JLG T500J Service And Maintenance Manual

PDF

Document

Service and Maintenance Manual

Model

T500J

PN -3121200

July

, 2018 - Rev I

AS/NZS

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

This section contains general safety precautions which must be observed during aerial platform maintenance. 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 the machine is safe to operate.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE

MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in 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 adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE

FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL-

ITY OF THE OWNER/OPERATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted 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.

Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION

COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A

SAFETY VIOLATION.

• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE

IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR

COMPONENTS.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-

TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND

SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-

FORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-

TING 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 COOL-

ANT 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 PER-

FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL

POWER CONTROLS.

• ALWAYS DISCONNECT BATTERY DURING REPLACEMENT OF

ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

VENTS.

3121200

A-1

INTRODUCTION

Original Issue

Revised

REVISON LOG

A - January 15, 2005

B - July 15, 2005

C - August 26, 2005

D - December 12, 2005

E - February 24, 2006

F - May 1, 2007

G - September 28, 2011

H - January 9, 2013

I - July

, 2018

A-2

3121200

TABLE OF CONTENTS

SECTION NO. TITLE

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

PAGE NO

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

.

SECTION 1 - SPECIFICATIONS

1.1

1.2

1.3

Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Electric Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Batteries (electric machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maintenance & Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SECTION 2 - GENERAL

Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Do Not Do The Following When Welding On Jlg Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3121200

TABLE OF CONTENTS

SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE

PAGE NO.

Breaking-in a New Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Retighten Lug Nuts at First 10, 25 & 50 Miles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Adjust Brake Shoes at First 200 Miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Synchronizing the Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Trailer inspection and Service Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Fasteners and Frame Members. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Brake Shoes and Drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Manually Adjusting Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Electric Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Brake Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Brake Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Shoes and Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic (Surge) Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Self Adjusting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Mechanical Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Adjustment and Readjustment of the Overrun Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hubs, Drums, Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Hub Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Brake Drum Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Seal Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Tire Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Lug Nuts (Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Hydraulic Brake Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Bleeding the Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Backing Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Extended Storage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Proper Towing Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Combination Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Bleeding the Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Servicing the Emergency Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Coupler Assembly (SN 0030002099 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Engaging Manual Lockout Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Servicing the Breakaway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Actuator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Coupler Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Hitch Coupler & Axle (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Ball Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Coupling Head Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Damper Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

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PAGE NO

Trailer Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Swing Motor (Prior to S/N 0030000960) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Shaft Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Swing Motor (SN 0030001051 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Swing Drive Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Throttle & Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Fuel Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Checking RPM Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Choke Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Outrigger cylinder and Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Outrigger Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Automatic Leveling Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Procedure For Retracting Outriggers Using Service Harness (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Drive & Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Drive & Set Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

Drive Engage Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Batteries (Electric Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

Quarterly Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

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SECTION NO. TITLE

3.26

3.27

PAGE NO.

Battery Charger (Prior to S/N 030000236). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Shunt Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Interlock Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

SCR Rectifier Replacement (Either Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

AC Circuit Breaker Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

DC Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

Battery Charger (S/N 030000199 to 030000225 & S/N 030000236 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

SECTION 4 - BOOM & PLATFORM

Platform Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Main Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Boom And Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Main Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Boom Elevation Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Platform Control Enable System (Trigger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Side Entry Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Hydraulic Manual Descent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Replace Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

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SECTION NO. TITLE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

PAGE NO

Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spray Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Brake Release Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Drive Engage Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Hydraulic Pump(Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Telescope In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Telescope Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Platform Level Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Outrigger Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Hydraulic Oil Fill at Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Hydraulic Filter and Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

.

SECTION 6 - JLG CONTROL SYSTEM

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Changing Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Adjust Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Platform Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Leveling, Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

When Machine Is on a Firm Level Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure:. . . . . . . . . . . . . . . . . . 6-16

User Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

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SECTION NO. TITLE PAGE NO.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Brad Harrison/phoenix Contact M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Engine Control Unit Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Electrical Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

3121200

LIST OF FIGURES

FIGURE NO. TITLE

PAGE NO.

Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Torque Chart (SAE Fasteners - Sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Torque Chart (SAE Fasteners - Sheet 2 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Torque Chart (SAE Fasteners - Sheet 3 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Torque Chart (SAE Fasteners - Sheet 4 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Torque Chart (METRIC Fasteners - Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Electric Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydraulic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Mechanical Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Overrun Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Wheel Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Transmission System For Tandem and Single-axle Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Axle and Tongue Installation With Electric Brakes (2 in Ball) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Axle and Tongue Installation With Electric Brakes (50mm ball) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Axle and Tongue Installation With Hydraulic Brakes (2in Ball) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Axle and Tongue Installation with Mechanical Brakes (50mm ball) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Spare Tire (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Hydraulic Brake Coupler with 2in Ball - Prior to SN 0030002099 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Hydraulic Brake Coupler with Combination 2in ball - Prior to SN 0030002099 . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Hydraulic Brake Coupler with Combination 2 In Ball - SN 0030002099 through Present . . . . . . . . . . . . . . . 3-29

Hydraulic Brake Coupler (CE and CSA Spec Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Swing Motor- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Seal Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Notch Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Timing Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Swing Motor- Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Swing Motor- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Swing Motor- Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Outrigger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Drive and Set - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

Drive and Set - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Drive and Set - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

Drive and Set Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Wheel Drive - Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Wheel Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

Battery and Contactor Installation (Prior to SN 0030001804) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

Battery and Contactor Installation (Prior to SN 0030001804)- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Battery Cable Routing (Prior to SN 0030001804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

Battery and Contactor Installation (SN 0030001804 to Present) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . 3-101

Battery and Contactor Installation (SN 0030001804 to Present) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

Battery Cable Routing (SN 0030001804 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Battery Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Battery Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110

Battery Charger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

Powertrack Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Boom and Cylinders Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

3121200

vii

LIST OF FIGURES

FIGURE NO. TITLE

PAGE NO.

Cylinder Locations - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinder Locations - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Brake Release Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Drive Engage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Hydraulic Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Hydraulic Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Control Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Control Valve Torque Values (Engine Powered Machines) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Control Valve Torque Values (Engine Powered Machines) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Control Valve Torque Values (Electric Powered Machines) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Control Valve Torque Values (Electric Powered Machines) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Drive Directional Valve Identification - Drive & Set Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Drive Directional Valve Torque Values - Drive & Set Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Drive Enable Valve Identification - Drive & Set Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Hydraulic Schematic - Electric Machines - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Hydraulic Schematic - Electric Machines - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Hydraulic Schematic - Gas Machines - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

Hydraulic Schematic - Gas Machines - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Hydraulic Schematic - Drive Option (Gas) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Hydraulic Schematic - Drive Option (Gas) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Hydraulic Schematic - Drive Option Electric Motor - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Hydraulic Schematic - Drive Option Electric Motor - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

viii

3121200

LIST OF FIGURES

FIGURE NO. TITLE

PAGE NO.

Machine - Sheet 1 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Machine - Sheet 2 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

Chassis Circuit (Electric) - Sheet 3 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Chassis Circuit (Electric) - Sheet 4 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

Chassis Circuit (Gas) - Sheet 5 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Chassis Circuit (Gas) - Sheet 6 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Boom Circuit - Sheet 7 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Boom Circuit - Sheet 8 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Drive and Set Circuit (Gas) - Sheet 9 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Drive and Set Circuit (Gas) - Sheet 10 of 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Drive and Set Circuit (Electric) - Sheet 11 of 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Drive and Set Circuit (Electric) - Sheet 12 of 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Analyzer Flow Chart P1.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Analyzer Flow Chart P1.7 - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Analyzer Flow Chart P1.7 - Personalties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

System Test Flow Chart - Platform Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Ground Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Applying Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Application to plug/male connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Connector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Electrical Components Installation - Electric Powered Machines



(Prior to SN 00300001804) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Electrical Components Installation - Electric Powered Machines



(Prior to SN 00300001804) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Electrical Components Installation - Electric Powered Machines



(Prior to SN 00300001804) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Electrical Components Installation - Electric Powered Machines



(SN 00300001804 to Present) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Electrical Components Installation - Engine Powered Machines - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Electrical Components Installation - Engine Powered Machines - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Controller and Valve Body Connector Locations - Electrical Machine without Drive



(Prior to SN 0030001804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Controller and Valve Body Connector Locations - Electrical Machine without Drive



(SN 0030001804 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

3121200

LIST OF FIGURES

FIGURE NO. TITLE

PAGE NO.

Controller and Valve Body Connector Locations - Engine Machine without Drive . . . . . . . . . . . . . . . . . . . . . 7-22

Electrical Schematic (Boom Operations) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Electrical Schematic (Boom Operations) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Electrical Schematic (Trailer) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Electrical Schematic (Trailer) - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Electrical Schematic (Trailer) - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Electrical Schematic (Trailer) - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

3121200

LIST OF TABLES

TABLE NO. TITLE

PAGE NO.

Operating & Towing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Electric Power Unit Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Engine Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Batteries Specifications (Electric Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Malfunctions and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Wheel Torque Chart - ANSI, ANSI Export, CSA, Aus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Wheel Torque Chart - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Surge Brake Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Torques of Locknut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

User Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Machine Model Adjustments and Speeds - ANSI & CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Machine Model Adjustments and Speeds - CE Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

3121200

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

xii

3121200

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Table 1-1. Operating & Towing Specifications

Tongue Weight (ANSI):

Note: Tongue weight may increase with options.

Maximum Allowable Tow Speed:

(Do NOT exceed legal speed limit)

Maximum Work Load (Capacity) w/Rotator

Maximum Work Load (Capacity) w/o Rotator

Maximum Work Load (Capacity) w/Rotator & Panel Tray

Maximum Work Load (Capacity)

w/o Rotator & w/Panel Tray

Material Hook Capacity (Optional)

350 lbs.(154 kg)

65 mph (105 kph)

440 lbs.(200 kg)

500 lbs.(230 kg)

320 lbs.(145 kg)

350 lbs.(158 kg)

Accessory Tray Capacity

500 lbs.(227kg)

250 lbs.

(114 kg)

Panel Tray Capacity

(w/Rotator)

Panel Tray Capacity

(w/o Rotator)

Swing

Max.Vertical Platform Height (Unrestricted)

Vertical Reach (unrestricted)

Horizontal Reach



(from center line of machine)



(from outrigger pad edge)

Up and Over Clearance

Maximum Outrigger Load

Maximum Ground Bearing Pressure

Maximum Travel Gradeability - (ANSI, CSA, AUS)

Maximum Travel Gradeability - (CE)

Maximum Side slope - (ANSI, CSA, AUS)

Maximum Side slope - (CE)

Max. Hydraulic System Pressure

Maximum Operating Wind Speed

Maximum Horizontal Manual Force

Electrical System Voltage - Electric Machine

Electrical System Voltage - Gas Machine

Gross Machine Weight (Platform Empty)

ANSI/CSA/AUS Machines

Note: Machine weight may increase with options.

Gross Machine Weight (Platform Empty)

CE Machines

Note: Machine weight may increase with options.

Do NOT exceed axle rating or GVW rating.

70 lbs.(32 kg)

100 lbs.(45 kg)

410° non-continuous

50 ft. (15.2 m)

31 ft.(9.45 m)

25 ft.(7.62 m)

18 ft.(5.49 m)

2660 (1206.5 kg)

30.7 psi (2.15 kg/cm

)

20%

15%

11°

8.5°

2950 psi.(203 Bar)

28 mph (12.5 m/s)

90 lb. force (400 N)

24 Volts

12 Volts

4750 lbs.(2155 kg)

5776 lbs. (2620 kg)

1.2 DIMENSIONAL DATA

Table 1-2. Dimensional Data

Overall Length

Surge Brake, 2" ball/50mm ball



Electric Brake, 2" ball



Surge Brake Combination, 2" ball/50mm ball

Overall Height ANSI

Overall Height CE

Overall Width - (outriggers up)

Overall Width (outriggers down - ANSI)

Overall Width (outriggers down - CE)

27 ft 4 in (8.33 m)

26 ft 8 in (8.1 m)

27 ft 0.75 in (8.32 m)

6 ft 7.25 in (2 m)

7 ft 0.5 in (2.15 m)

5 ft 8.25 in (1.8 m)

12 ft 7.75 in (3.9 m)

13 ft 5.25 in (4.1 m)

1.3 CAPACITIES

Table 1-3. Capacities

Fuel Tank

Hydraulic Tank



Filling Volume



Usable Volume

Engine Crank case

1.525 Gallon (5.77 Liters)

6.9 Gallon (26.11 Liters)

6.3 Gallon (23.84 Liters)

1.16 qt. (1.0 Liter)

3121200

1-1

SECTION 1 - SPECIFICATIONS

1.4 ELECTRIC POWER UNIT

Motor

Pump

Table 1-4. Electric Power Unit Specifications

Power

Voltage

Amperage

Speed

Short Term

Operation

Intermittent

Operation

@ 740PSI

(51 Bar)

3.0 kW

24 VDC

4000 rpm

9 minutes

28%

@1500PSI

(103 Bar)

3.0 kW

24 VDC

140

3600 rpm

6 minutes

19%

@ 3000PSI

(207 Bar)

3.0 kW

24 VDC

230

2900 rpm

2 minutes

10%

Flow Rate

Displacement

3.0 gpm

(11.3 lpm)

2.7 gpm

(10.2 lpm)

0.192 cu.in. (3.15 cc)

2.2 gpm

(8.3 lpm)

1.5 TIRES

Size

Load Rating

Ply Rating/Load Range

Weight

Speed Category

Inflation Pressure

Wheel Nut Torque

Table 1-5. Tire Specifications

ANSI/ANSI EXPORT/

AUS/CSA

CE/SA

225-75-R15

2540 lbs. @ 65 psi

(1158 kg @458 kPa)

225/75-R16

3190 lbs. @ 83 psi

(1450 kg @ 575 kPa)

10/E

46 lbs. (21kg)

---

52 lbs. (24kg)

65 psi 450 kpa

90-120 ft. lbs. (120-163Nm) 221 ft. lbs. (300 Nm)

1.6 ENGINE

Type

Displacement

Bore x Stroke

Max. Output

Max. Torque

Fuel Consumption

Fuel Type

Spark Plug

Spark Plug Gap

Table 1-6. Engine Specifications

4-stroke, overhead valve, single cylinder

16.5 cu.in. (270 cm³)

3.0 x 2.3 in. (77 x 58 mm)

8.4 hp (6.3 kW) @ 3600 rpm

14.1 ft.lbs. (19.1 Nm) @ 2500 rpm

2.4 L/hr @ 3600 rpm

Unleaded gasoline with a pump octane rating of 86 or higher

NGK: BPR6ES

DENSO: W20EPR-U

0.028 - 0.031 in. (0.70 - 0.80 mm)

1.7 BATTERY

Table 1-7. Engine Battery Specifications

BCI Group Size

Cranking Performance

Reserve Capacity

Voltage

Capacity

450 amps @ 0

80 minutes @ 80

F (-18

F (0

51R

12V

50Ah @20hr rate

1.8 BATTERIES (ELECTRIC MACHINES)

Type

Table 1-8. Batteries Specifications (Electric Machines)

Voltage

Amp Hour Rating

Reserve Capacity @ 75

Amps

AT -40° F (-40° C) Open

Circuit Voltage

Life Cycle Rating

Prior to SN 0030001804 SN 0030001804 to Present

GC-110VNL EVGC6A-A

6-V Deep Cycle

225Ah @20hr

6-Volt

213Ah @20hr

447 Minutes 492 Minutes

Greater or Equal to 6 Volts

Internal Resistance

600 Cycles

No more than 2.5 m Ohms @ 70° F (21° C) / 4.0

m Ohms @ 0° F (-18°C)

Battery Weight

(minimum allowable)

60 lbs.(27.12kg) 66 lbs.(30 kg)

1-2

3121200

SECTION 1 - SPECIFICATIONS

1.9 LUBRICATION

Hydraulic Oil

Table 1-9. Hydraulic Oil

Hydraulic System Operating

Temperature Range

+0° to + 180° F (-18° to +83° C)

+0° to + 210° F (-18° to +99° C)

+50° to + 210° F (+10° to +99° C

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

NOTE:

Hydraulic oils require anti-wear qualities at least API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service2.

NOTE:

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.

Table 1-10. Mobilfluid 424 Specs

SAE Grade

ISO Grade

Gravity, API

Density, Lb/Gal. 60°F

Pour Point, Max

Flash Point, Min.

10W30

29.0

7.35

-46 ° F (-43 ° C)

442 ° F (228 ° C)

Viscosity

Brookfield, cP at -18°C at 40° C at 100° C

Viscosity Index

2700

55 cSt

9.3 cSt

152

1.10 COMPONENT WEIGHTS

Component

Frame (bare)

Frame - CE, Aus (bare)

Turntable (bare)

Booms & Cylinders Assembly

Main Boom

Engine Assembly



(Including Tray)

Engine (bare)

Axle

Platform w/Rotator

Platform W/o Rotator

Table 1-11. Component Weights

Pounds

597

939

262

1905.6

1451

113

271.2

137

Kilograms

271

382

119

866.2

435

123.4

1.11 PRESSURE SETTINGS

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 Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures.

Circuit

Main Relief

Telescope In

Telescope Out

Platform Level Up

Platform Level Down

Swing Right

Swing Left

Jacks In

Table 1-12. Pressure Settings

PSI

2950

2850

2400

2800

2000

600 - 800

2500

Bar

203.5

196.5

166

193

138

41 - 55

172.5

3121200

1-3

SECTION 1 - SPECIFICATIONS

1-4

4,5

7,8

2,3

10,11

MAE29490

Figure 1-1. Operator Maintenance & Lubrication Diagram

3121200

SECTION 1 - SPECIFICATIONS

1.12 MAINTENANCE & LUBRICATION

NOTE:

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.

KEY

MPG

EPGL

OGL

Table 1-13.Lubrication Specifications

SPECIFICATIONS

Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).

Extreme Pressure Gear Lube (oil) meeting API Service Classification

GL-5 or Mil-Spec Mil-L-2105.

Hydraulic Oil. API Service Classification GL-3, SAE 10W-20, Viscosity

Index 152, e.g. Mobilfluid 424.

Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API

CC/CD class, MIL-L-2104B/MIL-L-2104C.

Open Gear Lubricant - Mobiltac 375 or equivalent.

Wheel Bearings

Hydraulic Oil

Lube Point(s) - Fill Cap



Capacity - 6.3 gal. (23.8 L)



Lube - HO



Interval - Check oil daily, change after,

 every 1200 hours of operation.

Hydraulic Filter & Breather

3121200

Lube - MPG



Interval - every 12 months or 12,000 miles



Comments - Refer to Section 3.6, Hubs, Drums, Wheel

Bearings.

NOTE:

The cap securing the filter must be torqued



154 to 170 ft.lbs. (209 to 230.5 Nm).

Interval - 100 hours



Comments - Change after the first 20 hours, then

 every 100 hours of operation.

1-5

SECTION 1 - SPECIFICATIONS

Swing Bearing 7.

Engine

Lube Point(s) - 1 Grease Fitting



Capacity - As Required



Lube - MPG



Interval - Every month or 50 hours



Comments - Rotate the bearing back and forth

 to ensure grease is distributed evenly the whole

 way around the bearing.

Swing Bearing Teeth

Lube Point(s) - Spray On



Capacity - As Required



Lube - OGL



Interval - Every month or 50 hours



Comments - More frequent lubrication intervals may

 be required.

Swing Drive

Capacity - See Engine Manual.



Lube - EO, 10W30 API SJ



Interval - Check level daily; change per

 manufacturer’s engine manual.



Comments - Adjust final oil level by mark on dipstick.

Fuel Tank a. Engine (Prior to SN 0030004208)

Capacity - 1.6 Gal. (6 L)



Fuel - Gasoline



Interval - Check periodically during each shift.

b. Engine (SN 0030004208 to Present)

Capacity - 1.5 Gal. (5.7 L)



Fuel - Gasoline



Interval - Check periodically during each shift.

Lube Point(s) - 2 Grease Fittings



Capacity - As Required



Lube - MPG



Interval - As Required.

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN

BLOWING OUTER SEALS IN HOUSING.

1-6

3121200

Trailer Jack

GREASE

Capacity - As necessary



Lube - MPG & EO



Interval - As necessary.

10.

Surge Brake

OIL

11.

Coupler & Hitch Ball

SECTION 1 - SPECIFICATIONS

Capacity - Coupler 2 Grease Fittings (CE Only); Hitch Ball



As necessary



Lube - MPG



Interval - As necessary.

12.

