
2
0
1
X
X
3
X
5
0
0
1
0
1
AUSTRALIA
6
4
12
0
1
2
0
1
0
1
2
0
1
X
X
3
X
5
0
0
1
0
1
JAPAN
6
5
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
0
0
1
0
1
JIB
GEN SET CUTOUT
0
TILT
ENGINE
6
FUEL CUTOUT
MARKET
ANSI USA
GLOW PLUG
MODEL NUMBER
STARTER LOCKOUT
600SC
0
1
0
1
0
ANSI EXPORT
0
1
0
1
0
1
2
CSA
0
1
0
1
0
X
X
CE
0
1
0
1
0
X
2
AUSTRALIA
0
1
0
1
0
X
JAPAN
0
1
0
1
0
1
ANSI USA
6-42
X
DISPLAY UNITS
GROUND ALARM
FUNCTION CUTOUT
LOAD SENSOR
LOAD SYSTEM
HEAD & TAIL LIGHTS
CABLE BREAK SWITCH
600SC
X
0
1
0
X
2
X
0
1
2
3
0
3
4
0
1
0
1
2
3
0
1
2
3
0
1
X
X
0
1
0
1
2
3
0
1
2
3
0
1
3
X
0
1
0
1
X
X
0
1
2
3
0
1
2
X
X
0
1
0
1
2
3
0
1
2
3
0
1
2
3
4
0
1
0
1
2
3
0
1
2
3
0
1
X
X
– JLG Lift –
1
3121607
SECTION 6 - 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.
ALERT BEACON
ALARM/HORN
FUEL TANK SIZE
CLEARSKY
DRIVE CONTROL
BOOM CONTROL
600SC
ANSI USA
0
1
2
0
1
0
1
0
1
0
1
0
1
ANSI EXPORT
0
1
2
0
1
0
1
0
1
0
1
0
1
CSA
0
1
2
0
1
0
1
0
1
0
1
0
1
CE
0
1
2
0
1
0
1
0
1
0
1
0
1
AUSTRALIA
0
1
2
0
1
0
1
0
1
0
1
0
1
JAPAN
0
1
2
0
1
0
1
0
1
0
1
0
1
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.
GEN SET / WELDER
ENGINE SHUTDOWN
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
1
0
1
0
1
ANSI EXPORT
6
1
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
1
0
1
0
1
CSA
6
2
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
1
0
1
0
1
CE
6
3
12
0
1
2
0
1
0
1
2
0
1
X
X
3
X
5
1
0
1
0
1
AUSTRALIA
6
4
12
0
1
2
0
1
0
1
2
0
1
X
X
3
X
5
1
0
1
0
1
JAPAN
6
5
12
0
1
2
0
1
0
1
2
0
1
1
2
3
4
5
1
0
1
0
1
3121607
– JLG Lift –
JIB
GEN SET CUTOUT
0
TILT
ENGINE
6
FUEL CUTOUT
MARKET
ANSI USA
GLOW PLUG
MODEL NUMBER
STARTER LOCKOUT
660SJC
6-43
SECTION 6 - 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.
0
1
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ANSI EXPORT
0
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2
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AUSTRALIA
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JAPAN
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ANSI USA
X
DISPLAY UNITS
GROUND ALARM
FUNCTION CUTOUT
LOAD SENSOR
LOAD SYSTEM
HEAD & TAIL LIGHTS
CABLE BREAK SWITCH
660SJC
X
0
1
0
X
2
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1
2
3
0
3
4
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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.
DRIVE CONTROL
ALERT BEACON
ALARM/HORN
FUEL TANK SIZE
CLEARSKY
BOOM CONTROL
DRIVE CONTROL
660SJC
ANSI USA
0
1
2
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0
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JAPAN
0
1
2
0
1
0
1
0
1
0
1
0
1
0
1
6-44
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
Figure 6-11. Control Module Locations
3121607
– JLG Lift –
6-45
SECTION 6 - JLG CONTROL SYSTEM
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6-46
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
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3121607
– JLG Lift –
6-47
SECTION 6 - JLG CONTROL SYSTEM
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6-48
– JLG Lift –
3121607
SECTION 6 - JLG CONTROL SYSTEM
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3121607
– JLG Lift –
6-49
SECTION 6 - JLG CONTROL SYSTEM
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Figure 6-16. Platform Control Module Pin Connections 2 of 2
6-50
– JLG Lift –
3121607
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1
GENERAL
Polarity
This section contains basic electrical information and schematics for locating and correcting most electrical problems. If
a problem develops which is not presented in this section or
corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any additional maintenance.