Jockey Wheel Bearing (Drive and Set Option Only)

Lube Point(s) - Fill Cap



Capacity - No more than 1/2” (13 mm) from top of reservoir



Lube - DOT 3 or 4 Brake Fluid



Interval - Check before each tow. Flush the system

 yearly or when system is known to be contaminated.

Lube Point(s) - 1 Grease Fittings



Capacity - As Required



Lube - MPG



Interval - As Required.

3121200

1-7

SECTION 1 - SPECIFICATIONS

1-8

Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 5)

3121200

SECTION 1 - SPECIFICATIONS

3121200

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 5)

1-9

SECTION 1 - SPECIFICATIONS

1-10

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 5)

3121200

SECTION 1 - SPECIFICATIONS

3121200

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 5)

1-11

SECTION 1 - SPECIFICATIONS

1-12

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 5)

3121200

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND

MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition.

For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service. With proper care, maintenance and inspections performed per JLG's recommendations with any and all discrepancies corrected, this product will be fit for continued use.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a

Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety

Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start

Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule

SECTION 2. GENERAL

for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed 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 the

Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual

Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic.

JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

3121200

2-1

SECTION 2 - GENERAL

Type Frequency

Maintenance Manual.

Table 2-1. Inspection and Maintenance

Primary

Responsibility

User or Operator Pre-Start Inspection Prior to use each day; or

At each Operator change.

Pre-Delivery Inspection Prior to each sale, lease, or

 rental delivery.

Frequent Inspection

Annual Machine

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.

Annually, no later than 13 months from the date of the prior inspection.

Preventive



Maintenance

At intervals as specified in the Service and



Owner, Dealer, or User

Service

Qualification

User or Operator

Qualified JLG Mechanic

Factory-Trained Service

Technician

(Recommended)

Reference

Operator and Safety Manual

Service and Maintenance Manual and applicable JLG inspection form.

Qualified JLG Mechanic Service and Maintenance Manual

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

Cleanliness

The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

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.

Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

2-2

3121200

SECTION 2 - GENERAL

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

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.

Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness.

Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING

LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

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.

Unless specific torque requirements are given within the text, standard torque values should be used on heattreated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

3121200

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SECTION 2 - GENERAL

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

2.3 LUBRICATION AND INFORMATION

Hydraulic System

The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in

Section 1. Always examine filters for evidence of metal particles.

Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion.

If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE:

Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.

Hydraulic Oil

Refer to Section 1 for recommendations for viscosity ranges.

JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE:

Start-up of hydraulic system with oil temperatures below -

15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).

Changing Hydraulic Oil

Filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils.

Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the

Lubrication Chart.

2-4

3121200

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT

Theory

When a hydraulic cylinder is supporting a load, cylinder drift may occur as a result of any of the circumstances below:

• Normal leakage of load holding valves or malfunction of load holding valves. See Cylinder Leakage Test and



Table 2-2, Cylinder Drift below for evaluation.

• Damaged or worn piston seals.

• Normal thermal expansion or contraction of the hydraulic oil within cylinders (See Cylinder Thermal Drift below).

The first two circumstances may result in cylinder movement due to oil leaking out of the cylinder externally or by leaking back to tank or due to oil leaking internally from one cylinder chamber to the other.

Thermal expansion or contraction of oil in hydraulic cylinders is a normal occurrence and does not result in oil leaking out of the cylinder or leaking internally from one cylinder chamber to the other. Thermal expansion or contraction is the tendency for materials to change size in response to a change in temperature.

Platform Drift

Measure the drift of the platform to the ground. Lower booms

(if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following.

Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature before beginning this test.

Measure drift at cylinder rod with a calibrated dial indicator.

In an area free of obstructions, cylinder must have load applied and appropriately positioned to detect drift.

Cylinder leakage is acceptable if it passes this test.

Table 2-2. Cylinder Drift

Cylinder Bore

Diameter

Max. Acceptable Drift in 10 Minutes inches mm inches mm

3.5

76.2

101.6

127

0.026

0.019

0.015

0.009

0.66

0.48

0.38

0.22

152.4

177.8

203.2

228.6

0.006

0.005

0.0038

0.0030

0.15

0.13

0.10

0.08

NOTE:

This information is based on 6 drops per minute cylinder leakage.

Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to thermal effects over time and may result in changes to the boom and or platform position while the machine is stationary. These effects occur as the cylinder oil changes temperature, usually from a higher oil temperature as it cools and approaches the ambient air temperature. Results of these effects are related to several factors including cylinder length and change in temperature over the time the cylinder remains stationary.

3121200

2-5

SECTION 2 - GENERAL

2.5 PINS AND COMPOSITE BEARING REPAIR

GUIDELINES

Filament wound bearings.

Pinned joints should be disassembled and inspected if the following occurs: a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

Filament wound bearings should be replaced if any of the following is observed: a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their housing.

d. Debris embedded in liner surface.

Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection): a. Detectable wear in the bearing area.

b. Flaking, pealing, scoring, or scratches on the pin surface.

c. Rusting of the pin in the bearing area.

Re-assembly of pinned joints using filament wound bearings.

a. Housing should be blown out to remove all dirt and debris. Bearings and bearing housings must be free of all contamination.

b. Bearing/pins should be cleaned with a solvent to remove all grease and oil. Filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins).

c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation and operation.

2.6 WELDING ON JLG EQUIPMENT

NOTE:

This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external structure, or component.

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted).

• Ground only to structure being welded.

• Unplug all pressure transducers Refer to Section 6 - JLG

Control System.

Do Not Do The Following When Welding On Jlg

Equipment

• Ground on frame and weld on any other area than the chassis.

• Ground on turntable and weld on any other area than the turntable.

• Ground on the platform/support and weld on any other area than the platform/support.

• Ground on a specific boom section and weld on any other area than that specific boom section.

• Allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between the grounding position and the welded area.

FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-

PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR

RING, BOOM WIRE ROPES ETC.)

2-6

3121200

SECTION 2 - GENERAL

Item/Function

Wheel Lugs

Coupler Ball

Safety Chains

Brakes

Method

Table 2-3. Maintenance Schedule

Tighten to specified torque rating

Check for unusual wear

Check for unusual wear in links

Check general operation and proper adjustment

Brake Fluid

Breakaway

Suspension

Welds

Floor, hinges, door and dividers

Tires

Check reservoir

Check cable and all components

Check for worn components or broken springs

Check welds for cracks or separations

Wash both sides. Wash floor.

Inspect - repair or replace damaged, worn or broken parts.

Rotate every 5000 miles

Inspect tread and sidewalls thoroughly replace tire when treads are worn, when sidewall has a bulge, or sidewall is worn.

Brakes, electric

Magnets

Controller (in tow vehicle)

Roof vents, windows

Brakes - All types

Jack, drop leg

Check wear and current draw

Check power output (amperage) and modulation

Clean dirt buildup, lubricate hinges and slides

Check for scoring and wearing

Frame members/ welds

Grease gears at top

Inspect all frames members, bolts and rivets. repair or replace damaged worn or broken parts

Inspect all welds. repair as needed

Wheels - Sealed bearings

(hubs), Unsealed bearings,

Rims

Check and confirm free running. Replace if not. (sealed bearings are not serviceable)

Disassemble/inspect/assemble and repack. replace promptly, if immersed in water.

Inspect for cracks and dents. Replace as needed.

Check by dealer Axle attachment bolts

Footnote:

1 = Retighten when new and at the first 10, 25 and 50 miles



2 = Adjust after first 200 miles, 3000 mile intervals or as use requires.



3 = 1000 miles or 1 month when used in hot and dry environment.

Break-In

INTERVAL

Every 3000 Miles or 3 Months

Every 6000 Miles or 6 Months

Every 12,000

Miles or 1 year

3121200

2-7

SECTION 2 - GENERAL

NOTES:

2-8

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.1 BREAKING-IN A NEW TRAILER

SECTION 3. CHASSIS & TURNTABLE

3.2 TRAILER INSPECTION AND SERVICE

INSTRUCTIONS

Retighten Lug Nuts at First 10, 25 & 50 Miles

Wheel lugs can shift and settle quickly after being first assembled, and must be checked after the

first

10, 25 and 50 miles of driving. Failure to perform this check could result in a wheel coming loose from the trailer, causing a crash leading to death or serious injury.

CHECK LUG NUTS FOR TIGHTNESS ON A NEW TRAILER OR WHEN WHEEL(S)

HAVE BEEN REMOUNTED AFTER THE FIRST 10, 25 AND 50 MILES OF DRIVING.

Adjust Brake Shoes at First 200 Miles

Brake shoes and drums experience a rapid initial wear. The brakes must be adjusted after the first 200 miles of use, and each 3,000 miles thereafter. The brakes are adjusted manually.

Refer to section 3 for manual brake adjustment.

Synchronizing the Brake Systems

Trailer brakes are designed to work in synchronization with the brakes on the tow vehicle. Do not use either brake system alone to stop the combined tow vehicle and trailer.

When the tow vehicle and trailer braking systems are synchronized, both braking systems contribute to slowing, and the tongue of the trailer will neither dive nor rise sharply.

Fasteners and Frame Members

Inspect all of the fasteners and structural frame members for bending and other damage, cracks, or failure. Repair or replace any damaged fastener and repair the frame member. If you have any questions about the condition or method of repair of fasteners or frame members, get the recommendation of, or have the repair done by, your dealer.

The various fastener types used on your trailer are:

• Bolts, which are used mainly for attaching door and gate hinges to the trailer body.

• Buck Rivets, which are used to attach the sides and roof panels of the body to each other, and to the frame of the trailer.

• Huck Bolts may be at various locations on the sub-frame.

Huck bolts are not user serviceable. If you detect a loose huck bolt fastener, do not tow the trailer. Call your dealer for instructions.

INSPECT FOR BROKEN OR DAMAGED FASTENERS, WELDS OR OTHER DAMAGED

PARTS AT LEAST ONCE A YEAR AND HAVE ALL DAMAGED PARTS REPAIRED OR

REPLACED.

ROAD TEST THE BRAKES IN A SAFE AREA AT NO MORE THAN 30 M.P.H. BEFORE

EACH TOW.

Brake Shoes and Drums

Properly functioning brake shoes and drums are essential to ensure safety. You must have your dealer inspect these components at least once per year, or each 12,000 miles.

The brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have "seated," (2) at 3000 miles intervals, (3) or as use and performance requires.

To insure safe brake performance and synchronization, read and follow the axle/brake and the brake controller manufacturers’ instructions. If you do not have these instructions, call your dealer or JLG to obtain a copy.

A hard stop is used to:

• Confirm that the brakes work

• Confirm that the trailer brakes are properly synchronized with the tow vehicle brakes.

3121200

3-1

SECTION 3 - CHASSIS & TURNTABLE

Manually Adjusting Brake Shoes

The manually adjusted brakes should be adjusted in the following manner:

Jack up the trailer and secure it on adequate capacity jack stands.

Be sure the wheel and brake drum rotate freely.

Remove the wheel and brake drum. Because of the special stub axle arrangement, adjustment cannot be made through the backing plate.

With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum produces a slight drag.

Remount the wheel and brake drum.

Repeat the above procedure on all brakes.

Lower the trailer to the ground.

3.3 ELECTRIC BRAKES

The electric brakes on a trailer are similar to the drum brakes on an automobile. The basic difference is that the automotive brakes are actuated by hydraulic pressure while electric trailer brakes are actuated by an electromagnet. With all of the brake components connected into the system, the brake will operate as follows:

Primary Shoe

Retractor Spring

Secondary Shoe

Hold Down Spring

Adjuster Assembly

Adjuster Spring

Magnet

Actuating Lever

Figure 3-1. Electric Brake Assembly

When the electrical current is fed into the system by the controller, it flows through the electromagnets in the brakes. The high capacity electromagnets are energized and are attracted to the rotating armature surface of the drums, which moves the actuating levers in the direction that the drums are turning.

The resulting force causes the actuating block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum. The force generated by the primary shoe acting through the adjuster assembly then moves the secondary shoe out into contact with the brake drum.

Increasing the current flow to the electromagnet causes the magnet to grip the armature surface of the brake drum more firmly. This results in increasing the pressure against the shoes and brake drums until the desired stop is accomplished.

3-2

3121200

SECTION 3 - CHASSIS & TURNTABLE

Brake Controller

A tow vehicle brake controller is required. These controllers have gain control to vary the amount of current to the brakes, and a level control which sets the controller's inertia sensor to sense deceleration. The level adjustment also can be used to vary when the trailer braking is felt. The gain or output control adjustment usually controls the maximum amount of amperage available to the brakes. This can be adjusted for varying trailer loads.

The electric brakes that operate in conjunction with the tow vehicle brakes must be “synchronized” so that braking is properly distributed to the tow vehicle brakes and the trailer brakes. For proper operation and synchronization, read and follow the axle/brake and the brake controller manufacturers’ instructions

Brake Cleaning and Inspection

Your trailer brakes must be inspected and serviced at yearly or

12,000 miles intervals or more often as use and performance requires. Magnets and shoes must be changed when they become worn or scored thereby preventing adequate vehicle braking. Clean the backing plate, electromagnet, and brake shoes. Make certain that all the parts removed are replaced in the same brake and drum assembly. Inspect the magnet arm for any loose or worn parts. Check shoe retractor springs, hold down springs, and adjuster springs for stretch or deformation and replace if required.

Shoes and Linings

A simple visual inspection of your brake linings will tell if they are usable. Replacement is necessary if the lining is worn (to within 1/16” or less), contaminated with grease or oil, or abnormally scored or gouged. It is important to replace both shoes on each brake and both brakes of the same axle. This is necessary to retain the “balance” of your brakes.

3.4 HYDRAULIC (SURGE) BRAKES

In the hydraulic brake system, hydraulic fluid from the master cylinder is used to actuate the hydraulic wheel cylinder, which, in turn, applies force against the brake shoes and drum. The main differences between automotive hydraulic brakes and hydraulic trailer brakes are the actuation systems that transfer the braking signal from the tow vehicle to the brake. A surge tongue actuator is required for a trailer with hydraulic brakes.

The hydraulic brake uses a single acting cylinder. Upon actuation, the primary shoe is pressed against the brake drum, which causes the shoe to move in the direction of rotation.

This movement in turn actuates the secondary shoe through the adjuster link assembly. Braking in reverse is significantly less effective than in the forward direction.

Anchor Post

Wheel Cylinder

Hold Down Spring

Primary Shoe

Adjuster Assembly

Adjuster Spring

Secondary Shoe

Backing Plate

Retractor Spring

Figure 3-2. Hydraulic Brake Assembly

The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle, but no less than once per year. This inspection includes an assessment of the condition and proper operation of the wheel cylinders, brake shoes, brake drums and hubs.

Check the fluid level in the master cylinder reservoir at least every three months. If you tow your trailer an average of 1,000 miles per month in a hot and dry environment, you must check the brake fluid level once a month. The brake fluid reservoir is located on the tongue of the trailer. Fill with DOT 3 or 4 brake fluid.

3121200

3-3

SECTION 3 - CHASSIS & TURNTABLE

Self Adjusting Mechanism

The self adjusting feature adjusts the brakes on both forward and reverse stops. Brake adjustment occurs only when lining wear results in enough gap between the shoes and the drum surface. The added clearance allows the adjuster mechanism to rotate the screw assembly at the bottom of the brake. That action expands the distance between the shoes and thus closes the gap to the drum surface.

Parking Brake

The parking brake is cable operated. The parking cable body is mounted to the brake backing plate. The cable end is attached to the internal parking brake lever to actuate the brake. The internal parking brake lever, which is mounted to the secondary shoe, transfers applied cable force through a parking strut which is attached to the primary shoe. This transferred load generates a spreading force between the primary and secondary shoes. The shoes move toward the drum until contact is made. Friction generated between the drum and lining contact surface results in parking brake capablilty.

General Maintenance

DRUM BRAKE ADJUSTMENT

Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated,” (2) at

3000 miles intervals, (3) or as used and performance requires.

The brakes should be adjusted in the following manner:

DO NOT LIFT OR SUPPORT THE TRAILER ON ANY PART OF THE AXLE OR SUS-

PENSION SYSTEM. NEVER GO UNDER ANY TRAILER UNLESS IT IS PROPERLY

SUPPORTED ON JACK STANDS WHICH HAVE BEEN RATED FOR THE LOAD.

IMPROPERLY SUPPORTED VEHICLES CAN FALL UNEXPECTEDLY AND CAUSE

SERIOUS INJURY OR DEATH.

Jack up trailer and secure on adequate capacity jack stands. check that the wheel and drum rotate freely.

Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate.

Rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag.

Replace the adjusting hole cove and lower the wheel to the ground.

Repeat the above procedure on all brakes. For best results, the brakes should all be set at the same clearance.

3-4

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.5 MECHANICAL BRAKE

Brake Maintenance

WHEEL BRAKES

The linings of the wheel brakes are wearing parts, so their condition must be checked every 3000 miles (5000 km) or every year, whichever comes first, using the view holes on the wheel backing plates.

If the connecting rod can be pushed in more than approximately 45 mm when the over-run braking system is checked as outlined above, this is a sure sign of advanced wearing of the brake linings. If this is the case, the wheel brakes must be readjusted at a qualified workshop, and if necessary, the brake shoes must be replaced.

WHEEL MOUNTS

The wheel hubs have maintenance-free, double row angular ball bearings.

The sideways bearing play should be checked at intervals of

3000 miles (5000 km) by checking whether the wheels have sideways play when the trailer is jacked up. If there is detectable play, the trailer should be checked at a qualified workshop.

REPLACING BRAKE ASSEMBLY COMPLETE

IT IS RECOMMENDED THAT THE BRAKE ASSEMBLIES ARE REPLACED IN AXLE

SETS.

Follow steps 1 thru 7 of REPLACING BRAKE SHOES.

The brake assemblies are left and right specific, check the new assembly against the one fitted noting the position of the brake cable attachment. Remove the four bolts securing the backplate to the axle, remove the old assembly and install the new using the proper torque values.

Continue with the procedure under REPLACING BRAKE

SHOES, starting at step 18.

Follow the procedure under ADJUSTMENT.

REPLACING BRAKE SHOES

Place the trailer on stands with all wheels off of the ground.

WARNING: The handbrake should be released and the handbrake locking bolt installed.

Some couplings do not have provision for the locking bolt. In this case or if a bolt cannot be used the handbrake lever should be secured in the off position to prevent the handbrake lever from operating.

NOTE:

It is recommended that the brake shoes are replaced in axle sets.

Remove the wheels.

Remove the hub cap.

Slacken off the brake adjuster bolt until free. Some brake assemblies have a ratchet accessible through an opening in the backplate instead of the bolt.

Remove the axle nut, this may be a castellated nut retained with a cotter pin or it may be a locknut.

Remove the brake drum (hub puller may be required) taking care not to displace the bearings.

AVOID INHALING BRAKE DUST. DON’T USE AN AIR LINE TO CLEAN THE DRUM.

CAREFULLY REMOVE THE DUST USING A SMALL BRUSH.

Check the condition of the brake drum. Replace the brake drum if deep score marks are visible.

3121200

3-5

SECTION 3 - CHASSIS & TURNTABLE

3-6

Flanged Nut

Lockwasher

Hub/Drum Assembly

Cotter Pin

Dust Cap

Washer

Castle Nut

Inner Bearing

Outer Bearing

10. Washer

11. Brake Shoe (Primary)

12. Brake Shoe (Secondary)

13. Tension Spring (Bottom)

14. Tension Spring (Top)

15. Tension Spring (Center)

16. Spring Clip

17. Compression Spring Spreader

18. Adjusting Key

Figure 3-3. Mechanical Brake Assembly

19. Adjusting Bolt

20. Bolt

21. Adjustment Hole Plug

22. Protective Shield

23. Drawbar Eye

24. Protective Sleeve

25. Brake Cable

3121200

SECTION 3 - CHASSIS & TURNTABLE

Undo the locknut on the brake rod (front to rear) adjacent to the compensator. Slacken the second nut on the brake rod. Remove the half shell from the backplate and detach the brake cable.

Record the orientation of the brake shoes and springs on the backplate to ensure the new shoes and springs are replaced in the same position as the old.

ADJUSTMENT

NOTE:

When adjusting the brake drum, only turn the wheel in the direction of forward rotation.

Turn each wheel in the direction of forward rotation.

Turn the brake adjuster bolt clockwise until some resistance is felt as the brake shoes begin to grip the drum, then slowly turn the brake adjuster bolt counterclockwise until the wheel begins to rotate freely again. Alternatively advance the adjuster using a screwdriver through the backplate hole until resistance is felt, then turn back by a few clicks until the wheel begins to rotate freely again.

Turn the nut on the brake rod until the nut is in contact with the compensator.

With care and using a suitable lever, lift sliding shoe carrier away from expander. Extract expander and retain.

10.

Remove brake shoe retaining spring taking care to retain the spring. Keep plate or pin at the rear of the backplate where installed.

11.

Lift off whole brake shoe assembly from backplate. Take care not to lose the two adjuster wedges.

12.

Examine the components and springs, replace any damaged parts. Clean the mechanism and ensure that all parts are free to move. Do not lubricate.

13.

Install the springs on the new brake shoes.

14.

Locate the shoes onto the backplate and position onto the adjuster wedges or cam block.

15.

Install the retaining springs.

16.

Locate the expander into position on the fixed plate.

17.

With care, and using a suitable lever, position the expander between the shoes and release the lever.

18.

Attach the brake cable and install the half shell. Always replace the brake cables if they show signs of wear, stiffness, damage, or fraying.

19.

Install the drum and bearing. Replace the split pin or lock nut depending upon which type of nut is used. If a cotter pin and castellated nut is used, the axle nut must be adjusted to allow the correct bearing clearance. If a locknut is used, it is tightened to a pre-determined torque.

20.

Install the hub cap.

21.

Repeat the procedure on the other drum.

22.

Install the tires and wheels.

23.

Follow the procedure under ADJUSTMENT.

DO NOT OVERTIGHTEN AS THIS WILL CAUSE THE BRAKES TO DRAG AND OVER-

HEAT.

DOUBLE CHECK THAT EVERYTHING HAS BEEN REASSEMBLED WITH ALL FAS-

TENERS SECURED.

Remove the handbrake locking bolt and operate the handbrake several times to ensure that the compensators are seated. Check the travel of individual brake cables. This should be 2-5 mm. If not, re-adjust the brake as appropriate.

With the handbrake engaged, turn each wheel in the reverse direction. They should turn a little and then lock as the auto-reverse mechanism operates. As each wheel is turned there will be a rearward movement of the handbrake lever as the energy store operates. This action should occur once on the rearward turn of each wheel. If any wheel fails to lock, there is too much slack in the system.

Check the compensators are at 90° to the brake rod with the brakes applied in forward and reverse. Misalignment can be corrected through adjustment of the cable locking nuts. This is particularly important if a new cable has been installed.

Operate the handbrake and leave it on. Lower the trailer to the floor and recheck the torque of the wheel nuts.

Please note the brakes will not be 100% effective until the new linings have bedded in.

The brake adjustment should be rechecked after a short journey.

THE DRUMS MAY BE HOT.

3121200

3-7

SECTION 3 - CHASSIS & TURNTABLE

Adjustment and Readjustment of the Overrun

Braking System

ADJUSTING THE BRAKING SYSTEM

Preparations:

Place the trailer on jacks with the wheels off of the ground.

Release the handbrake

Pull out the drawbar as far as it will go.

Preliminary Requirements:

When carrying out adjustments, always start with the wheel brakes.

When carrying out adjustments, turn the wheel only in the direction of forward travel.

Do not pre-tension the expanding locking mechanism in the brake. If necessary, loosen the brake linkage at the brake compensator.

Check the expanding locking mechanism and control cable for ease of movement.

NEVER READJUST THE BRAKING SYSTEM OR BRAKES BY THE BRAKE LINKAGE

OR TURNBUCKLES (IF APPLICABLE) IN THE LINKAGE. THE COMPRESSION

SPRING MAY ONLY BE LIGHTLY PRE-TENSIONED AND MUST NOT BECOME

FULLY COMPRESSED WHEN ACTIVATED!

ADJUSTMENT PROCEDURE

Brake

Loosen the linkage

Tighten the adjusting screw (12) (on the outside of the brake plate, opposite the cable entry[13]), turning clockwise until the wheel can only be turned with difficulty or not at all.

12. Adjusting Screw



13. Cable Entry

Figure 3-5. Wheel Brake System c.

Ease off the adjusting screw (12) in the counterclockwise direction (approx. 1/2 turn) until the wheel turns freely. Slight rubbing noises, which do not effect the free turning of the wheel, are permitted.

When the brake is correctly adjusted, the actuating travel of the control cable (11) will be 5-8 mm.

11 7

1. Contact Breaking Cable



2. Trailer Coupling Ring



3. Handbrake Lever



4. Transmission Lever

5. Drawbar & Bellows

Figure 3-4. Overrun Brake System



6. Brake Linkage

7. Compression Spring

8. Brake Compensator

9. Master Compensator



10. Brake Compensating Balances

11. Control Cable

Figure 3-6. Transmission System For Tandem and

Single-axle Chassis e.

Repeat the procedure on the other wheel.

3-8

3121200

SECTION 3 - CHASSIS & TURNTABLE

Brake Compensating System

Preadjust the length of the brake linkage (slight play permitted).

Operate the handbrake lever (3) and check the position of the compensating balances (9 & 10). They should be at right angles to the direction of towing.

If necessary, adjust the position of the balance (10) and control cables (11).

The compression spring may only be lightly pre-tensioned and must not become fully compressed when activated.

Brake Linkage

Adjust the brake linkage so that it is free of play longitudinally, without initial tension (reversing lever free of play).

b. Readjustment:



Operate the handbrake lever powerfully several

 times in order to settle the braking system.



Check the position of the brake compensating balances which should be at right angles to the direc-

 tion of towing.



Check the play in the linkage; if necessary, adjust the linkage again so that it is free of play, but with-

 out initial tension.



Check the position of the handbrake lever; when checking the dead center of the lever, resistance

 starts 10-15 mm above dead center



Check that the wheels rotate freely with the brake released.

c. Final Check:



Check fastenings for security (secure the hexagon locking nuts to the screw fastenings for the trans-

 mission system, control cables, brake compensators, turnbuckle, linkage, etc.)



Check the compression spring for initial tension.

d. Test Run:

If necessary, carry out 2-3 brake tests.

e. Brake Test:

Recheck the play in the brake linkage and if necessary, readjust the linkage for length free of play; during operating braking with empty trailer should be used maximally 1/2 of the overrun travel.

READJUSTING THE BRAKING SYSTEM

The main purpose of readjusting the braking system is compensate for brake lining wear. To readjust the wheel brakes, follow the instructions under ADJUSTING THE BRAKING SYS-

TEM. Check the play in the linkage and readjust if necessary.

CHECK THE EXPANDING LOCKING MECHANISM AND CONTROL CABLE. THE

EXPANDING LOCK COMPENSATOR MUST NOT BE PRE-TENSIONED IN THE

BRAKE. DO NOT ATTEMPT TO COMPENSATE FOR EASE OF MOVEMENT CAUSED

BY BRAKE LINING WEAR BY READJUSTING (SHORTENING) THE BRAKE LINK-

AGE, BY WAY OF THE LINKAGE SCREW FASTENINGS.

Readjustment:

Operate the handbrake lever powerfully several times in order to settle the braking system.

Check the position of the brake compensating balances (which should be at right angles to the direction of towing).

Recheck the play in the linkage.

If necessary, adjust the linkage again so that it is free of play, but without the initial tension.

Check the positions of the handbrake lever and compression spring (only light initial tension).

When checking the dead center of the lever, resistance starts 10-15 mm above dead centre.

Final Check:

Check the screw fastenings for the transmission system (control cables, brake compensators, linkage, etc.)

3121200

3-9

SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

Malfunction

Insufficient braking effect

Brake reacts by jerks

Table 3-1. Malfunctions and Remedies

Cause Remedy

Excessive backlash in brake system

Brake linings not run in

Brake linings glazed, oily or damaged

Overrunning hitch hard to operate

Brake linkage is jammed or deformed

Brake Bowden cables rusty or kinked

Excessive backlash in brake system

Shock absorber of overrunning hitch defective

Service at qualified workshop

Actuate hand-brake lever slightly; drive 1-2 miles (2-3 km)

Service at qualified workshop

Grease overrunning hitch

Service at qualified workshop

Backmat brake shoe is jammed in the brake shoe holder Service at qualified workshop

Wheel brakes are actuated unilaterally Service at qualified workshop

Shock absorber of overrunning hitch defective Service at qualified workshop

Trailer is braked unilaterally

Trailer is already braked when the accelerator pedal is released.

Reverse driving hard to accomplish or even impossible

Braking action of handbrake insufficient

Wheel brakes get hot

Ball coupling does not rest on ball

Brake system adjusted too tightly

Bowden cables pre-loaded

See "Brake reacts by jerks"

Incorrect setting

Service at qualified workshop

Brake system incorrectly set

Wheel brakes dirty

Reversing lever of overrunning hitch is jammed

Spring type actuator is pre-loaded in zero position; nuts are turned in too far

Actuate handbrake lever as far as possible

Service at qualified workshop

Handbrake lever not or only partially released

Coupling dirty on the inside

Ball of towing vehicle too big

Set handbrake lever into zero position

Clean and grease properly

Check ball diameter: According to DIN 74058 the ball on the tow vehicle must not exceed 50 mm in diameter when new and it must be Ø 49.5 mm. If the ball diameter decreases to less than 49.0 mm, the ball has to be replaced. The ball must be perfectly spherical.

3-10

3121200

SECTION 3 - CHASSIS & TURNTABLE

3121200

BRAKE

LEVER

2in Ball

* Torque to 120-155 ft. lbs (160-210 Nm)

Safety Chain

Pin and Cable

Coupler Assembly

Parking Brake Cable Assembly

Parking Brake Bracket

Conduit

Electric Brake Assembly

Tire Assembly

Tongue Adapter

10. Battery Charger

11. Tongue

Figure 3-7. Axle and Tongue Installation With Electric Brakes (2 in Ball)

0273654-I

MAE30540

3-11

SECTION 3 - CHASSIS & TURNTABLE

3-12

BRAKE

LEVER

50mm Ball

* Torque to 120-155 ft. lbs (160-210 Nm)

Coupler assembly

Spacer

Pin and cable

Tongue

Parking Brake Cable Assembly

Parking Brake Bracket

Conduit

Electric Brake Assembly

Tire Assembly

10. Battery Charger

Figure 3-8. Axle and Tongue Installation With Electric Brakes (50mm ball)

0274767-C

MAE30620

3121200

SECTION 3 - CHASSIS & TURNTABLE

2 in Combination

BRAKE

LEVER

* Torque to 120-155 ft. lbs (160-210 Nm)

2 in Ball

Safety Chain

Coupler Assembly

Lanyard Cable

Brake Line

Tongue Adapter

Parking Brake Cable Assembly

Parking Brake Bracket

Conduit

Hydraulic Brake Assembly

10. Tire Assembly

11. Tongue

12. Hairpin

Figure 3-9. Axle and Tongue Installation With Hydraulic Brakes (2in Ball)

3121200

0275908-E

MAE30550

3-13

SECTION 3 - CHASSIS & TURNTABLE

* Torque to 120-155 ft. lbs (160-210 Nm)

0273657-G

MAE30560

Hitch Adapter

Coupler Assembly

Tongue

Rod

Brake Rod Support

Tube Mount Bar

Mechanical Brake Assembly

Tire Assembly

Figure 3-10. Axle and Tongue Installation with Mechanical Brakes (50mm ball)

3-14

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.6 HUBS, DRUMS, WHEEL BEARINGS

The wheel bearing configuration consists of opposed tapered roller bearing cones and cups, fitted inside of a precision machined cast hub. This configuration requires a minimal amount of end play be provided at assembly, which is essential to the longevity of the bearing service life. This design is lubricated with grease packed into the bearings.

Hub Removal

Elevate and support the machine.

Bearing Inspection

Wash all grease and oil from the bearing cone using a suitable solvent. Dry the bearing with a clean, lint-free cloth and inspect each roller assembly.

NEVER SPIN THE BEARING WITH COMPRESSED AIR. THIS CAN DAMAGE THE

BEARING.

If any pitting, spalling, or corrosion is present, then the bearing must be inspected.

FOLLOW MAINTENANCE PROCEDURES TO PREVENT DAMAGE TO IMPORTANT

STRUCTURAL COMPONENTS. DAMAGE TO CERTAIN STRUCTURAL COMPO-

NENTS SUCH AS WHEEL BEARINGS CAN CAUSE THE WHEEL END TO COME OFF

OF THE AXLE. LOSS OF A WHEEL END WHILE THE MACHINE IS MOVING CAN

CAUSE A LOSS OF CONTROL AND LEAD TO AN ACCIDENT, WHICH CAN RESULT

IN SERIOUS INJURY OR DEATH.

Using adequate support to the wheel, Remove the nut securing wheel to hub.

Remove the wheel.

Remove the grease cap by carefully prying progressively around the flange of the cap.

Remove the cotter pin from the spindle nut.

Unscrew the spindle nut (counterclockwise) and remove the spindle washer.

Remove the hub from the spindle, being careful not to allow the outer bearing cone to fall out. The inner bearing cone will be retained by the seal.

Brake Drum Inspection

The drum surface (where the brake shoes make contact) should be inspected for excessive wear or heavy scoring.

If worn more than 0.020 in. (0.50 mm) oversized, or the drum has worn out of round by more than 0.015 in. (0.38 mm), then the drum surface should be re-machined. If scoring or other wear is greater than 0.090 in. (2.28 mm) on the diameter, the drum must be replaced (i.e. for a 10 in [25.400 cm] drum, no greater than 10.090 in.[25.628 cm]).

NOTE:

It is important to protect the wheel bearing bores from metallic chips and contamination which result from drum turning. Ensure the wheel bearing cavities are clean and free of contamination before reinstalling the bearing and seals. The presence of these contaminants will cause premature wheel bearing failure.

BEARINGS MUST ALWAYS BE REPLACED IN SETS OF A CONE AND CUP.

BE SURE TO WEAR SAFETY GLASSES WHEN REMOVING OR INSTALLING FORCE

FITTED PARTS. FAILURE TO COMPLY MAY RESULT IN SERIOUS EYE INJURY.

When replacing the bearing cup proceed as follows:

Place the hub on a flat work surface with the cup to be replaced on the bottom side.

Using a brass drift punch, carefully tap around the small diameter end of the cup to drive out.

After cleaning the hub bore area, replace the cup by tapping in with the brass drift punch. Be sure the cup is seated all the way up against the retaining shoulder in the hub.

Bearing Lubrication

Bearings should be lubricated every 12 months or 12,000 miles. The procedure to repack bearing cones is as follows:

Place a quantity of grease into the palm of your hand.

3121200

3-15

SECTION 3 - CHASSIS & TURNTABLE

Press a section of the widest end of the bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing.

Pry the seal out of the hub with a screwdriver. Never drive the seal out with the inner bearing as you may damage the bearing.

Repeat this while rotating the bearing from roller to roller.

Continue this process until the entire bearing is completely filled with grease.

Before installing, apply a light coat of grease on the bearing cup.

Thickener Type..................................................... Lithium Complex



Dropping Point ...................................... 419° F (215°C) Minimum



Consistency .........................................................................NLGI No. 2



Additives ............................EP, Corrosion & Oxidation Inhibitors



Viscosity Index............................................................... 80 Minimum



Approved Sources:



Mobil Oil ....................................... Mobilgrease HP, Mobilith AW2



Exxon/Standard ..................................................................Ronex MP



Kendall Refining Co. ...................................................Kendall L-427



Ashland Oil Co. ................................. Valvoline Multipurpose GM



76 Lubricants ............................................................76 Multiplex EP



Citgo Petroleum...................................................... Lithoplex MP#2



Mystik .................................................. Mystik JT-6 Hi Temp Grease



Pennzoil ...........................Premium Wheel Bearing Grease 707L

Seal Inspection and Replacement

Whenever the hub is removed, inspect the seal to assure it is not nicked or torn and is still capable of properly sealing the bearing cavity. If there is any question of condition, replace the seal.

To replace the seal:

Apply a sealant, such as PERMATEX, to the outside of the new seal.

NOTE:

Permatex sealant should not be used on rubber encased seals.

Tap the new seal into place using a clean wooden block.

Bearing Adjustment

If the hub has been removed or bearing adjustment is required, the following adjustment procedure must be followed:

Rotate the hub assembly slowly while tightening the spindle nut to approximately 50 ft.lbs. (68 Nm).

Loosen the spindle nut to remove the torque. DO NOT

ROTATE THE HUB.

Finger tighten the spindle nut until just snug.

Back the spindle nut out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin.

Bend over the cotter pin legs to secure the nut.

NOTE:

The nut should be free to move with the only restraint being the cotter pin.

3-16

3121200

SECTION 3 - CHASSIS & TURNTABLE

3121200

Grease Seal

Inner Bearing Cone

Inner Bearing Cup

Brake Assembly

Hub Assembly

Wheel Stud

Outer Bearing Cup

Outer Bearing Cone

Spindle Washer

10. Spindle Nut

11. Cotter Pin

12. Grease Cap

Figure 3-11. Hub and Brake Assembly

13. Wheel Nut

14. Hub

3-17

SECTION 3 - CHASSIS & TURNTABLE

WHEEL CYLINDERS

Inspect for leaks and smooth operation. Clean with brake cleaner and flush with fresh brake fluid. Hone or replace as necessary.

BRAKE LINES

Check for cracks, kinks, or blockage. Flush with fresh brake fluid. Bleed system to remove all air. Replace as necessary.

SHOES AND LININGS

Inspect visually. Replace if the lining is worn to within 1/16"

(1.6 mm) or less, contaminated with grease or oil, or abnormally scored or gouged. When replacement is necessary, it is important to replace both shoes on each brake and both brakes of the same axle to maintain balance in the braking system.

After replacement of the brake shoes and linings, the brakes must be re-burnished to seat in the new components. This should be done by applying the brakes 20 to 30 times from an initial speed of 40 mph, slowing the vehicle to 20 mph. Allow ample time for the brakes to cool between applications. This procedure allows the brake shoes to seat in to the drum surface.

HARDWARE

Check all hardware. Check shoe retractor spring, hold down springs, and adjuster springs for stretch or wear. Replace as required.

DRUMS

Check drums for scoring, cracking, or uneven wear. Turn drum smooth only if under maximum diameter. Replace as necessary.

3.7 TIRES & WHEELS

Tire Inflation

Tire pressure is the most important factor in tire life. Inflation pressure should be as recommended and stated on the sidewall of the tire. Pressure should be checked cold before operation. Do not bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Tire Wear

Inspect tires periodically for wear or damage. Tires with less than 1/16" (2 mm) tread depth or visible wear bands require replacement.

A bubble, cut or bulge in a sidewall can result in a tire blowout.

Inspect both sidewalls of each tire for any bubble, cut or bulge; and replace a damaged tire before towing the trailer.

WORN, DAMAGED OR UNDER-INFLATED TIRES CAN CAUSE LOSS OF CONTROL,

RESULTING IN DAMAGE, SERIOUS INJURY OR DEATH. INSPECT TIRES BEFORE

EACH TOW.

The following tire wear diagnostic chart will help you pinpoint the causes and solution of tire wear problems.

Table 3-2. Tire Wear

Wear Pattern Cause Action

Center Wear Over Inflation

Adjust Pressure to value specified in

Section 7

Edge Wear Under Inflation

Adjust Pressure to value specified in

Section 7

Cupping Out of balance

Check bearing adjustment and balance tires

Flat Spots

Wheel lockup and tire skidding

Avoid sudden stops when possible and adjust brakes.

3-18

3121200

SECTION 3 - CHASSIS & TURNTABLE

Tire Replacement

JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the

JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the original

Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

Wheel Replacement

Replacement wheels must have the same diameter, width, and profile as the original. Replacement tires must be the same size, ply rating, and load range as the tire being replaced. Refer to the Vehicle Identification plate on the chassis for wheel and tire specifications.

Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.

Tighten nuts in the following sequence:

The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart.

Table 3-3. Wheel Torque Chart - ANSI, ANSI Export, CSA, Aus

1st Stage

20-25

(25-35)

TORQUE SEQUENCE - Ft Lbs (Nm)

2nd Stage

50-60

(70-80)

3rd Stage

90-120

(122-163)

Table 3-4. Wheel Torque Chart - CE

1st Stage

(70)

TORQUE SEQUENCE - Ft Lbs (Nm)

2nd Stage

125

(170)

3rd Stage

221

(300)

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE

TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS

SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS

MATCHED TO THE CONE ANGLE OF THE WHEEL.

Tighten the lug nuts to the proper torque for the axle size on your trailer, to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows:

Start all nuts by hand to prevent cross threading. DO

NOT use a lubricant on threads or nuts.