NOTE: Some procedures/connectors shown in this section may
not apply to all models.
Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, location of the signal and
leads are correctly connected to the device under test. Also
check the lead on the "COM" port goes to the ground or negative side of the signal and lead on the other port goes to the
positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
7.2 MULTIMETER BASICS
m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) can
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more
information.
μ = micro = (Displayed Number) / 1,000,000
Example: 1.2 kΩ = 1200 Ω
Example: 50 mA = 0.05 A
Voltage Measurement
Grounding
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connector such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector.
Min/Max
Figure 7-1. Voltage Measurement (DC)
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
"Min/Max" recording feature of some meters can help when
taking measurements of intermittent conditions while alone.
For example, you can read voltage applied to a solenoid when
it is only operational while a switch, far from the solenoid and
meter, is held down.
3121607
– JLG Lift –
7-1
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Resistance Measurement
Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable
audible continuity testing
• Circuit power must be turned OFF before testing continuity
Figure 7-2. Resistance Measurement
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance)
• Circuit power must be turned OFF before testing resistance
• Disconnect component from circuit before testing
• Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
7-2
– JLG Lift –
3121607
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
• To prevent oxidation at mechanical joint between male
and female pins.
Current Measurement
• 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.
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.
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.
NOTE: This condition is especially common when machines are
pressure washed since the washing solution is much more
conductive than water.
Figure 7-4. Current Measurement (DC)
• Set up meter for expected current range
3.
• Be sure to connect meter leads to correct jacks for
selected current range
• If meter is not auto ranging, set it to correct range (See
multi meter’s operation manual)
Anderson connectors for battery boxes and battery
chargers should have silicone grease applied to contacts
only.
NOTE: Curing-type sealants can also be used to prevent shorting
and would be less messy, but make future pin removal difficult.
• Use firm contact with meter leads
7.3
APPLYING SILICONE DIELECTRIC COMPOUND
TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
When applied to electrical connections, dielectric grease helps
prevent corrosion of electrical contacts and improper conductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connections:
• Main Boom Rotary sensor connections (on Celesco Sensor),
• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the following reasons:
3121607
– JLG Lift –
7-3
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Dielectric Grease Application
AMP Seal
Before following these instructions, refer to excluded connector types (See Exclusions below).
1.
Use dielectric grease in a tube for larger connection
points or apply with a syringe for small connectors.
2.
Apply dielectric grease to the female contact (fill it
approximately ½ full; see example below)
3.
Leave a thin layer of dielectric grease on connector face.
4.
Assemble connector system immediately to prevent
moisture or dust contamination
5.
Pierce one of the unused wire seals before assembly if
the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.
The AMP Seal connector system is used on Control ADE Platform and Ground Modules.
Apply dielectric grease to the female contact. If trapped air
prevents connector from latching, pierce one of the unused
wire seals.
A
Figure 7-7. Dielectric Grease On Female Contacts
A
Fill 1/2 full with
dielectric grease
(Thin layer of grease
may remain on connector
face and adjacent areas.)
Detail A
After assembly, install a seal plug (JLG #4460905) to keep out
moisture. Seal plugs may also be installed by the wire harness
manufacturer if an unused wire seal was damaged during
assembly.
Figure 7-5. Applying Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
The Deutsch connector system is commonly used for harsh
environments. Follow installation instructions.
Figure 7-8. Seal Plugs
Figure 7-6. Deutsch Connector
7-4
– JLG Lift –
3121607
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
BRAD HARRISON/PHOENIX CONTACT M12
AMP Mate-N-Lok
This connector uses gold contact material to resist corrosion
and an O-ring seal for moisture integrity. Low-force contacts
cannot displace dielectric grease to achieve electrical contact.
Once contaminated, replacement of female contacts is
required. The JLG Load Sensing System and 1250AJP Rotary
Angle Sensors are examples of components with the M12 connector system.
Follow manufacturer installation instructions.