Wheel nuts should be torqued before first road use and after each wheel removal. Check and torque after the first 10 miles, 25 miles, and again at 50 miles. Check periodically thereafter.

Lug Nuts (Bolts)

Lug nuts are prone to loosen right after a wheel is mounted to a hub. When driving on a remounted wheel, check to see if the lug nuts are tight after the first 10, 25 and 50 miles of driving and before each tow thereafter.

CHECK LUG NUTS FOR TIGHTNESS ON A NEW TRAILER OR WHEN WHEEL(S)



HAVE BEEN REMOUNTED AFTER THE FIRST 10, 25 AND 50 MILES OF DRIVING.



METAL CREEP BETWEEN THE WHEEL RIM AND LUG NUTS WILL RESULT IN A

WHEEL COMING OFF, LEADING TO DEATH OR SERIOUS INJURY. TIGHTEN LUG

NUTS BEFORE EACH TOW.

3121200

3-19

SECTION 3 - CHASSIS & TURNTABLE

PLACE THE SPARE ON THE HOOK

PROVIDED ON THE MOUNTING

FIXTURE AND THEN FOLLOW

DIRECTOINS BELOW

ROTATE THE SPARE SO THE TWO HOLES LINE UP WITH

THE TWO SLOTS IN THE MOUNTING PLATE AND INSERT

CARRIAGE BOLTS THROUGH FROM THE BACK SIDE.

ASSEMBLE WHEEL NUTS TO THIS SIDE.

3-20

INSERT CARRIAGE BOLTS SO THAT THE

SQUARE NECKS ARE IN SLOTS ON THIS SIDE

AS SHOWN

Figure 3-12. Spare Tire (Optional)

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.8 HYDRAULIC BRAKE COUPLER

Troubleshooting

IF ANY OF THE FOLLOWING CONDITIONS DEVELOP, TRAILER MUST NOT BE

USED UNTIL PROPER CORRECTIVE ACTION IS TAKEN.

Symptom

Squeaking, Clatter, or Chucking

Release handle does not close easily

Brake Overheating, Side Pull, Brakes do not

Operate, Poor Brake Performance

Towing Vehicle Shaking Back and Forth

Table 3-5. Surge Brake Troubleshooting

Cause

Lack of Hitch Ball Lubrication

Binding Linkage & Pivots on Brake Actuator

Loose Hitch Ball

Loose Hitch

Actuator loose on trailer frame

Hitch ball worn or too small

Overheated Brakes

Broken Brake Drum(s)

Low Brake fluid level

Worn out shock absorber

Partial application of breakaway cable

Brakes improperly adjusted

Broken brake return spring

Seized actuator master cylinder

Worn out brake shoes

Leaky wheel cylinders

Oversized ball

Ball not fully inserted into socket

Foreign material in actuator socket

Only one brake is applying

Leaking wheel cylinder

Seized wheel cylinder piston

Foreign Material in Brake Unit

Low hydraulic fluid level

Bent shoulder bolt

Bent push rod in the shock absorber

Damaged socket assembly

Broken/Pinched brake lines

Brake actuator frame damaged

Worn brake shoe(s)

Worn vehicle suspension

Hitch not secure

Under-sized hitch ball

Solution

Lubricate with conventional automotive grease or commercial lubricant made for hitch balls

Oil linkage & pivots on brake actuator

Inspect hitch and tighten

Inspect brake actuator and tighten

Replace

Replace wheel bearing

Replace brake drum(s) & check brake shoes

Fill & bleed brakes

Replace

Fully release breakaway cable

Check brakes

Replace return spring

Replace/rebuild actuator master cylinder

Replace brake shoes and check brake drums

Replace/rebuild wheel cylinders and replace brake shoes. Clean drums and other hardware.

Check ball size

Check for proper ball size. Check to see if tongue jack is fully retracted.

Hold release handle open when inserting ball.

Clean and lubricate

Check brake adjustment

Check and replace wheel cylinder and bleed brakes

Check and rebuild/replace wheel cylinder and bleed system.

Clean thoroughly

Fill and bleed brakes

Replace

Replace shock absorber

Replace actuator

Replace

Replace actuator

Replace brake shoe(s)

Replace shock absorber

Tighten all bolts and nuts

Replace with proper size

3121200

3-21

SECTION 3 - CHASSIS & TURNTABLE

Bleeding the Brake System Towing

DO NOT USE BRAKE FLUID DRAINED FROM THE BRAKE SYSTEM IN REFILLING

THE MASTER CYLINDER. USED BRAKE FLUID CAN BE CONTAMINATED FROM

THE SYSTEM.

Remove the master cylinder filler cap and fill reservoir with DOT type 3 or 4 automotive brake fluid.

Check all hydraulic line fittings and connections to make sure they are leak free.

At brake assembly, connect a bleeder hose to bleeder fitting on the wheel cylinder and submerge the free end in a container with brake fluid. DO NOT reuse brake fluid.

NOTE:

Use a power bleeder or a bar with a 2" (50 mm) hitch ball attached. Do not use the breakaway cable for bleeding the brake system. If a power bleeder is used, air pressure of 35 psi (2.4 Bar) is most effective.

THE TRAILER MAY DISCONNECT IF NOT PROPERLY SECURED. THE RELEASE

HANDLE MUST BE FULLY CLOSED BEFORE TOWING. DO NOT FORCE THE

RELEASE HANDLE INTO THE CLOSED POSITION.

Position the actuator ball socket above the ball.

DO NOT DAMAGE THE ACTUATOR WHEN BACKING UP TOWING VEHICLE FOR

HOOK-UP.

Hold the release handle in the open position. Release handle must be held in fully open position to remove from or place on ball.

Loosen the bleeder fitting at the top of the brake assembly.

Apply the actuator and tighten the bleeder fitting.

Return the actuator to the forward position. Again, loosen the bleeder valve one turn and apply the actuator. Repeat this procedure until fluid expelled from the bleeder hose is free of air bubbles. It is helpful to lower the trailer tongue to promote air bubble movement in the brake tubing. It is also helpful to tap gently along the brake tubing during the brake bleeding to keep air bubbles from sticking to the inside of the brake tubing. During this procedure, the master cylinder reservoir fluid level must be maintained at no less than 1/2 full and no more than 1/2" (13 mm) from the top of the reservoir.

When no air bubbles are visible, close the bleeder valve securely and remove the bleeder hose.

Repeat steps 1 thru 6 for the remaining brake.

After bleeding has been completed, re-check fluid level in the master cylinder.

3-22

3121200

SECTION 3 - CHASSIS & TURNTABLE

Lower trailer tongue until ball rests in ball socket.

Close the release handle. The release handle will close freely with finger pressure when the ball is properly inserted into the ball socket.

DO NOT USE THE BREAKAWAY CABLE AS A PARKING BRAKE.

CHECK THE LOCATION OF THE BREAKAWAY CABLE PERIODICALLY DURING

EACH TRIP. THE INDICATOR SHOULD REST AGAINST THE SPRING STOP. ACCI-

DENTAL APPLICATION WILL CAUSE BRAKES TO DRAG AND HEAT UP.

Cross safety chains under the tongue and securely attach to bumper or frame of tow vehicle.

To make sure actuator is securely latched onto the ball, extend the trailer tongue jack to the ground and lift the tow vehicle and trailer combination 2 to 4 in. (50 to 100 cm). If the ball does not disengage, the actuator is securely attached.

Insert a padlock or bolt through the lock hole for theft protection.

Connect the breakaway cable solidly to the bumper or frame of tow vehicle as near to the center as possible.

Cable must hang clear of trailer tongue and long enough to permit short radius turns without pulling breakaway cable forward.

Make sure the breakaway cable (C) is in the released position with the indicator bead (B) touching or resting against the cable spring stop (A) as shown below.

FAILURE TO USE SAFETY CHAINS COULD DAMAGE THE TRAILER BOOM.

10.

Retract the jack fully. Place the caster wheel in the stowed position.

11.

Check for proper tow vehicle to trailer hook-up; the tow vehicle and trailer should be level with positive tongue load.

12.

The back-up lever must be positioned in the towing position (A) as shown below.

13.

You are now ready to tow your vehicle.

AVOID SHARP TURNS. THIS COULD BEND, CREATE EXTREME STRESS, OR FRAC-

TURE EITHER THE ACTUATOR OR TRAILER TONGUE.

3121200

3-23

SECTION 3 - CHASSIS & TURNTABLE

Backing Up

Follow steps 1 thru 13 under Towing.

Before backing up a slope or through soft ground, pull the trailer forward slightly to assure the actuator socket is in the fully forward position.

Move the lever knob on the side of the actuator downward from the towing position (A) along the curved slot in the actuator frame to the back-up position (B). The slot has a notch at the bottom of its’ travel. Plush the lever knob down to engage the locking notch.

Back the trailer up.

AVOID SHARP TURNS. THIS COULD BEND, CREATE EXTREME STRESS, OR FRAC-

TURE EITHER THE ACTUATOR OR TRAILER TONGUE.

If the machine is to be uncoupled from the tow vehicle after backing with the lever knob engaged, block all wheels and pull forward slightly to take strain off of the actuator. Uncouple the actuator by lifting the release handle and raising the trailer tongue. Make sure the lever knob is in the towing position (A) when uncoupling from the trailer.

Maintenance

Keep all links and pivots lubricated to prevent rusting and ensure ease of operation. Use SAE 30 oil, lubricate inside release handle and inside actuator body from the underside of the actuator.

NOTE:

Lubricate the hitch ball with conventional automotive grease or a lubricant made for hitch balls.

Check for leaks in the brake system. Periodic checks should be made on all hoses and fittings to guard against cuts and worn hoses which may cause failure

(leaks, rupturing under pressure, and collapsing).

Replace defective hoses.

Check brake fluid level in the master cylinder reservoir.

Keep filled to within 1/2" (13 mm) from the top of the reservoir. Use only a DOT type 3 or 4 brake fluid.

Flush the system yearly or when system is known to be contaminated.

NOTE:

Wheel bearings and seals should be inspected and packed at this time.

Extended Storage Instructions

Preventative maintenance is recommended for extended periods of storage.

Check brake system for proper fluid level in master cylinder, bleed all lines.

Lubricate all links and pivots to prevent any rusting.

Remove wheel and drum assemblies and spray a good anti-corrosion compound under rubber boot on forward end of brake wheel cylinder. Avoid spraying drum and lining.

Grease all bearings and reinstall wheel and drum assemblies.

Make sure breakaway cable is fully released.

After extended storage, refer to Maintenance to insure trailer readiness for towing.

Adjust drum brakes.

Proper Towing Checklist

Inspect brake fittings for leaks.

Adjust brakes every 2000 miles.

Lubricate all mechanical moving parts.

Inspect the breakaway cable for any kinks.

Verify the correct size ball is used, without chips, dirt, or hairline cracks.

Securely attach safety chains to trailer and tow vehicle.

For proper braking, trailer should be level when attached to tow vehicle to produce a positive tongue load.

DOT 3 or DOT 4 brake fluid should be used in master cylinder and fill it from 1/2 full to 1/2" (13 mm) from top of cylinder reservoir.

3-24

3121200

SECTION 3 - CHASSIS & TURNTABLE

Not Used

Push Rod

Shock Absorber

Release Handle

Master Cylinder

Gasket

Boot

Stop

10. Not Used

11. Locknut

12. Not Used

13. Spring

14. Bolt

15. Cap

16. Lanyard

17. S-Hook

18. Bolt

19. Not Used

20. Bolt

21. Flatwasher

22. Link

23. Flatwasher

24. Locknut

25. Block

26. Bushing

27. Flatwasher

28. Flatwasher

29. Flatwasher

30. Bracket

Figure 3-13. Hydraulic Brake Coupler with 2in Ball - Prior to SN 0030002099

31. Shipping Plug

32. Not Used

33. Not Used

34. Piston

35. Housing

36. Hitch

3121200

3-25

SECTION 3 - CHASSIS & TURNTABLE

3.9 COMBINATION COUPLER

THE WEIGHT RATING OF THE COUPLER IS DEPENDENT UPON THE CORRECT

BOLTS BEING USED. USE THE BOLTS PROVIDED WITH THE COUPLER. IF BOLTS

ARE MISSING, REFER TO THE PARTS MANUAL AND OBTAIN REPLACEMENT

BOLTS OR USE THE EXACT SIZE, GRADE, AND NUMBER OF BOLTS AS SPECI-

FIED. USING THE WRONG SIZE, GRADE, OR NUMBER OF BOLTS WILL REDUCE

THE WEIGHT RATING OF THE COUPLER AND COULD CAUSE SEPARATION OF

THE MACHINE FROM THE TOW VEHICLE.

Bleeding the Brake System

Remove the bolts and lockwashers that hold the lever guide and flat emergency lever spring.

Remove the lever guide and emergency lever spring.

Using short strokes, pull forward on the emergency lever, pumping the master cylinder until brake fluid within the master cylinder stops bubbling.

Attach a bleeder hose to the bleeder valve on one of the wheels and submerge the other end of the hose into a transparent container partially filled with brake fluid.

Loosen the bleeder valve one turn, and while watching the hose in the container, use the emergency lever to pump the master cylinder as long as air bubbles continue to leave the hose. When bubbles stop, close the bleeder valve and repeat the process on the other wheel.

NOTE:

Check the fluid level in the master cylinder frequently while bleeding the brakes. Refill as necessary.

Once bleeding is completed, refill the master cylinder and attach the cap securely.

Replace the emergency lever spring, lever guide, lockwashers, and bolts.

Test the brakes by pulling the emergency lever forward until it locks into its second notch position (the lever should be approximately straight up).

Attempt to rotate the wheels in a forward direction. If any wheels rotate, the brakes must be adjusted. To adjust the brakes, release the emergency lever from the locked position, set each wheel’s brake adjustment up 2 or 3 notches.

Repeat the test procedure as necessary.

General Maintenance

Frequently check brake fluid level. Fluid must be approved, clean, and uncontaminated.

Make sure actuator mounting bolts are secure.

Inspect the actuator and replace any bent, worn, or damaged parts.

Be constantly aware of the system’s braking quality, make periodic checks. Consult a certified brake specialist to make necessary adjustments or repairs.

Servicing the Emergency Lever

If the emergency lever of the actuator is applied, it can be disengaged by using a screwdriver to lift upward on the front of the flat emergency lever spring while pulling the lever forward until it is released. A thorough inspection of the emergency lever, emergency lever spring, and cable with S-hooks is required. Damaged parts must be replaced as outlined below:

Remove the master cylinder and push rod assembly. Be careful not to get dirt into the master cylinder. A new master cylinder gasket should be used when reinstalling the master cylinder.

Remove the cable S-hook from the emergency lever, emergency lever guide and flat emergency lever spring, then pull the lever out of the actuator outer case through the cross-slot in the top.

Install the new emergency lever through the cross-slot in top of the outer case. Attach a new emergency lever spring and emergency lever guide.

Insert the S-hook on the emergency cable into the hole in the emergency lever and squeeze shut.

Add adequate brake fluid to the master cylinder and bleed the brake system.

3-26

3121200

SECTION 3 - CHASSIS & TURNTABLE

Not Used

Damper Shock

Outer Case

Lockwasher

Cotter Pin

10. Cable with Hooks

11. Hook

12. Emergency Lever Spring Plate

13. Bolt

14. Bolt

15. Lockwasher

16. Lanyard

17. S-Hook

18. Push Rod & Piston Assembly

19. Nut

20. Gasket

21. Reservoir

22. Fitting w/ Orifice

23. Emergency Lever Guide

24. Boot

25. Pin

26. Upper Slider

27. Lower Slider

28. Side Spacer



55. Channel Centered Slider

Figure 3-14. Hydraulic Brake Coupler with Combination 2in ball - Prior to SN 0030002099

3121200

3-27

SECTION 3 - CHASSIS & TURNTABLE

3.10 COUPLER ASSEMBLY (SN 0030002099 TO

PRESENT)

Engaging Manual Lockout Lever

The manual lockout lever is used to control the brake pressure being applied to the trailer when backing up. Having the actuator in the extended position will make it easier to engage the lockout lever. To engage the lockout lever, move the lever back and upwards until the front of the lever nests into the round spacer as shown below. This will prohibit movement of the actuator when backing up. The lockout lever will move to the towing position when you drive forward again.

DO NOT TOW IF LOCK-OUT

LEVER IS ENGAGED

Servicing the Breakaway Assembly

A thorough inspection of the breakaway assembly is required if it is applied at any time. Damaged parts must be replaced. If there is any damage to the lanyard itself the entire pushrod assembly will need to be replaced.

To disengage the breakaway mechanism, first release the brake line pressure by briefly opening a bleeder valve. Extend the coupler forward to gain access to the 1/2" hole on the top of the coupler housing as shown below.

ACCESS HOLE

SCREWDRIVER

LOCKOUT LEVER

LIFT LEVER TAB TO

ENGAGE LOCKOUT

MAE31420

PUSHROD MUST BE

COMPLETELY FORWARD

MAE31430

Insert a flat head screwdriver into the access hole and push down on the pushrod assembly and pivot the pushrod towards the front of the coupler. Make sure the pushrod assembly is moved to its furthermost forward position

(towards the front of the coupler) by pushing down and forward on the rod. Inspect and replace parts as needed.

NOTE:

The end of the pushrod should line up with the front of the

1/2" access hole.

PUSHROD MUST BE

COMPLETELY FORWARD

(END OF PUSHROD SHOULD BE

IN LINE WITH FRONT OF

ACCESS HOLE)

3-28

MAE31440

3121200

SECTION 3 - CHASSIS & TURNTABLE

SN 0030002099 THROUGH

0030003342

SN 0030003342

TO PRESENT

MAE29550

Coupler

Emergency Lever Guide

Emergency Lever Spring Plate

Cap

Emergency Lever

Cable with Hooks

Outer Case

Cotter Ring Lock

10. Cover

11. Gasket

12. Fitting w/Orifice

13. Reservoir

14. Push Rod

15. Lower Slider

16. Side Slider

17. Lock Out Lever

18. Channel Centered Slider

19. Damper Shock

20. Upper Slider

21. Side Spacer

Figure 3-15. Hydraulic Brake Coupler with Combination 2 In Ball - SN 0030002099 through Present

3121200

3-29

SECTION 3 - CHASSIS & TURNTABLE

Actuator Maintenance

Frequently check brake fluid level (fluid must be DOT3 or 4 approved, clean and uncontaminated).

Make sure mounting bolts are properly tightened 15 to

20 ft lbs (20 to 27 Nm) without deformation of coupler.

Inspect entire actuator, replace any bent, worn or damaged parts immediately.

Be constantly aware of systems braking quality, make periodic checks as described in the brakes owners manual. Consult certified brake specialist to make necessary adjustments or repairs. Failure to do so could result in loss of braking.

Be sure hydraulic lines and fittings are tight to avoid fluid leaks.

Coupler Maintenance

Maintain a film of automotive grease in the ball pocket, ball clamp (front & back), ball clamp spring, where link pin enters housing, and where the housing contacts the bracket hardware.

Maintain a film of oil on the pivot points and safety latch spring using SAE 30W motor oil.

Keep the ball pocket and mechanism clean because dirt, paint, etc. can hinder proper operation. When parking or storing your trailer, keep the bracket and coupler off the ground so dirt and/or other foreign material will not build up in the coupler ball pocket.

Grease pivot hinge with automotive grease.

3-30

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.11 HITCH COUPLER & AXLE (CE ONLY)

To insure continuing reliability and road safety in traffic, the maintenance tasks have to be performed at the prescribed intervals. Maintenance, repairs, and replacement of wearing parts for the chassis and the braking system may only performed by a qualified garage.

Only original JLG parts may be used in order to:

• ensure proper functioning and safety

• preserve all rights under warranty

• prevent the operating license from becoming invalid under national and international regulations.

Ball Coupler

The ball coupler is equipped with a safety check indicator. This consists of clearly embossed symbols to which a red-green-red label with the same symbols has been glued and an indicator button. If the label is damaged, it can be removed and the embossed symbols used, or the label can be replaced, in which case the lines dividing the zones on the label and the embossing must be aligned.

UNCOUPLING

To open, pull the coupling handle upwards and then turn it forwards.

The coupling automatically remains in the open position, in which the indicator button points to the red field with the large X.

COUPLING

To couple the trailer, place the open ball coupler (X position) on the ball of the towing vehicle so that it clicks into place audibly.

When the ball coupler has clicked into place, the indicator jumps to the green zone marked +.

After coupling, it is essential to use the indicator to ensure that the ball coupler has clicked into place on the ball correctly.

If the indicator is in the green + zone, the ball coupler is correctly closed and locked, and the ball on the vehicle still has sufficient wearing reserves.

THE TRAILER MUST NEVER BE DRIVEN IN THIS POSITION.

THERE IS NO SAFE CONNECTION BETWEEN THE TOWING VEHICLE AND THE

TRAILER UNLESS THIS HAS HAPPENED, AND THE VEHICLE COMBINATION

MUST NOT BE USED ON THE ROADS UNTIL THEN. DO NOT FORGET TO RELEASE

THE HANDBRAKE ON THE TRAILER, AND TO FIT THE SAFETY CABLE TO THE

BALL NECK.

The safety cable has the function of forcing the emergency braking of the trailer if it should separate from the towing vehicle for any reason.

NEVER INSERT YOUR FINGERS IN THE OPEN BALL COUPLER. EVEN SLIGHT

PRESSURE ON THE SPHERE CAN TRIGGER THE SPRING-LOAD CLOSING MECHA-

NISM AND RESULT IN INJURY TO THE FINGERS.

3121200

3-31

SECTION 3 - CHASSIS & TURNTABLE

IF THE INDICATOR IS IN THE RED "-" ZONE, THE COUPLING IS NOT PROPERLY

CLOSED, AND THE TRAILER MUST NOT BE TOWED!

The position of the coupling point on the trailer must be in a range of 430 ± 35 mm above the horizontal tire contact surface.

To check the coupling height, the trailer and towing vehicle must be exactly horizontal and fully loaded to make up the permissible total weight. The tire pressure must also conform with the tire manufacturer’s specifications.

BALL COUPLER MAINTENANCE

To ensure easy operation and safety, all bolts and movable parts of the ball coupler must be lubricated using commonly available machine oils, or as a substitute, motor oil twice a year, or immediately if the coupling becomes stiff.

The ball mount should also be lightly greased, with the exception of all stabilizer couplings.

The bolts fastening the coupler to the adapter should be torqued to 85 ft.lbs. (115 Nm).

There are three possible causes of this problem:

The ball on the towing vehicle is very worn down and the ball coupler cannot grip it properly. A new ball has a diameter of 50.0 mm. If the diameter is worn down to less than 49 mm, even if only in places, it is vital to replace the ball on the towing vehicle.

The ball coupler itself is very worn down and no longer grips the ball sufficiently. In this case, the ball coupler must be replaced at a qualified workshop.

The closing mechanism in the ball coupler has been triggered, but there is no ball in the coupling. The ball coupler is only lying loose on the ball and is not firmly connected. The coupling will separate from the ball when the towing vehicle drives off. Open the coupling as described earlier and try once more to click the ball coupler correctly into place on the ball.

The coupling mechanism may be stiff due to insufficient lubrication. Carry out the instructions for maintenance and lubrication and try the coupling procedure again.

PERMISSIBLE SUPPORT LOAD

The support load permitted for each particular ball coupler is embossed on the hand lever of the ball coupler.

OVER-RUN HITCH MAINTENANCE

Relubricate the over-run hitch after 3000 miles (5000 km) or after one year at the latest, at both grease fittings. All movable parts such as bolts and articulating points on the hand brake lever and the turning lever must also be lightly oiled.

If the connecting rod can be pushed in more than half-way

(approx. 45 mm) when the hand brake is on, the braking system must be readjusted.

Check the brake response:

Put the handbrake on while the trailer is uncoupled and push the trailer slowly backwards until the handbrake lever has reached the hindmost end position.

Push the ball coupler/connecting rod into the over-run hitch. Depending on the over-run hitch, it will require a certain amount of force to push.

The connecting rod should then return automatically to zero position by means of the gas cushion in the hydraulic damper. If it takes longer than approximately 30 seconds to return, the over-run hitch must be checked at a qualified workshop.

NEVER DRIVE WITH A NEGATIVE SUPPORT LOAD AS THIS WILL HAVE A NEGA-

TIVE EFFECT ON THE TRAILER’S DRIVING STABILITY.

A negative support load can be avoided or remedied simply by changing the trailer’s load.

POSITION OF THE COUPLING POINT ON THE TRAILER

TO ACHIEVE THE CORRECT DRIVING AND BRAKING BEHAVIOR IN THE TRAILER,

IT IS ABSOLUTELY ESSENTIAL FOR THE COUPLING HEIGHTS OF THE TOWING

VEHICLE AND THE TRAILER TO MATCH.

3-32

3121200

SECTION 3 - CHASSIS & TURNTABLE

Coupling Head Maintenance

REPLACING

Prior to replacing the coupling head, it is essential to confirm the condition of the damper. Test the Damper as outlined under DAMPER REACTION TEST.

Follow steps 1 thru 4 under Damper Maintenance -

REMOVAL.

If you have been able to remove the coupling head/eye as instructed under Damper Maintenance - REMOVAL step 4, go to step 5 below, otherwise proceed with step

The damper will now be retained between the front coupling/eye bolt and the rear damper bracket. It is now necessary to remove the damper without destroying it.

WARNING: Proceed with caution!

The most efficient method is to remove the rear damper mounting bracket, but depending upon the coupling, there may still be tension in the damper.

Place a lever against the rear damper in such a manner that once the mounting bracket bolts are removed the tension can be released slowly. Take the tension and remove the mounting bracket bolts, release the tension in the damper.

Inspect the shaft for damage, dress burrs, and clean any dirt as the new coupling will be a close fit on the shaft.

If a new bellows is to be fitted cut the tie-wrap and discard the old one, fit the new and secure with a tie-strap.

Trial fit the new coupling. It should slide into place without any undue force. DO NOT hammer the coupling into place, this can damage the coupling itself or the overrun mechanism. If it proves to be tight, remove it and thoroughly clean the shaft inspecting for burrs.

Fit the bolts, washers and secure with NEW locking nuts and torque to 214 ft. lbs. (290 Nm). DO NOT re-use the old nuts as this is safety critical. Fit the plastic nut covers.

Where the damper has been removed ensure that the coupling head rear bolt passes through the hole in the damper body.

NOTE:

If there are any doubts about the condition of the damper, install a new one.

If the damper has been released the rear mounting bracket will need to be re-fitted. This means that the damper needs to be compressed so the bolts can be installed.

WARNING: Proceed with caution!

Compress the damper with the lever and secure the mounting bracket bolts.

10.

Reinstall the bellows with the coupling/eye horizontal

 taking care not to tear or damage the material.



If the replacement coupling/eye is a different part than the original:

Always ensure the corresponding length bolts are used.

Always ensure a compatible bellows is used.

Always ensure the hole sizes in the coupling and draw-bar tube match and the correct size bolts are used.

DAMPER REACTION TEST

Pull the handbrake lever on as far as possible.

Push the ball coupling as far back into the overrunning hitch as it will go. This requires force to compress and should extend smoothly when released.

If the draw tube is impossible to compress, compresses with just spring force and no damping resistance, or the extension is very rapid, the damper must be replaced by carefully following the replacement instructions above.

3121200

3-33

SECTION 3 - CHASSIS & TURNTABLE

Damper Maintenance

The dampers assembled within the overrun coupling is pressurized. During assembly, the damper is reloaded and compressed in order that the coupling operates correctly. Care must be exercised when working on, handling, and disposing of the coupling/damper. This is especially important if any damage or misuse of the coupling has occurred.

REMOVAL

Knock out the retaining pin and remove the rear bolt, this will allow the damper to move forward and contact the front bolt.

DO NOT POSITION ANYTHING OR STAND IMMEDIATELY TO THE FRONT OR

REAR OF THE COUPLING ASSEMBLY IN CASE A DAMPER FAILS DURING THE

PROCESS.

Pull back the bellows from the coupling to expose the two retaining bolts.

Undo the self locking nut from the rear bolt of the coupling as shown.

From underneath, through the bolt hole in the draw tube, drill a 3 mm hole into the damper body to a depth of 8 mm.

Remove the rear bolt; force may be required as the damper may still be preloaded. Raise the coupling operating handle in order to fully remove the bolt if necessary.

When the rear bolt is removed the damper will move forward to rest upon the front bolt.



In some instances a retaining pin is used; located between the bolt holes. This pin will hold the damper in its original position and will therefore need to be removed in the following manner.

Undo the self locking nut from the front bolt, extract the bolt and remove the head.

Replace both bolts in the draw tube and finger tighten the bolts.



OBSERVE NORMAL SAFETY PROCEDURES FOR THE USE OF HAND TOOLS.



WEAR SAFETY GLASSES.



DO NOT LIE IMMEDIATELY UNDERNEATH THE BOLT HOLE WHEN DRILLING.



WHEN THE DRILL PENETRATES THE DAMPER BODY GAS WILL BE ALLOWED TO

ESCAPE.

The pressure in the damper should now have been discharged. Remove the self locking nut on the front bolt of the coupling head. Remove the bolt and the coupling head. If the bolt is difficult to remove, it indicates that there is still residual force in the damper and step 5 should be repeated.

Remove the rear damper bracket retaining bolts. Also remove the nuts and spring washer from the rear of the damper.

The de-pressurized damper can now be removed by sliding the damper forward through the draw tube and be disposed of.

3-34

3121200

SECTION 3 - CHASSIS & TURNTABLE

1

8

21

20

19

16

12 17 16

15

18

2

10

22

9

14

13

14

13

6

7

5

11

Coupling Head

Gas Spring

Bellow

Draw Tube

Stop Ring

Housing

Gas Mounting Spring

Handle

Handbrake Lever

10. Cable

11. Transmission Lever

12. Spring Sleeve

Figure 3-16. Hydraulic Brake Coupler (CE and CSA Spec Machines)

3121200

1660283-D

MAE30680

3-35

SECTION 3 - CHASSIS & TURNTABLE

3.12 TRAILER JACK

Installation

Place the jack against the trailer tongue and position the mounting straps on the opposite side of the tongue.

Place the straps so the flat side is against the tongue.

Install the bolts through the bracket and straps. Position the jack so the top bolts rest directly on the top of the tongue and the bottom bolts are as close to the tongue as possible. The gap between the mounting bolts and the trailer tongue is not to exceed 1/16" (1.6 mm).

PLUNGER



Secure the bolts in place with the locknuts. Torque the nuts to 25 ft.lbs. (34 Nm).

Check for clearance of handle swing, trailer light cables, and coupler clearance.

Operation

NOTE:

To avoid damaging the handle while trailering in the horizontal position, secure the handle to the jack with a bungee cord or rope.

The jack is designed to be swiveled into a horizontal or storage position. In both the vertical and horizontal positions, the plunger must be securely positioned in the mating hole in the mounting bracket. To place the jack into the horizontal position, allow about 2" (5 cm) of ground clearance beneath the wheels. Pull the plunger pin out of the opening and swivel the jack. Rotate either left or right until the plunger pin snaps into the proper mounting bracket hole.

Maintenance

The internal gearing and bearings of the jack must be kept lubricated. Using a needle nose applicator, pump a small amount of automotive grease through the lubrication opening. The lubrication opening can be found on the side of the jack tube, right above the support plate. Rotate the jack handle to distribute the grease evenly. Lightly grease the inner tube of the jack using the same type of grease. A light weight oil must be applied to the handle unit at both sides of the tube. The axle bolt and nut assembly of the caster wheel must also be lubricated with the same light weight oil.

GREASE

OIL

3-36

3121200

SECTION 3 - CHASSIS & TURNTABLE

Assembly

HANDLE

NUT

SPLIT TUBE



SPACER

BOLT

ROLLER

Place one spacer over the bolt.

Lightly grease the split tube spacer.

Place the bolt and spacers through the roller. Insert the bolt through the handle.

Install the locknut onto the bolt and tighten. Adjust the nut so the bolt no longer turns freely. A minimum of two full bolt threads must be visibly extended through the nut.

CASTER WHEEL

Grease the outside of the wheel spacer using standard automotive grease and insert it into the wheel.

Place the wheel and spacer into the yoke and align the holes in the wheel with the holes in the yoke.

Insert the bolt through both sides of the yoke. Make sure the threads of the bolt are to the outside of the yoke when the yoke hangs down in the trailering position.

Install the locknut and tighten until the yoke is just tight enough against the metal spacer to keep the spacer from rotating. Do not overtighten, this can cause the spacer to deform and bind the wheel. The wheel must spin freely.

3121200

3-37

SECTION 3 - CHASSIS & TURNTABLE

3.13 SWING MOTOR (PRIOR TO S/N 0030000960)

NOTE:

This motor may also be used on some machines manufactured between S/N 0030000960 to 0030001050.

Removal

Remove the hardware securing the motor to the swing drive.

Lift the motor up to gain access to the hydraulic lines and tag and disconnect the lines running to the motor.

Cap or plug all openings.

Swing Motor

Remove the drive link pin and drive link from the motor and lay aside.

Gently tap the shaft upward through the housing and remove through the rear of the housing. Turn the shaft over and remove the cooling plug.

Remove the housing from the vise and turn over. Pry the dust seal from the housing.

10.

Push the seal carrier, thrust washer, and thrust bearing down and remove from the rear of the housing.

NOTE:

When removing the seal carrier, thrust washer, and thrust bearing take care not to scratch or nick the housing bore.

11.

If a new seal carrier and thrust washer are included in the repair kit, the old items may be discarded. If not, carefully pry the shaft seal, teflon backup seal, and metal backup shim from the seal from the seal carrier and discard the metal backup shim, backup seal, and shaft seal.

Lay the seal carrier aside.

12.

Remove the wire ring, metal backup shim, and high pressure seal from the inner bore groove of the housing with a small screwdriver and discard them.

13.

All parts should be cleaned in an oil based solvent and dried using compressed air. All new seals should be lightly coated in clean oil prior to installation.

MAE31640

Secure this end of the shaft when removing the swing motor. If it starts to pull out with the swing motor it could damage the internal seals.

Figure 3-17. Swing Motor- Removal

Disassembly

NOTE:

Before disassembling the motor, it is highly recommended that paint or a marker be used to make a V shaped set of lines from the end cover to the housing to aid in proper assembly. It is also important that the steps involving timing be followed carefully to insure proper motor operation.

Remove all shaft related components from the shaft (i.e. keys, wire rings, nuts). To aid in assembly of the motor, make a V shaped set of lines from the end cover to the housing using either paint or a marker.

With the shaft facing down, secure the motor in a vise by clamping onto the housing.

Loosen and remove the bolts holding the motor assembly together.

Remove the end cover.

Remove the body seal and discard the seal.

Remove the rotor assembly and wear plate. Remove the body seals from the rotor and housing and discard the seals.

3-38

3121200

SECTION 3 - CHASSIS & TURNTABLE

Assembly Shaft Timing Procedure

FOR PROPER OPERATION, THE MOTOR DEPENDS ON THE CORRECT ORIENTA-

TION OF PARTS AS WELL AS THE CORRECT INTERNAL TIMING.

Place the shaft on a clean flat surface with the output end facing up.

Place the thrust bearing, then thrust washer, on the shaft.

Install the shaft seal down onto the shaft making sure

the lip on the seal faces down. Refer to Figure 3-18., Seal

Orientation.

DUST SEAL

METAL



BACKUP



SHIM

SEAL



CARRIER

TEFLON



BACKUP



SEAL

SPLIT WIRE

RING



HIGH



PRESSURE



SEAL

METAL

SHIM



BACKUP



Figure 3-18. Seal Orientation

SHAFT

SEAL



Install the teflon backup seal onto the shaft with the flat side up and the seal lip facing the shaft seal.

Place the metal backup shim onto the shaft and against the teflon backup seal.

Place the seal carrier onto the shaft (large end down) and carefully press the seal carrier down onto the seal assembly using an arbor press and sleeve to compress the seals into the carrier.

Install the high pressure seal into the groove in the housing.

Install the metal backup shim against the high pressure seal in the groove in the housing bore by squeezing the shim between the thumb and forefinger to bow shim

(bow in the shim should be in the shape of a hill and not a valley for easier installation).

While maintaining the bow in the shim, start the shim into the groove and use a small screwdriver to push the shim into the groove. Install the wire ring into the groove making sure the ends are butted.

FOR PROPER OPERATION, THE MOTOR DEPENDS ON THE CORRECT ORIENTA-

TION OF PARTS AS WELL AS THE CORRECT INTERNAL TIMING.

Turn shaft over so the output end of the shaft faces down.

Install the cooling plug into the shaft making sure the large OD end of the cooling plug faces up.

Lower the drive link into the shaft making sure that the timing mark end of the drive link faces up and the timing mark on the end of the drive link is aligned with one of the through holes in the shaft.

When the splines contact each other, slowly rotate the drive link counterclockwise until the drive link splines engage with those on the shaft.

Turn the housing over so the pilot of the housing faces down and secure the housing in a vise.

Without disturbing the seal carrier assembly or drive link, carefully lower the shaft assembly into the housing.

To seat the seal carrier against the wire ring, gently tap the drive link down until the end of the shaft is nearly flush with the rear surface of the housing.

Place a body seal in the groove in the rear surface of the housing.

Using alignment marks as a guide, place the wear plate on the housing making sure the notch in the wear plate is aligned with the port side of the housing as shown in

Figure 3-19., Notch Alignment.

NOTCH IN ROTOR

HOUSING

PORTS



NOTCH IN STATOR

Figure 3-19. Notch Alignment

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SECTION 3 - CHASSIS & TURNTABLE

10.

Place a body seal in the grove in the face of the rotor.

11.

Lower the rotor onto the drive link making sure the timing mark on the drive link is aligned with a peak on the

rotor as shown in Figure 3-20., Timing Mark.

TIMING MARK

PEAK ON ROTOR

Installation

Connect the two hydraulic lines to the motor as tagged during Removal.

Swing Motor

Figure 3-20. Timing Mark

12.

Once splines are engaged, rotate rotor so the notch on the rotor is aligned with the notch on the wear plate and

the ports on the housing. Refer to Figure 3-19., Notch

Alignment.

13.

Insert the drive link pin into the end of the drive link making sure the concave end faces up.

14.

Place the remaining body seal in the groove in the end cover.

15.

Using alignment marks as a guide, place the end cover onto the motor making sure the end of the drive link pin is in the hole in the center of the end cover.

16.

Insert the four bolts and torque to an initial value of 10 ft.lbs. (13.5 Nm). Using a criss-cross pattern, apply a final torque of 50 ft.lbs. (68 Nm).

17.

Remove the motor from the vise and place on a clean work surface with the shaft facing up. Making sure the lip seal faces up, place the dust seal over the shaft. Using a seal and hammer, carefully drive the dust seal into place.

MAE31640

Secure this end of the shaft when removing the swing motor. If it starts to pull out with the swing motor it could damage the internal seals.

Figure 3-21. Swing Motor- Installation

Position the motor on the swing drive and secure in place with the retaining bolts. Torque the bolts to



95 ft.lbs. (130 Nm).

3-40

3121200

SECTION 3 - CHASSIS & TURNTABLE

3121200

Dust Seal

Retainer Ring

Backup Shim

Housing Seal

Body Seal

Shaft Seal

Thrust Washer

Thrust Bearing

Wear Plate

10. End Cover

11. Ball

12. Cooling Plug

13. Housing

14. Drive Link

15. Rotor Set

Figure 3-22. Swing Motor

16. Drive Link Pin

17. Bolt

18. Shaft

19. Key

3-41

SECTION 3 - CHASSIS & TURNTABLE

3.14 SWING MOTOR (SN 0030001051 TO PRESENT)

NOTE:

This motor may also be used on some machines manufactured between S/N 0030000960 to 0030001050.

Removal

Remove the two bolts securing the motor to the swing drive.

Lift the motor up to gain access to the hydraulic lines and tag and disconnect the lines running to the motor.

Cap or plug all openings.

Scribe an alignment mark down and across the Torqlink™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover. 3/16 or 3/8 inch Allen wrench or 1 inch hex socket required.

Swing Motor



MAE31640

Secure this end of the shaft when removing the swing motor. If it starts to pull out with the swing motor it could damage the internal seals.

Figure 3-23. Swing Motor- Removal

Disassembly and Inspection

Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable.

Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket.

Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.

IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED

DURINGTHE SERVICE PROCEDURES, CAUSING INJURY.