Figure 7-9. AMP Mate-N-Lok Connector
DIN Connectors
This connector is typically used on hydraulic valves. Follow
manufacturer installation instructions.
Figure 7-11. Brad Harrison/Phoenix Connectors
AMP JUNIOR TIMER
This type of connector uses back-seals to keep out moisture.
Low-force contacts cannot displace dielectric grease and create electrical contact. Use solvents (i.e. contact cleaner or mineral spirits) to remove dielectric grease. The Deutz EMR2
engine control module uses this connector.
Figure 7-10. DIN Connector
Exclusions
Some connectors do not require or may be permanently damaged by application of dielectric grease. Dielectric grease may
not be required in properly sealed enclosures.
DO NOT USE DIELECTRIC GREASE ON BRAD HARRISON/PHOENIX CONTACT
M12 OR AMP JUNIOR TIMER CONNECTORS. LOW-FORCE CONTACTS CANNOT
DISPLACE DIELECTRIC GREASE AND CREATE ELECTRICAL CONTACT.
3121607
– JLG Lift –
Figure 7-12. AMP Junior Timer
7-5
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.4 AMP CONNECTOR
Connector Assembly
Plug and header assembly colors are mechanically keyed to
mate only with identical colors.
1.
Check wedge lock is in the open, or as-shipped, position.
Figure 7-13. AMP Connector
Figure 7-15. AMP Connector Assembly
Contact Assembly
1.
Strip wire and install in crimp end of connector as
shown in Figure 7-14.
2.
Crimp connector. Do not damage cutoff tab.
2.
Push contact straight into circuit cavity as far as it will go.
3.
Pull on contact wire with a force of 1 - 2 lb to be sure
retention fingers are holding contact.
Figure 7-16. AMP Contact Installation
Figure 7-14. AMP Contact Assembly
7-6
– JLG Lift –
3121607
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
4.
After all contacts are inserted, close wedge lock to its
locked position. Release locking latches by squeezing
them inward.
NOTE: Wedge lock should never be removed from housing for
insertion or removal of contacts.
Figure 7-17. Close Wedge Lock
5.
Slide wedge lock in housing until flush with housing.
Figure 7-19. AMP Connector Disassembly
Wedge Lock
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.
Service - Voltage Reading
Figure 7-18. Seating Wedge Lock
HOLES IN WIRE INSULATION CAN LET IN MOISTURE AND CAUSE SYSTEM FAILURE. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
Disassembly
1.
Insert a 4.8 mm (3/16") wide screwdriver blade between
mating seal and one of red wedge lock tabs.
2.
Pry wedge lock open.
3.
While rotating wire back and forth over a half turn (1/4
turn in each direction), gently pull wire until contact is
removed.
3121607
It has been common practice in electrical troubleshooting to
probe wires by piercing insulation with a sharp point. This
practice should be discouraged when dealing with an
AMPSEAL plug assembly or any other sealed connector system. Resulting pinholes in the insulation allows moisture to
enter by traveling along wire strands and could result in system failure.
– JLG Lift –
7-7
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.5 DEUTSCH CONNECTORS
DT/DTP Series Disassembly
DT/DTP Series Assembly
1.
Grasp crimped contact (1) about 25mm behind contact
barrel.
2.
Hold connector with rear grommet (2) facing you.
3.
Push contact straight into connector grommet (3) until a
click is felt. A slight tug confirms it is locked in place.
4.
1.
Remove wedgelock (1) using needle-nose pliers or a
hook shaped wire to pull wedge straight out.
2.
To remove contacts, gently pull wire backwards at the
same time releasing the locking finger (2) by moving it
away from contact with a screwdriver.
3.
Hold rear seal (3) in place. Removing contact may displace seal.
Once all contacts are in place, insert wedgelock (4) with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. They may go in either way.
NOTE: Receptacle shown - use same procedure for plug.
1
1
2
2
3
Figure 7-21. DT/DTP Contact Removal
3
4
Figure 7-20. DT/DTP Contact Installation
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HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
1.
Grasp contact (1) about 25mm behind contact crimp
barrel.
1.
With rear insert toward you, snap appropriate size
extractor tool (1) over wire of contact to be removed.
2.
Hold connector with rear grommet (2) facing you.
2.