3-42

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SECTION 3 - CHASSIS & TURNTABLE

3121200

1. Special Bolts



2. End Cover



3. Seal Ring-Commutator



4. Seal Ring



5. Commutator Ring



6. Commutator Ring



7. Manifold



8. Rotor Set

8A. Rotor

8B. Stator or Stator Vane

8C. Vane

8D. Stator Half



9. Wear Plate



10. Drive Link



12. Coupling Shaft



13. Bearing/Bushing, Inner



14. Thrust Washer



15. Thrust Bearing

Figure 3-24. Swing Drive Motor

16. Seal



17. Back-up Washer



18. Housing



18A. O-Ring



19. Bearing/Bushing, Outer



20. Dirt & Water Seal



21. Plug

3-43

SECTION 3 - CHASSIS & TURNTABLE

Remove end cover assembly (2) and seal ring (4). Discard seal ring.

Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination.

Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.

NOTE:

Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being serviced.

If the end cover (2) is equipped with shuttle valve components, remove the two previously loosened plugs

(21).

NOTE:

A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set.

Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.

BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS

THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE

REMOVED.

NOTE:

The insert and if included the orifice plug in the end cover

(2) must not be removed as they are serviced as an integral part of the end cover.

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SECTION 3 - CHASSIS & TURNTABLE

Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set.

NOTE:

The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice.Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.

10.

Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. The drive link (10) may come away from the coupling shaft

(12) with the rotor set, and wearplate.You may have to shift the rotor set on the warplane to work the drive link out of the rotor (8A) and warplane. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the warplane for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and wear plate.

Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal.

Remove and discard the seal rings (4) that are on both sides of the manifold.

NOTE:

The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pencil before removal from Torqlink™ will ensure correct reassembly of rotor into stator and rotor set intoTorqlink™.Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqlink™.

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SECTION 3 - CHASSIS & TURNTABLE

NOTE:

Series TG Torqlinks™ may have a rotor set with two stator halves (8B) with a seal ring (4) between them and two sets of seven vanes (8C). Discard seal ring only if stator halves become disassembled during the service procedures.

NOTE:

A polished pattern on the wear plate from rotor rotation is normal.

11.

Place rotor set (8) and wear plate (9) on a flat surface and center rotor (8A) in stator (8B) such that two rotor lobes

(180 degrees apart) and a roller vane (8C) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than 0.005 inches (0.13 mm) of clearance, replace rotor set

13.

Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers.

14.

Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used.

NOTE:

If rotor set (8) has two stator halves (8B & 8D) and two sets of seven vanes (8C & 8E) as shown in the alternate construction TG rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

12.

Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing

(18).

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SECTION 3 - CHASSIS & TURNTABLE

15.

Remove coupling shaft (12), by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. Replace coupling shaft if any of these conditions exist.

18.

Remove seal (16) and back up washer (17) from Small

Frame, housing (18). Discard both.



NOTE:

Minor shaft wear in seal area is permissible. If wear exceeds

0.020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE:

A slight “polish” is permissible in the shaft bearing areas.

Anything more would require coupling shaft replacement.

16.

Remove and discard seal ring (4) from housing (18).

17.

Remove thrust bearing (15) and thrust washer (14)

Inspect for wear, brinelling, corrosion and a full complement of retained rollers.



19.

Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required.

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SECTION 3 - CHASSIS & TURNTABLE

20.

Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly.



21.

If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion.

The bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.010 inch (0.025 mm). A bearing, bushing, or thrust washer that does not pass inspection must be replaced. If the housing has passed this inspection the disassembly of the Torqlink™ is completed.

NOTE:

The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings.

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SECTION 3 - CHASSIS & TURNTABLE

22.

If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13).

Assembly

Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

NOTE:

Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most OEM parts distributors or Parker approved Torqlink™ distributors. (Contact your local dealer for availability).

NOTE:

Unless otherwise indicated, do not oil or grease parts before assembly.

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY

SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR

DEATH.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-

IMUM AIR PRESSURE REQUIREMENTS.

If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a

new

outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counterbore at the mounting flange end of the housing, using the appro-

 priate sized bearing mandrel, which will control the bearing/ bushing depth.



Torqlink™ housings require the use of bearing mandrel to press bearing/ bushing (19) into the housing to a required depth of 0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore.

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SECTION 3 - CHASSIS & TURNTABLE

NOTE:

Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.

IF THE BEARING MANDREL SPECIFIED IN THE “ TOOLS AND MATERIALS

REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE

METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE

BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-

QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-

PONENTS WHEN ASSEMBLED.

BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE

HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE

REUSED.

The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).

3-50

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SECTION 3 - CHASSIS & TURNTABLE

Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange.

Press a

new

dirt and water seal (20) into the housing (18) outer bearing counterbore.

The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.

On the Torqlinks™ assemble a

new

backup washer (17) and

new

seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2.

3121200

ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A

NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).

3-51

SECTION 3 - CHASSIS & TURNTABLE

Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.

THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC

FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED

GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT

#K-70M.

NOTE:

Mobil Mobilith SHC ® 460

NOTE:

A 102Tube (P/N 406010) is included in each seal kit.

NOTE:

The coupling shaft (12) will be flush or just below the housing wear plate surface on Torqlinks™ when properly seated.

The coupling shaft must rotate smoothly on the thrust bearing package.

NOTE:

Torqlinks™ require one thrust washer (14) with thrust bearing (15).The coupling shaft will be seated directly against the thrust

Apply masking tape around splines or keyway on shaft

(12) to prevent damage to seal.

Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing

(15) in the housings.

Apply a small amount of clean grease to a

new

seal ring

(4) and insert it into the housing (18) seal ring groove.

3-52

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SECTION 3 - CHASSIS & TURNTABLE

NOTE:

One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures.The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/

16-24 UNF 2A bolts as required that are over 0.5 inch (12.7 mm) longer than the bolts (1) used in the Torqlink™.

10.

Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.

12.

Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B).

13.

Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines.

NOTE:

Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

11.

Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).

NOTE:

It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE:

If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”

NOTE:

The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down.The rotor set seal ring groove faces toward the wear plate (9).

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3-53

SECTION 3 - CHASSIS & TURNTABLE

14.

Apply clean grease to a

new

seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7).

17.

Assemble the commutator ring (6) over alignment studs onto the manifold.

NOTE:

The manifold (7) is made up of several plates bonded together permanently to form an integral component.The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle around the inside diameter.The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

15.

Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set.

18.

Assemble a

new

seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.



16.

Apply grease to a

new

seal ring (4) and insert it in the seal ring groove exposed on the manifold.



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SECTION 3 - CHASSIS & TURNTABLE

19.

If shuttle valve components items #21, were removed from the end cover (2) turn a plug (21), loosely into one end of the valve cavity in the end cover. A 3/16 inch

Allen wrench is required.

20.

Assemble a

new

seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 bolt end cover bolt hole relationship to housing port bosses.



NOTE:

If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

21.

Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of



45-55 ft. lbs. (61-75 N m) for the seven 3/8-24 threaded bolts.

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SECTION 3 - CHASSIS & TURNTABLE

One Piece Stator Construction

A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures.

Place stator (8B) onto wear plate (9) with seal ring (4) side down, after following Torqlink™ assembly procedures 1 through 13. Be sure the seal ring is in place.

NOTE:

The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

22.

Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs. (12-16 N m) if cover is so

 equipped.



Torque the two relief valve plug assemblies (21) in end cover assembly to 45-55 ft. lbs.(61-75 N m) if cover is so equipped.

If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

NOTE:

If the manifold side of the rotor was etched during Torqlink disassembly, this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.

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SECTION 3 - CHASSIS & TURNTABLE

Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.

Installation

Connect the two hydraulic lines to the motor as tagged during Removal.

Swing Motor

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD

SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

MAE31640

NOTE: Secure this end of the shaft when removing the swing motor. If it starts to pull out with the swing motor it could damage the internal seals.

Figure 3-25. Swing Motor- Installation

Position the motor on the swing drive and secure in place with the retaining bolts. Torque the bolts to



95 ft.lbs. (130 Nm)

Remove the two assembled bolts (1) if used to retain stator and wear plate.

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3-57

SECTION 3 - CHASSIS & TURNTABLE

3.15 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

NOTE:

This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter. If during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the value specified in the torque chart, after lubricating the bolt threads with loctite #271. After replacing and retorquing bolt or bolts recheck all existing bolts for looseness.

Check the frame to bearing attach bolts as follows:

Fully elevate the main boom.

Do a visual inspection of the bolts to see if any bolts are missing.

Place a wrench on each one of the bolts and torque to a 100 ft-lb (135.5 Nm), this should not break the



Loctite but ensure the bolts are not loose or broken.



Check the turntable to bearing Attach bolts as follows:

Elevate the fully retracted main boom to full elevation.

Try to insert the 0.0015" (0.038 mm) feeler gauge between the bolt head and hardened washer at the unloaded side of the turntable bearing.

Figure 3-26. Swing Bolt Feeler Gauge Check c.

Lower the boom to horizontal and fully extend the boom.

Try and insert the 0.0015" (0.038 mm) feeler gauge between the bolt head and hardened washer at the unloaded side of the turntable bearing.

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SECTION 3 - CHASSIS & TURNTABLE

3121200

Inner Race Bolt

Outer Race Bolt

Inner Bearing Cup

Swing Motor

Bearing

Swing Arm

Figure 3-27. Swing Bearing

3-59

SECTION 3 - CHASSIS & TURNTABLE

Wear Tolerance Swing Bearing Removal

From the underside of the machine, at rear center, with the main boom fully elevated and fully retracted, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. See

Figure 3-28., Swing Bearing Tolerance Measuring Point

At the same point, with the main boom at horizontal and fully extended, using a magnetic base dial indicator, measure and record the distance between the swing

bearing and turntable. See Figure 3-28., Swing Bearing

Tolerance Measuring Point.

If a difference greater than 0.057 in. (1.40 mm) is determined, the swing bearing should be replaced.

If a difference less than 0.057 in. (1.40 mm) is determined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following:

Metal particles in the grease

Increased drive power required

Noise

Rough rotation

If bearing inspection shows no defects, reassemble and return to service.

THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL

LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE

CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE

SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-

TEM.

Remove the boom assembly. refer to Section 4.3, Boom and Cylinder Assembly.

Tag and disconnect the hydraulic lines from the fittings on the turntable. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports.

Attach suitable overhead lifting equipment to the base of the turntable.

Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable. This will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the turntable to the bearing inner race. Discard the bolts.

Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or framemounted components.

Carefully place the turntable on a suitably supported trestle.

Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use suitable lifting equipment to remove the bearing from the frame, then move the bearing to a clean, suitably supported work area.

Figure 3-28. Swing Bearing Tolerance Measuring Point

3-60

3121200

SECTION 3 - CHASSIS & TURNTABLE

Swing Bearing Installation

Place the swing drive on a table.

Place the bearing on the housing making sure the grease fitting is aligned in the proper location.

On the underside of the bearing, assemble two screws loosely in the counterbored holes.

Put the crank in the worm bore and crank the worm gear until the painted area of the bearing teeth is in mesh with the worm.

Using suitable lifting equipment, carefully lower the swing bearing into position on the frame. Ensure the scribed line of the outer race of the bearing aligns with the scribed line on the frame. If a new swing bearing is used, ensure that the soft spot (stamped with an "S") is in the vicinity shown below (90° relative to the load axis) before securing it to the turntable. If it is not, manually rotate the outer race using the 7/8 hex until the soft spot is located as shown.

HIGH SPOT

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS-

CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE

ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER-

ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.

USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

Apply a light coating of JLG Threadlocker 0100019 to the new bearing bolts, and loosely install the bolts and washers through the frame and outer race of bearing.

Adjust the bearing until 0.010 - 0.015 inch (0.20 - 0.38 mm) backlash is achieved.

Tighten the screws in the counterbored holes.

Check that the 0.010 - 0.015 inch (0.20 - 0.38 mm) backlash has been maintained when the painted are of the bearing is in mesh with the worm.

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED

FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING

ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

Refer to the Torque Sequence diagram as shown in



Figure 3-29., Swing Bearing Torque Sequence. Spray a light

coat of Safety Solvent 13 on the new bearing bolts. Then apply a light coating of JLG Threadlocker 0100019 to the new bearing bolts, and install the bolts and washers through the frame and outer race of the bearing. Note the position of the two shorter bolts as shown below. Tighten all bolts to an initial torque of 115 ft. lbs. (155 Nm) w/Loctite.

10.

Remove the lifting equipment from the bearing.

11.

Using suitable lifting equipment, carefully position the turntable assembly above the machine frame.

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SECTION 3 - CHASSIS & TURNTABLE

12.

Carefully lower the turntable onto the swing bearing, ensuring that the scribed line of the inner race of the bearing aligns with scribed line on the turntable.

13.

Spray a light coat of Safety Solvent 13 on the new bearing bolts. Then apply a light coating of JLG Threadlocker

0100019 to the new bearing bolts, and install the bolts and washers through the turntable and inner race of the bearing.

14.

Following the Torque Sequence diagram shown in Figure 3-29., Swing Bearing Torque Sequence, tighten the

bolts to a torque of 118 ft.lbs. (160 Nm) w/Loctite.

15.

Remove the lifting equipment.

16.

Connect the hydraulic lines to the fittings on the turntable as tagged prior to removal.

17.

Install the boom assembly. Refer to Section 4.3, Boom and Cylinder Assembly.

18.

Using all applicable safety precautions, activate the hydraulic system and check the swing system for proper and safe operation.



Swing Drive Checks

There are three visual checks that can be used to determine if the swing drive is worn. Gently rock the boom back and forth and look for the following:

Movement of the turntable gear (this indicates the motor is spinning due to a worn out motor or air in the lines)

Rotation of the Screw Shaft

Screw shaft moving in and out of the end plate

Swing Bearing Torque Values

Outer Race - 118 ft.lbs. (160 Nm)

Inner Race - 118 ft.lbs. (160 Nm)

See Swing Bearing Torquing Sequence.

CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR

LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS



THEREAFTER.



3-62

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SECTION 3 - CHASSIS & TURNTABLE

0440286-E

MAE30640

NOTE:

Swing Bearing Torque Sequence is typical for both inner and outer races.

Figure 3-29. Swing Bearing Torque Sequence

3-63

SECTION 3 - CHASSIS & TURNTABLE

3-64

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SECTION 3 - CHASSIS & TURNTABLE

3.16 ENGINE

NOTE:

Refer to the engine manufacturer’s manual for detailed operating and maintenance instructions.

Throttle & Choke Adjustment

Start the engine.

Checking RPM Level

Connect the JLG Analyzer to the ground control box.

Refer to Section 6.2, To Connect the JLG Control System

Analyzer.

Set the Analyzer to Access Level 2. Refer to Section 6.3,

Changing Access Level.

Use the right arrow key to scroll to DIAGNOSTICS.

Use the down arrow key then the right arrow key

to scroll to PLATFORM,

to scroll over to ENGINE.

From ENGINE, use the down arrow key to scroll to the SPEED display, which will display engine RPM as shown below:

SET CABLE HEX TO 2.75" (7 CM) TO FACE OF SOLENOID THEN TIGHTEN

JAM NUT FOR THROTTLE

SET CABLE HEX TO 2.375" (6 CM) TO FACE OF SOLENOID THEN TIGHTEN

JAM NUT FOR CHOKE

Hold the throttle open. Adjust the stop screw to 3600 rpm.

Release the throttle and set idle to 2000 rpm.

Set the choke control cable to 2.375" (6 cm) and tighten the jam nuts.

Fuel Valve Lever

NOTE:

The fuel valve is turned off upon delivery and must be turned on prior to use. The fuel valve should be turned off when machine is not being used.

The fuel valve lever must be in the ON position for the engine to run. When the engine is not in use, leave the fuel valve lever in the OFF position to prevent carburetor flooding and to reduce the possibility of fuel leakage.

SPEED 2000

 rPM

ESC ENTER

MAE19060

Choke Actuator

If a new carburetor is needed, the choke detent must be removed from the new carburetor in order to make the choke actuator function freely. Use the following procedure.

Remove the choke set from the carburetor by carefully opening the slot in the choke shaft to remove the choke plate and pull the shaft out the top.

Carefully file or grind the choke detent away.

Replace the choke shaft and choke plate.

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SECTION 3 - CHASSIS & TURNTABLE

Checking Oil Level

Make sure the machine is level.

Switch the engine off before checking oil level.

Remove the valve compartment cover to gain access to the engine.



Remove the dipstick.

Wipe the dipstick with non-fibrous, clean cloth.

Fully seat the dipstick and remove again.

Check the oil level, and if necessary, top the oil level with an approved grade and type of oil as outlined in the engine manufacturer’s operator’s manual.



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SECTION 3 - CHASSIS & TURNTABLE

16 22

Engine Assembly

Fuel Tank

Heat Shield

Starter

Air Filter

Carburetor

Muffler

Dipstick

Throttle Relay

10. Voltage Regulator

11. Choke Relay

12. Engine Stop Relay

13. Engine Mounting Plate

14. Throttle Solenoid Actuator

15. Choke Solenoid Actuator

16. Gear Pump

17. Pump Coupling

18. Oil Fill Plug

Figure 3-31. Engine Assembly

MAE29590

19. Battery

20. Battery Hold-Down

21. Battery Cable

22. Throttle Cable

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SECTION 3 - CHASSIS & TURNTABLE

3.17 OUTRIGGER CYLINDER AND STABILIZER

Removal

Using the analyzer and service mode, lower the outrigger cylinder to be removed but DO NOT lower enough that the outrigger is supporting any of the machine’s weight.

Place an appropriate lifting strap around the cylinder and use an adequate lifting device to support the weight of the cylinder.

NOTE:

The outrigger cylinder weighs approximately 72 lbs.



(33 kg).

Use the lifting device to fully support the weight of the outrigger cylinder. With the weight of the cylinder relieved, remove the retaining clips securing the outrigger pin and outrigger cam pin and remove the two pins.

At the opposite end of the cylinder, remove the bolt and keeper securing the pin and remove the pin.

Remove the cylinder from the machine. If necessary, remove the cylinder cover from the cylinder.

NOTE:

Steps 7 and 8 are only necessary if removing the stabilizer.

Place adequate blocking under the stabilizer to support it.

NOTE:

The stabilizer on ANSI spec machines weighs approximately 73.1 lbs. (33.2 kg). The stabilizer on CE spec machines weighs approximately 78 lbs. (35.3 kg).

Remove the bolt and keeper securing the pin that connects the stabilizer to the frame and remove the pin.

Lift the outrigger cylinder slightly up out of the frame to gain better access to the hydraulic lines running to the cylinder. Tag and disconnect the lines from the cylinder and cap or plug all openings.

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

SECTION 3 - CHASSIS & TURNTABLE

Installation

If removed, position the stabilizer in place on the frame and install the pin, keeper, and bolt that connects the stabilizer to the frame.

Lift the outrigger cylinder slightly up out of the frame to gain better access to the hydraulic lines running to the cylinder. Connect the lines to the cylinder as tagged during disassembly.

Install the outrigger pin and outrigger cam pin and secure in place with the retaining clips.

If removed, install the cylinder cover on the cylinder.

Using an adequate lifting device, position the cylinder in place on the machine.

NOTE:

The outrigger cylinder weighs approximately 72 lbs. (33 kg).

Install the bolt and keeper securing the pin at the pad end of the stabilizer and install the pin.



Using the analyzer and service mode, raise the outrigger.

Function the outriggers several times to check for proper operation and any leakage.

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SECTION 3 - CHASSIS & TURNTABLE

3-70

Outrigger Pad

Stabilizer

Cylinder Cover

Cylinder

Pad Rod

Bolt

Keeper

Outrigger Pin

10. Retaining Cup

11. Outrigger Cam Pin

Figure 3-32. Outrigger Assembly

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SECTION 3 - CHASSIS & TURNTABLE

3.18 OUTRIGGER LIMIT SWITCHES

A mechanical limit switch at each outrigger senses the outrigger has been set. The control system reports status of each outrigger through the analyzer and also displays a solid lit LED at the ground control when set. All outriggers must be set prior to leveling. In addition, unset outriggers are reported to the controls system, and the machine functions will be cut back in the event two outriggers are unset or if one outrigger is unset and the machine is tilted (>2.0°).

Adjustment

Adjust the limit switch position so the switch is activated when the outriggers are fully retracted (pin to the left side of the slot) as shown below and the switch resets when the outriggers are down and set (pin to the right side of the slot).

3.20 PROCEDURE FOR RETRACTING OUTRIGGERS

USING SERVICE HARNESS (OPTIONAL)

NOTE:

Outrigger harness P/N 4923341 is an accessory that must be purchased separately.

TIP OVER HAZARD

BEFORE RETRACTING THE OUTRIGGERS, MAKE SURE THE BOOM IS FULLY

RETRACTED, LOWERED, AND SWUNG INTO STOWED POSITION. REMOVE ALL

PERSONNEL FROM PLATFORM. REFER TO THE MACHINE OPERATION AND

SAFETY MANUAL, SECTION 6, FOR THE MANUAL DESCENT PROCEDURES. FAIL-

URE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS

INJURY.

To begin the outrigger retract procedure, locate the outrigger retract coil wire connected to the control valve located in the valve compartment and disconnect the connector from coil.

Utilizing the service outrigger retract harness (JLG P/N

4923341), locate the wire labeled outrigger retract and plug into the outrigger retract connector on the control valve.

3.19 AUTOMATIC LEVELING SENSING SYSTEM

When all outriggers are set, the system looks at the angle reported by the bi-directional tilt sensor mounted on the ground board. The system automatically adjusts the outriggers until the chassis is level within 1.0° a compound angle prior to allowing operating the boom above elevation.

OUTRIGGER

RETRACT

COIL

EMERGENCY

OUTRIGGER

HARNESS

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SECTION 3 - CHASSIS & TURNTABLE

On the right front outrigger cylinder, remove the electrical connector from the electrical solenoid. Plug the service outrigger retract harness plug labeled right front outrigger into the outrigger cylinder connection.

RIGHT

FRONT

OUTRIGGER

EMERGENCY

OUTRIGGER

HARNESS

Repeat step 3 for the left front, right rear, and left rear outriggers.

Power to operate the retract function can be supplied from any 12 volt power source. Connect the harness’ red alligator clip to positive and the black alligator clip to negative.

Located on the harness is a push button switch. Pushing the switch will activate all five solenoids, the four on the outrigger cylinders and the one on the control valve. At this point the outriggers will automatically begin retracting until the tires and tongue jack are resting on the ground.

To complete the retraction of the outriggers, the hand pump located on the control valve must be utilized. The pump handle is located inside the valve compartment.

Insert the handle into the pump jack on the control valve. Pump the handle until all outrigger are fully retracted. Remove the pump handle and store in the control valve compartment.

PUMP

3.21 DRIVE & SET

The Drive & Set Option is used to position the machine after it has been towed to the job site. Before the drive function can be operated, the machine must be in the stowed position and the hand brake set. The control system senses this by using a proximity switch on the frame to see that the boom is completely lowered, by the telescope limit switch to see that the boom is fully retracted, and by a proximity switch near the brake release cylinder to see that the brake is set.

Pushing down on the Drive Engagement Release Valve causes hydraulic oil to extend the Drive Engage Cylinder.

Hydraulic flow from the drive enable valve is routed to the flow divider which, in turn, provides flow to the Drive Directional Valve. The Drive Directional Valve receives electrical signals through the control system from the joystick in the platform to route the flow to the drive motors in the appropriate manner to achieve drive in the desired direction.

The Drive & Set system consists of the Propulsion Module,

Drive Enable Valve, Drive Directional Valve, Flow Divider, Manual Pull Valve, Drive Motors, Drive Wheels, Brake Release Cylinder, and Drive Engage Cylinder.

The Propulsion Module is located in the frame near the battery charger. It is used to control the Drive Directional Valve and the Drive Enable Valve. The module is connected to and communicates with the Ground Control Module through the CAN-

BUS system.

HANDLE

Disconnect the service outrigger harness from the four outriggers and control valve. Reconnect the wiring connectors to each cylinder’s solenoid and the solenoid on the control valve.

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SECTION 3 - CHASSIS & TURNTABLE

The Drive Enable Valve sends oil to either the Main Valve Bank for boom functions or the Drive Directional Valve. A filter, check valve, priority flow valve, and relief valve are also housed in this manifold block.

In order to use Drive & Set, the following conditions must be met:

• The machine must be stowed

• Turntable position so basket is over tongue

• Telescoped fully in

• Boom not elevated

• Hand brake set

When driving, no boom functions are available.

To drive:

Satisfy position sensors

Turn Selector switch to drive or O/R set

Push the green enable button (no time limit to function start)

Pull the Enable trigger

Joystick must be moved within 7 seconds (after 7 seconds, begin with trigger switch again)

The left and right Drive Motors are attached to Friction Drive

Wheels. The Drive Engage Cylinder pushes the Drive Motor/

Friction Drive Wheel assembly against the trailer tires. The drive motors can turn in either direction for steering and positioning the machine.

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SECTION 3 - CHASSIS & TURNTABLE

Drive & Set Interlocks

Turntable position switch



Proximity switch below the tower link (on boom rest) to sense boom is on rest. This switch will self monitor and be able to sense it is alive upon power up.

Hand brake set switch



Proximity Switch to sense location of brake release cylinder.

Telescope Switch



Mechanical switch that can sense the boom is telescoped fully or in some position not fully telescoped.

Elevation switch



Mechanical switch on the lift cylinder that can sense main boom above horizontal

Adjust the limit switch to be 0.125 inches, +0.063,-0 (3.175 mm, +1.600 -0) from the tower link when the boom is fully lowered into the transport position.

3-74

Apply JLG Threadlocker 0100011 and torque bolt to 190 ft. lbs. (258 Nm)

Flow Divider

Drive Enable Valve

Proximity Sensor

Propulsion Module

Drive Engagement Release Valve

Brake Release Cylinder

Drive Engage Cylinder

Friction Drive Wheel

Drive Directional Valve

Figure 3-33. Drive and Set - Sheet 1 of 3

10. Drive Motor

11. Proximity Sensor

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SECTION 3 - CHASSIS & TURNTABLE

Adjust the limit switch to be 0.125 inches, +0.063,-0 (3.175 mm, +1.600 -0) from the tower link when the boom is fully lowered into the transport position.

Flow Divider

Drive Enable Valve

Proximity Sensor

Apply JLG Threadlocker 0100011 and torque bolt to 190 ft. lbs.(258

Propulsion Module

Drive Engagement Release Valve

Brake Release Cylinder

Drive Engage Cylinder

Friction Drive Wheel

Drive Directional Valve

Figure 3-34. Drive and Set - Sheet 2 of 3

MAE30520

10. Drive Motor

11. Proximity Sensor

3-75

SECTION 3 - CHASSIS & TURNTABLE

3-76

ADJUST THE LIMIT SWITCH SO CLEARANCE BETWEEN THE SWITCH AND CYLINDER IS

0.125 INCHES, +0.063, -0 (3.175 MM, +1.600 -0).

ADJUST THE SWITCH MOUNTING SO THE CYLINDER BARREL MOVES FORWARD

COMPLETELY OFF THE TARGET ZONE OF THE LIMIT SWITCH WHEN THE PARKING BRAKE IS ENGAGED.

Figure 3-35. Drive and Set - Sheet 3 of 3

MAE30500

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SECTION 3 - CHASSIS & TURNTABLE

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SECTION 3 - CHASSIS & TURNTABLE

3.22 WHEEL DRIVE

Removal

Tag and disconnect parking brake cables from machine.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

Tag and disconnect the hydraulic lines from the drive motor. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

Tag and disconnect the hydraulic lines from the drive engage cylinder. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

Remove hardware securing friction drive wheel. Remove friction drive wheel.

Remove drive engage cylinder. Refer Section 3.24, Drive

Engage Cylinder.

Remove retaining bolt, keeper pin, and pin (1) securing drive set assembly. Remove drive set assembly from the machine.

NOTE:

The drive motor weighs approximately 34.5 lbs. (16 kg).

Remove hardware securing drive motor to the spindle.

Remove drive motor.

Place drive motor on suitable and clean workspace.

Installation

Align and install drive motor to spindle and secure with hardware.

NOTE:

The drive motor weighs approximately 34.5 lbs. (16 kg).

Install pin (1), keeper pin, and retaining bolt securing drive set assembly.

Align and install friction drive wheel, secure with hardware. Torque to 190 ft. lbs. (258 Nm).

Install drive engage cylinder. Refer Section 3.24, Drive

Engage Cylinder.

Reconnect all hydraulic lines as tagged during removal.

Reconnect parking brake cables to machine.

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SECTION 3 - CHASSIS & TURNTABLE

3121200

1

SPINDLE

DRIVE MOTOR

Figure 3-37. Wheel Drive - Removal and Installation

MAE29600

3-79

SECTION 3 - CHASSIS & TURNTABLE

3.23 DRIVE MOTOR

Disassembly and inspection



Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket.

Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.

IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED

DURING THE SERVICE PROCEDURES, CAUSING INJURY.

Scribe an alignment mark down and across the Torqlink™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs for disassembly later if included in end cover. 3/16 or 3/8 inch Allen wrench or 1 inch hex socket required.

Remove end cover assembly (2) and seal ring (4). Discard seal ring.

3-80

NOTE:

Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being serviced.

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SECTION 3 - CHASSIS & TURNTABLE

1. Special Bolts



2. End Cover



3. Seal Ring-Commutator



4. Seal Ring



5. Commutator Ring

6. Commutator

7. Manifold

8. Rotor Set

9. Wear Plate

10. Drive Link

11. Thrust Bearing

12. Coupling Shaft

13. Bearing/Bushing, Inner

14. Thrust Washer

15. Thrust Bearing



16. Seal

17. Back-up Washer

18. Housing



19. Bearing/Bushing, Outer

20. Dirt & Water Seal

Figure 3-38. Wheel Drive Motor

MAE29890



21. Backup Washer



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3-81

SECTION 3 - CHASSIS & TURNTABLE

If the end cover (2) is equipped with shuttle valve components, remove the two previously loosened plugs.

Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.

BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS

THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE

REMOVED.

NOTE:

The insert and if included the orifice plug in the end cover

(2) must not be removed as they are serviced as an integral part of the end cover.

Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination.

Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.

NOTE:

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SECTION 3 - CHASSIS & TURNTABLE

Remove and discard the seal rings (4) that are on both sides of the manifold.

NOTE:

Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and Torqlink™.

NOTE:

The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of them an if old to ensure that same surface is reassembled against the rotor set.

10.

Remove rotor set (8) and wear plate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane to stator contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wear plate.You may have to shift the rotor set on the wear plate to work the drive link out of the rotor and wear plate. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wear plate for cracks, brinelling, or scoring. Discard seal ring

(4) that is between the rotor set and wear plate.

NOTE:

Series TG Torqlinks™ may have a rotor set with two stator halves with a seal ring (4) between them and two sets of seven vanes. Discard seal ring only if stator halves become disassembled during the service procedures.

NOTE:

A polished pattern on the wear plate from rotor rotation is normal.

11.

Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 degrees apart) and a roller vane centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gauge at this common centerline. If there is more than 0.005 inches (0.13 mm) of clearance, replace rotor set



3121200

NOTE:

If rotor set (8) has two stator halves and two sets of seven vanes as shown in the alternate construction TG rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor.

3-83

SECTION 3 - CHASSIS & TURNTABLE

12.

(18).

15.

13.

Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers.

14.

NOTE:

Minor shaft wear in seal area is permissible. If wear exceeds

0.020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE:

A slight “polish” is permissible in the shaft bearing areas.

Anything more would require coupling shaft replacement.

16.

Remove and discard seal ring (4) from housing (18).

17.

Remove thrust bearing (15) and thrust washer (14)

Inspect for wear, brinelling, corrosion and a full complement of retained rollers.

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SECTION 3 - CHASSIS & TURNTABLE

18.

Remove and Discard seal (16) and backup washer (17) from small frame, housing (18).

20.



19.

Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required.

21.

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3-85



SECTION 3 - CHASSIS & TURNTABLE

22.

NOTE:

3-86

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SECTION 3 - CHASSIS & TURNTABLE

Assembly

Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

NOTE:

Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most

OEM parts distributors or Parker approved Torqlink™ distributors. (Contact your local dealer for availability).

NOTE:

Unless otherwise indicated, do not oil or grease parts before assembly.

NOTE:

SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY

SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR

DEATH.

IF THE BEARING MANDREL SPECIFIED IN THE “ TOOLS AND MATERIALS

REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE

METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE

BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-

QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-

PONENTS WHEN ASSEMBLED.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-

IMUM AIR PRESSURE REQUIREMENTS.

If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a

new

 bearing/ bushing depth.



BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE

HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE

REUSED.

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3-87

SECTION 3 - CHASSIS & TURNTABLE

Press a

new

dirt and water seal (20) into the housing (18) outer bearing counterbore.



The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.

3-88

3121200

SECTION 3 - CHASSIS & TURNTABLE

Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange.

Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.

On the Torqlinks™ assemble a

new

backup washer (17) and

new

seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2.

NOTE:

Torqlinks™ require one thrust washer (14) with thrust bearing (15). The coupling shaft will be seated directly against the thrust

Apply masking tape around splines or keyway on shaft

(12) to prevent damage to seal.

ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (21) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A

NEW BACKUP WASHER (17), NEW BACKUP WASHER (21), AND NEW SEAL (16).

3121200

(15) in the housings.

3-89

SECTION 3 - CHASSIS & TURNTABLE

THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC

FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED

GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT

#K-70M.

NOTE:

Mobil Mobilith SHC ® 460

NOTE:

A 102Tube (P/N 406010) is included in each seal kit.

NOTE:

The coupling shaft (12) will be flush or just below the housing wear plate surface on Torqlinks™ when properly seated.

The coupling shaft must rotate smoothly on the thrust bearing package.

10.

Apply a small amount of clean grease to a

new

seal ring

(4) and insert it into the housing (18) seal ring groove.

NOTE:

16-24 UNF 2A bolts as required that are over 0.5 inch (12.7 mm) longer than the bolts (1) used in the Torqlink™.

11.

Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.

Install thrust bearing (11) onto the end of coupling shaft

(12).

NOTE:

Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

3-90

3121200

SECTION 3 - CHASSIS & TURNTABLE

12.

Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).

NOTE:

The rotor set rotor counter bore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counter bore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down. The rotor set seal ring groove faces toward the wear plate (9).

15.

Apply clean grease to a

new

seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7).

13.

Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator.

14.

Install the assembled rotor set (8) onto wear plate (9) with rotor counter bore and seal ring side down and the splines into mesh with the drive link splines.

NOTE:

The manifold (7) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

16.

Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set.

NOTE:

It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE:

If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”

3121200

3-91

SECTION 3 - CHASSIS & TURNTABLE

17.

Apply grease to a

new

seal ring (4) and insert it in the seal ring groove exposed on the manifold.



18.

Assemble the commutator ring (6) over alignment studs onto the manifold.



20.

If shuttle valve components items #21, were removed from the end cover (2) turn a plug, loosely into one end of the valve cavity in the end cover. A 3/16 inch Allen wrench is required.

19.

Assemble a

new

seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.

21.

Assemble a

new

seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses.

3-92

3121200

SECTION 3 - CHASSIS & TURNTABLE

22.



45-55 ft. lbs. (61-75 Nm) for the seven 3/8-24 threaded bolts.



NOTE:

If the end cover has a valve or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

3121200

NOTE:

The special bolts required for use with the relief or shuttle valve end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.

3-93

SECTION 3 - CHASSIS & TURNTABLE

23.

Torque the two shuttle valve plug assemblies in end

 cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so equipped.



Torque the two relief valve plug assemblies in end cover assembly to 45-55 ft. lbs. (61-75 Nm) if cover is so equipped.

Assemble the rotor, counterbore down if applicable, into stator, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

One Piece Stator Construction

A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the following procedures.

Place stator onto wear plate (9) with seal ring (4) side down, after following Torqlink™ assembly procedures 1 through 13. Be sure the seal ring is in place.

NOTE:

Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets.

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD

SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.

3-94

3121200

Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

SECTION 3 - CHASSIS & TURNTABLE

Remove the two assembled bolts (1) if used to retain stator and wear plate.

3121200

3-95

SECTION 3 - CHASSIS & TURNTABLE

3.24 DRIVE ENGAGE CYLINDER

Removal

Tag and disconnect the hoses running to the drive

engage

cylinder. Cap or plug all openings.

Using an adequate supporting device, support the drive engage cylinder so it doesn’t fall when the pin is removed.

NOTE:

The drive engage cylinder weighs approximately 26 lbs.



(12 kg).

Remove the retaining pins and pivot pin from the rod end of the cylinder.

Installation

Using suitable lifting device, lift the drive engage cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder.

MAE29610

Remove the retaining pins and pivot pin from the barrel end of the cylinder and remove the cylinder from the machine.

MAE30670

NOTE:

The drive engage cylinder weighs approximately 26 lbs.



(12 kg).

Install the pivot pin and retaining pin into the rod end of the cylinder.

3-96

MAE30670

MAE29610

Connect the hydraulic hoses to the drive engage cylinder as tagged during removal.

Cycle the drive engage cylinder several times to check for proper operation and any leakage.

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.25 BATTERIES (ELECTRIC MACHINES)

The electrical system is a 24 volt system, supplied by four, six volt, 220 amp-hour batteries. Two batteries are located on the right side of the frame and two are located on the left side. A gray quick disconnect is used to disconnect electrical power between the batteries and the machine if needed.

NOTE:

Battery weight is important for stability. Each battery weighs 59 lbs. (26.8 kg). Do not use batteries that are not approved by JLG.

Remove all vent caps and inspect electrolyte level of each cell. Electrolyte level should be to the ring approximately one inch from top of battery. Fill batteries with distilled water only. Replace and secure all vent caps.

Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or ammonia) and wire brush. Replace cables and/or cable clamp bolts as required.

Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly.

When all cables and terminal posts have been cleaned, ensure all cables are properly positioned and do not get pinched. Close battery compartment cover.

Start hydraulic system and ensure that it functions properly.

IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH AT LEAST 59 LBS

(26.8 KG). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT

WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERI-

OUS INJURY OR DEATH.

Quarterly Battery Maintenance

Open battery compartment cover to allow access to battery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COV-

ERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE

PLATES.

NOTE:

When adding distilled water to batteries, non-metallic containers and/or funnels must be used.



To avoid electrolyte overflow, add distilled water to batteries after charging.



When adding water to the battery, fill only to level indicated or 3/8" above separators.



3121200

3-97

SECTION 3 - CHASSIS & TURNTABLE

Contactor Assembly

Fuse

Clamping Bar

Relay

Battery

Battery Pad

Tie Down Strap

Rubber Tape

3-98

Figure 3-39. Battery and Contactor Installation (Prior to SN 0030001804) - Sheet 1 of 2

3121200

SECTION 3 - CHASSIS & TURNTABLE

A Apply Dielectric Grease

B Torque M10 Bolts to 84 in. lbs. (9.5 Nm)

C Torque nuts on fuse to 120 in.lbs. (13.5 Nm)

D Torque contactor nuts to 45 in.lbs. (5 Nm)

3121200

Sevcon Controller

10. Relay

11. Ground Control Module

Figure 3-40. Battery and Contactor Installation (Prior to SN 0030001804)- Sheet 2 of 2

3-99

SECTION 3 - CHASSIS & TURNTABLE

3-100

Figure 3-41. Battery Cable Routing (Prior to SN 0030001804)

3121200

BATTERY

SECTION 3 - CHASSIS & TURNTABLE

PRIOR TO

SN 0030003105

PRIOR TO

SN 0030003105

TO PRESENT

0275709-B

MAE29640B

Contactor

Fuse to Battery Cable

Fuse

Clamping Bar

Relay

Battery

Plate

Bolt

Nut

10. Rubber Tape

Figure 3-42. Battery and Contactor Installation (SN 0030001804 to Present) - Sheet 1 of 2

3121200

3-101

SECTION 3 - CHASSIS & TURNTABLE

A Apply Dielectric Grease

B Torque M6 Bolts to 5 ft. lbs. ± 1 ft. lbs. (7 Nm)

C Torque nuts on fuse to 120 in.lbs. (13.5 Nm)

D Torque contactor nuts to 45 in.lbs. (5 Nm)

3-102

MAE30470

11. Sevcon Controller 12. Relay 13. Ground Control Module

Figure 3-43. Battery and Contactor Installation (SN 0030001804 to Present) - Sheet 2 of 2

3121200

SECTION 3 - CHASSIS & TURNTABLE

TONGUE END

BATTERY DISCONNECT

RUNS FROM FUSE TO BATTERY+

JUMPER CABLE

CONTACTOR POST TO SEVCON "B+"

CABLE FROM FUSE

TO CONTACTOR

BATTERY - RIGHT SIDE

MISMATCHING BATTERY SIZE

AND-OR AMP/HR RATING WITHIN

THE (4) PACK NOT RECOMMENDED

24 VOLT

POS

18 VOLT

POS

NEG

6 VOLT

POS

12 VOLT

JUMPER CABLE

BATTERY + LEFT SIDE

TO ANDERSON CONNECTOR

AND THEN TO SEVCON "B-"

Figure 3-44. Battery Cable Routing (SN 0030001804 to Present)

MAE29660

3121200

3-103

SECTION 3 - CHASSIS & TURNTABLE

3.26 BATTERY CHARGER (PRIOR TO SN 030000236)

OPENING THE BATTERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY



WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY REQUEST A

REPLACEMENT CHARGER.