Push tool in the insert cavity (2) until it engages contact
and resistance is felt.
1
2
1
Figure 7-22. HD/HDP Contact Installation
3.
Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm it is locked
in place.
2
Figure 7-24. HD/HDP Contact Removal
3.
Pull contact-wire assembly out of connector
NOTE: Do Not twist or insert tool at an angle.
Figure 7-23. HD/HDP Locking Contacts Into Position
Figure 7-25. HD/HDP Unlocking Contacts
NOTE: Insert sealing plugs in unused wire cavities for full environmental sealing.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
FOOTSWITCH
GENERATOR
SWITCH
PLATFORM
WORK LIGHTS
J2
J5 J6
J1
J7
2500W
GENERATOR
J8
ABOVE HORIZONTAL LIMIT SWITCH
(ALL SPECS EXCEPT CE SPEC)
TRANSPORT LIMIT SWITCH (CE SPEC)
DRIVE DISABLE/ANGLE
LIMIT SWITCH
PLATFORM
CONTROL
BOX
BROKEN CABLE
PROXIMITY SWITCH
(AUS & CE SPECS)
J2
J12 J7
J1
J8
J3
J4
HEADLIGHTS
GROUND
CONTROL
BOX
DIAGNOSTIC
ANALYZER
TAILLIGHTS
Figure 7-26. Electrical Components 1 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
GENERATOR
CONTROL BOX
2500W
GENERATOR
RELAY
7500W
GENERATOR
RELAYS
(DEUTZ 2011)
7500W GENERATOR
CONTROL BOX
7500W
SKYPOWER
GENERATOR
7500W GENERATOR
PLATFORM BOX
ENGINE
CONTROL
(DEUTZ TD2.9L4)
WATER IN
FUEL IND.
TO FUEL
PUMP
ER
VALVE
(DEUTZ
D2011)
OR
RELAY
(DEUTZ
D2011)
ENGINE
CONTROL
(DEUTZ D2011)
ENGINE
HARNESS(DEUTZ)
TO GLOW PLUGS
DEUTZ TD2.9L4
COMPONENTS
TO ENGINE EIC
BOLT ON
ENGINE
TO COOLANT
LEVEL IND.
POWER
MODULE
RELAY
STROBE
LIGHT
AUX
PUMP
START
RELAY
+
GLOW
PLUGS
2 SPEED
& BRAKE
VALVE
STARTER
START
RELAY
HYDRAULIC
PUMPS
HORN
BATTERY
GLOW
PLUG
RELAY
AUX
RELAY
DRIVE
ORIENTATION
SWITCH
ALTERNATOR
(DEUTZ
TD2.9L4)
–
MAIN
CONTROL
VALVE
UNUSED
CONNECTION
JIB
VALVE
FUEL
LEVEL
SENSOR
ALARM
Figure 7-27. Electrical Components 2 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-28. Platform and Ground Control Electrical Schematic - 1 of 2
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Figure 7-29. Platform and Ground Control Electrical Schematic - 2 of 2
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Figure 7-30. Generator Wiring Schematic
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Deutz EMR2 Engine
Figure 7-31. Deutz EMR2 Wiring Schematic
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-32. Deutz Engine Harness Electrical Schematic 1 of 2
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Figure 7-33. Deutz Engine Harness Electrical Schematic 2 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-34. Hydraulic Schematic 1 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-35. Hydraulic Schematic 2 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-36. Crawler Hydraulic Drive Schematic 1 of 2
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Figure 7-37. Crawler Hydraulic Drive Schematic 2 of 2
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Figure 7-38. Hydraulic Port Schematic - 1 of 2
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Figure 7-39. Hydraulic Port Schematic - 2 of 2
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-40. Crawler Drive Motor Hydraulic Schematic
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Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
+61 2 65 811111
+61 2 65813058
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+55 19 3295 1025
+44 (0)161 654 1000
+44 (0)161 654 1001
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
(852) 2639 5783
+39 029 359 5210
+39 029 359 5845
(852) 2639 5797
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
Oshkosh-JLG Singapore
Technology Equipment Pte Ltd
29 Tuas Ave 4,
Jurong Industrial Estate
Singapore, 639379
+65-6591 9030
+65-6591 9031
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534
www.jlg.com