BEFORE REPLACING ANY COMPONENT, USE THE CHARGER MANUFACTURERS

TROUBLESHOOTING GUIDE FOR CHECKING THE INTERNAL AC AND DC CIR-

CUITS TO DETERMINE WHICH COMPONENT HAS FAILED. COMPLETE WIRING

DIAGRAMS PERTAINING TO YOUR MODEL CHARGER ARE ALSO INCLUDED IN

THE MANUFACTURERS CHARGER MANUAL.

The VP Series battery charger allows for replacement of the following internal components. Consult your Illustrated Parts

Manual for part numbers of these components which are available from the JLG Parts Department:

• Transformer

• Printed Circuit Board

• Shunt Assembly

• Interlock Relay

• SCR Rectifier

• AC Circuit Breaker

• DC Circuit Breaker

Replacement and troubleshooting of these components requires removal of the battery charger from the machine.

Removal

Remove the rear cover from the machine.

Unbolt and lower the MC-1 Controller Box.

Remove the four (4) capscrews securing the charger to it’s mounting plate.

Disconnect the DC wiring from the positive/negative battery terminals and interlock connector from the wiring harness.

Remove the charger from the machine.

Cover Removal

Remove the eight (8) screws on the sides of the charger cover and remove cover.

Transformer Replacement

Disconnect the wiring connecting the transformer to other components within the charger assembly.

Remove the four nuts from the cap screws securing the transformer brackets to the base of the charger chassis.

3-104

Remove transformer.

3121200

SECTION 3 - CHASSIS & TURNTABLE

Printed Circuit Board Replacement

Disconnect the wide wiring connector from the end of the circuit board.

Remove the four (4) screw attaching the card to the front face of the charger chassis.

Interlock Relay Replacement

Disconnect the wiring connected to the relay.

Remove the two (2) nuts securing the interlock relay to the chassis base.

Remove the circuit board.

Shunt Assembly Replacement

Carefully remove the screw from each end of the shunt assembly. The white insulator may need to be restrained to keep it from turning while removing the shunt assembly fasteners. Also make note of the position of each washer, nut and wire connector when removing for later assembly.

Remove the relay.

SCR Rectifier Replacement (Either Side)

Remove the wiring from the SCR Rectifier.

Remove the nut securing the rectifier to the insulated aluminum chassis bracket.

Remove the SCR Rectifier.

3121200

3-105

SECTION 3 - CHASSIS & TURNTABLE

AC Circuit Breaker Replacement

Disconnect wiring connected to the breaker poles.

Remove the two (2) nuts securing the AC breaker to the chassis screws.

DC Circuit Breaker Replacement

Remove the wiring from the DC breaker terminals.

To remove the breaker from the front face of the charger, on the inside of the charger front face, push in on the tabs located on the sides of the breaker assembly and remove the breaker out the front of the charger.

LOCKING

TABS

Remove the breaker from the chassis.

3-106

3121200

SECTION 3 - CHASSIS & TURNTABLE

3121200

3-107

SECTION 3 - CHASSIS & TURNTABLE

3-108

1. Selector Switch



2. AC Circuit Breaker



3. Interlock Relay



4. Varistor



5. Shunt Assembly

6. DC Harness



7. DC Circuit Breaker



8. SCR Rectifier



9. Transformer



10. Circuit Card

Figure 3-46. Battery Charger

3121200

ORG

WHITE

BLK

YELLOW

SECTION 3 - CHASSIS & TURNTABLE

3-109

SECTION 3 - CHASSIS & TURNTABLE

3-110

1. AC Cord Assembly



2. AC Circuit Breaker



3. Interlock Relay



4. Varistor



5. Shunt Assembly

6. DC Harness



7. DC Circuit Breaker



8. SCR Rectifier



9. Transformer



10. Circuit Card

Figure 3-48. Battery Charger

0400164-C

MAE29680

3121200

SECTION 3 - CHASSIS & TURNTABLE

3.27 BATTERY CHARGER (SN 030000199 TO

030000225 & SN 030000236 TO PRESENT)

LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING

NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS

AWAY FROM BATTERIES. PROVIDE ADEQUATE VENTILATION DURING CHARG-

ING. NEVER CHARGE A FROZEN BATTERY. STUDY ALL BATTERY MANUFACTUR-

ERS' SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND

REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.

RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO AN OUTLET

THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE

WITH ALL LOC AL CODES AND ORDINANCES. A GROUNDED OUTLET IS

REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK - DO NOT USE GROUND

ADAPTERS OR MODIFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF OUT-

PUT CONNECTOR OR UNINSULATED BATTERY TERMINAL. DISCONNECT THE AC

SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY

WHILE CHARGING. DO NOT OPEN OR DISASSEMBLE CHARGER. DO NOT OPER-

ATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS

RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY

WAY - REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL. NOT FOR USE BY

CHILDREN.

Operating Instructions

ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTENSION CORD,

AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3-WIRE 12 AWG

CORD.

The charger will automatically turn on and go through a short self-test. All LED’s will flash in an up-down sequence for two seconds. The yellow "Charging" LED will turn on and a trickle current will be applied until a minimum voltage is reached.

Once a minimum battery voltage of 2 volts per cell is detected, the charger will enter the constant-current charging stage and the yellow LED will remain on. The length of charge time will vary by input voltage and ambient temperature.

When the green "Charged" LED turns on, the batteries are completely charged. The charger may now be unplugged from AC power. If left plugged in, the charger will automatically restart a complete charge cycle if battery voltage drops below a minimum voltage or 30 days have elapsed.

If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error.

Maintenance Instructions

For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.

Make sure charger connections to battery terminals are tight and clean.

Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle.

Battery Charger Fault Codes

If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. Refer to the table following for the flash codes and their removal.

Table 3-6. Battery Charger Fault Codes

Flash(s)

Fault Fault Removal

Battery Voltage

High

Battery Voltage

Low

Charge

 time-out

Auto-recover - Indicates a high battery pack voltage

Auto-recover - Indicates either a battery pack failure, battery pack not connected to charger or battery volts per cell is less than 0.5 VDC. Check the battery pack and connections

Indicates the batteries did not charge in the allowed time. This could occur if the batteries are a larger capacity than the algorithm is intended for or if the batteries are damaged old or in poor condition.

Check Battery Indicates the batteries could not be trickle charged up to the minimum voltage per cell level required for the charge to be started.

Over Temperature Auto-recover - Indicates charger has shut down due to high internal temperature

QuiQ Fault Indicates that the battery will not accept charge current, or an internal fault has been detected in the charger. This fault will nearly always be set within the first 30 seconds of operation. Once it has been determined that the batteries and connections are not faulty and fault 6 is again displayed after interrupting

AC power for at least 10 seconds, the charger must be brought to a qualified service depot.

3121200

3-111

SECTION 3 - CHASSIS & TURNTABLE

3-112

Battery Charger with Optional Generator

Battery Charger

AC Extension Cord

Reprogram Controller

Figure 3-49. Battery Charger Installation

0274380-B

MAE29700

3121200

4.1 PLATFORM AND ROTATOR

Removal

SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

NOTE:

The platform rotator weighs approximately 69 lbs. (32 kg).

Remove hardware securing rotator crank handle to the platform rotator, then remove rotator crank handle.

PLATFORM

ROTATOR

CRANK

HANDLE

ROTATOR

PIVOT WELDMENT

MAE31610

Using a suitable lifting device, support the platform assembly.

NOTE:

The platform with console and rotator weighs approximately 150 lbs. (68 kg).

Remove hair pin, lanyard cable and gravity lock pin securing the platform assembly to boom assembly and then remove the platform assembly.

MAE29000

Using a suitable lifting device, support the platform.

Remove the hardware securing the platform to the platform rotator. Remove the platform.

MAE29020

3121200

MAE29010

4-1

SECTION 4 - BOOM & PLATFORM

Installation

Using a suitable lifting device, support the platform rotator to platform.

NOTE:

The platform rotator weighs approximately 69 lbs. (32 kg).

Align and install platform rotator to the platform and secure with hardware.

Align and install rotator crank handle to platform rotator and secure with hardware.

ROTATOR

CRANK

HANDLE

MAE29010

NOTE:

The platform with console and rotator weighs approximately 150 lbs. (68 kg).

MAE29000

Using a suitable lifting device, support the platform assembly and position ion the boom assembly.

Align and install platform assembly to platform support and secure with gravity lock pin, lanyard cable and hair pin.

4-2

MAE29020

3121200

SECTION 4 - BOOM & PLATFORM

4.2 MAIN BOOM POWERTRACK

Removal

Disconnect wiring harness from ground control box.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

Tag and disconnect hydraulic lines at boom assembly.

Use a suitable container for residual hydraulic fluid. Cap hydraulic lines and ports.

Remove hydraulic lines and electrical cables from the powertrack.

Using a suitable lifting equipment, adequately support powertrack weight along entire length.

Remove hardware (1) securing push tube on fly boom section.

Remove hardware (2) securing push tube on base boom section.

With powertrack support and using all applicable safety precautions, remove bolts (3) securing rail to the base boom section. Remove powertrack from boom section.

Installation

With powertrack supported and using all applicable safety precautions, install hardware (3) securing rail to the base boom.

With adequate support and lifting device align, push tube on the boom section to get access to install hardware (2).

Install the hardware (1) securing push tube to fly boom section.

Connect all hydraulic lines and electrical cables to powertrack as tagged during removal.

Connect wiring harness to ground control box.

3121200

Figure 4-1. Powertrack Removal and Installation

MAE30240

4-3

SECTION 4 - BOOM & PLATFORM

4.3 BOOM AND CYLINDER ASSEMBLY

Removal

Using an adequate supporting device, support the weight of the boom and cylinders assembly.

NOTE:

The boom and cylinder assemblies weigh approximately

1905 lbs. (864 kg).

Tag and disconnect all hoses and wiring in the turntable that runs to the boom.

Remove the bolt, keeper pin, and pivot pin that secures the tower boom link to the turntable.

Lift the assembly away from the machine and lower it onto proper supporting devices.

Installation

Using an adequate lifting device, position straps around the boom and cylinders assembly, taking care to ensure the weight of the assembly is evenly distributed.

NOTE:

The boom and cylinder assemblies weigh approximately

1905 lbs. (866 kg).

Lower the boom and cylinder assembly into position on the machine.

Install the pivot pin, keeper pin, and bolt that secures the tower boom to the turntable.

Remove the bolt, keeper pin, and pivot pin that secures the tower boom to the turntable.

Install the pivot pin, keeper pin, and bolt that secures the tower boom link to the turntable.

Using an adequate lifting device, position straps around the boom and cylinders assembly, taking care to ensure the weight of the assembly is evenly distributed.

NOTE:

The boom and cylinder assemblies weigh approximately

1905 lbs. (866 kg).

4-4

Connect all hoses and wiring in the turntable that runs to the boom as tagged during removal.

Operate all boom functions and check for proper operation or any leakage.

3121200

SECTION 4 - BOOM & PLATFORM

4.4 MAIN BOOM ASSEMBLY

Removal

NOTE:

Prior to removing the boom, it will be helpful to extend the boom fly section out far enough to access the telescope cylinder retaining pin if the boom is to be disassembled.

Using an adequate lifting device, support the weight of the main boom.

NOTE:

The main boom weighs approximately 1455 lbs. (660 kg).

To gain access to the tele cylinder, remove the master

cylinder. Refer Section 4.6, Master Cylinder.

Tag and disconnect the hydraulic hoses at the rear of the telescope cylinder.

Place blocking under the lift cylinder to prevent it from dropping. Remove the bolt, keeper pin, and pivot pin securing the rod end of the lift cylinder to the boom.

Remove the bolt, nut, and pivot pin securing the top of the timing link to the boom.

MAE29050

Remove the bolt, keeper pin, and pivot pin securing the boom to the turntable. Lift the boom away from the machine and place it on proper supports for servicing.

3121200

4-5

SECTION 4 - BOOM & PLATFORM

Disassembly

Using an adequate supporting device, support the jib cylinder assembly so it doesn’t fall when the pivot pin is removed.

Remove the bolt, keeper pin, upper and lower pivot pin securing the platform pivot from channel and jib assembly.

Remove the hardware securing the platform level and jib assembly.

MAE31680

Remove the hardware securing the platform level cylinder.

MAE30290

Using an adequate lifting device, support the weight of the platform pivot.

NOTE:

The pivot weighs approximately 24 lbs. (11 kg).

Remove the pivot from the jib assembly.

MAE30400

Remove the Platform level cylinder. Refer Section 4.7,

Platform Level Cylinder.

Remove the hardware securing the telescope cylinder to the boom base section.

MAE30690

4-6

3121200

SECTION 4 - BOOM & PLATFORM

Remove the retaining rings and attach pins securing the telescope cylinder to the boom fly section.

11.

Remove the wear pads from the front of the boom base section.

10.

Pull the telescope cylinder out from the rear of the boom.

12.

Using an adequate lifting device, support the weight of the fly boom section.

13.

Pull the fly section out of the base section.

NOTE:

The boom fly section weighs approximately 238 lbs.



(108 kg.).

14.

If necessary, remove the wear pads from the rear of the fly section.

NOTE:

The telescope cylinder weighs approximately 140.2 lbs.



(63.59 kg).

3121200

4-7

SECTION 4 - BOOM & PLATFORM

Assembly

If removed, install the wear pads and shims onto the rear of the fly section. Apply JLG threadlocker 0100011 to the bolts and torque to 40 ft.lbs. (55 Nm).

Push the telescope cylinder into the rear of the boom.

Using an adequate lifting device, support the weight of the fly boom section.

Align and install the fly section into the base section.

NOTE:

The boom fly section weighs approximately 238 lbs.



(108 kg).

If removed, install the wear pads into the front of the boom base section. Apply JLG threadlocker 0100011 to the bolts and torque to 35 ft.lbs. (47 Nm).

NOTE:

The telescope cylinder weighs approximately 140.2 lbs.



(63.59kg).

Align and install the retaining rings and attach pins securing the telescope cylinder to the boom fly section.

4-8

3121200

SECTION 4 - BOOM & PLATFORM

Apply JLG threadlocker 0100011 to the bolts and secure the telescope cylinder to the boom base section. Torque the bolts to 85 ft. lbs. (115 Nm).

With adequate support, position the jib assembly with platform level cylinder and boom.

10.

Install jib assembly with platform level cylinder and boom, secure with hardware.

Install the Platform level cylinder. Refer Section 4.7, Platform Level Cylinder.

MAE31680

11.

With adequate support, position the pivot with the jib assembly.

NOTE:

The pivot weighs approximately 24 lbs. (11 kg).

MAE30400

MAE30690

3121200

4-9

SECTION 4 - BOOM & PLATFORM

12.

Install the bolt, keeper pin, upper and lower pivot pin securing the platform pivot to the channel and jib cylinder assembly.

Install the pivot pin, nut, and bolt securing the top of the timing link to the boom.

MAE30290

Installation

Using adequate lifting support, lift the boom into position on the machine. Install the pivot pin, keeper pin, and bolt securing the boom to the upright.

NOTE:

The main boom weighs approximately 1451 lbs. (435 kg).

MAE29050

Install the pivot pin, keeper pin, and bolt securing the rod end of the lift cylinder to the boom.

4-10

Connect the hydraulic hoses at the rear of the telescope cylinder as tagged during removal.

Install the master cylinder. Refer Section 4.6, Master Cylinder.

Operate the boom through all functions and check for proper operation or any leakage.

3121200

SECTION 4 - BOOM & PLATFORM

4.5 MAIN LIFT CYLINDER

Removal

Swing the boom away from the tongue.

Place a suitable support or blocking under the boom.

Tag and disconnect the hoses running to the main lift cylinder. Cap or plug all openings.

Using an adequate supporting device, support the main lift cylinder so it doesn’t fall when the pin is removed.

NOTE:

The lift cylinder weighs approximately 130 lbs. (59 kg).

Remove the retaining pins and pivot pin from the rod end of the cylinder.

Installation

Using suitable lifting device, lift the main lift cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder.

MAE29180

NOTE:

The lift cylinder weighs approximately 130 lbs. (59 kg).

Install the pivot pin and retaining pin into the rod end of the cylinder.

MAE29170

Remove the retaining pins and pivot pin from the barrel end of the cylinder and remove the cylinder from the machine.

MAE29170

Connect the hydraulic hoses to the lift cylinder as tagged during removal.

Cycle the lift cylinder several times to check for proper operation and any leakage.

MAE29180

3121200

4-11

SECTION 4 - BOOM & PLATFORM

4.6 MASTER CYLINDER

Removal

Swing the boom away from the tongue.

Place a suitable support or blocking under the platform pivot.

Tag and disconnect the hoses running to the master cylinder. Cap or plug all openings.

Using an adequate supporting device, support the master cylinder so it doesn’t fall when the pin is removed.

NOTE:

The master cylinder weighs approximately 22 lbs. (10 kg).

Remove the retaining pins and pivot pin from the rod end of the cylinder.

Installation

Using suitable lifting device, lift the master cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder.

NOTE:

The master cylinder weighs approximately 22 lbs. (10 kg).

Install the pivot pin and retaining pin into the rod end of the cylinder.

Remove the retaining pins and pivot pin from the barrel end of the cylinder and remove the cylinder from the machine.

Connect the hydraulic hoses to the master cylinder as tagged during removal.

Cycle the master cylinder several times to check for proper operation and any leakage.

4-12

3121200

SECTION 4 - BOOM & PLATFORM

4.7 PLATFORM LEVEL CYLINDER

Removal

Swing the boom away from the tongue.

Place a suitable support or blocking under the base of the jib.

Tag and disconnect the hoses running to the platform level cylinder. Cap or plug all openings.

Using an adequate supporting device, support the platform level cylinder so it doesn’t fall when the pin is removed.

NOTE:

The platform level cylinder weighs approximately 28.2 lbs.

(12.8 kg).

Remove the retaining pins and pivot pin from the rod end of the cylinder.

Installation

Using suitable lifting device, lift the platform level cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder.

MAE30400

NOTE:

The platform level cylinder weighs approximately 28.2 lbs.

(12.8 kg).

Install the retaining pins and pivot pin into the rod end of the cylinder.

MAE30260

Remove the retaining pins and pivot pin from the barrel end of the cylinder and remove the cylinder from the machine.

MAE30260

Connect the hoses running to the platform level cylinder as tagged during removal.

Function the platform level cylinder through several cycles and check for proper operation and any leakage.

MAE30400

3121200

4-13

SECTION 4 - BOOM & PLATFORM

4.8 JIB CYLINDER

Removal

Swing the boom away from the tongue.

Remove the platform from jib assembly. See Section 4.1

- Platform and Rotator.

Tag and disconnect the hoses running to the jib cylinder. Cap or plug all openings.

NOTE:

The jib cylinder weighs approximately 40 lbs. (18 kg).

Remove the lower retaining pins and pivot pin from channel and rod end of the cylinder.

Installation

Using suitable lifting device, align the jib cylinder barrel end with mounting holes on jib cylinder assembly and install the pivot pin and retaining pin into barrel end of the cylinder.

MAE30310

NOTE:

The jib cylinder weighs approximately 40 lbs. (18 kg).

Install the retaining pins and pivot pin into rod end of the cylinder.

MAE30290

Using an adequate supporting device, support the jib cylinder so it doesn’t fall when the pin is removed.

Remove the retaining pins and pivot pin from barrel end of the cylinder and remove the cylinder from the machine.

MAE30290

Connect the hoses running to the jib cylinder as tagged during removal.

Function the jib cylinder through several cycles and check for proper operation and any leakage.

MAE30310

4-14

3121200

SECTION 4 - BOOM & PLATFORM

2,3

Boom & Cylinders Assembly

Keeper Bolt

Retaining Pin

Pivot Pin

Boom Rest

Gravity Lock Pin

Main Boom

Tower Boom

Tower Boom Link

10. Master Cylinder

11. Lift Cylinder

12. Upright

Figure 4-2. Boom and Cylinders Assembly

13. Timing Link

14. Powertrack

15. Platform level Cylinder

16. Jib Cylinder

MAE30280

3121200

4-15

SECTION 4 - BOOM & PLATFORM

4.9 BOOM SENSORS

There are two mechanical sensors that are standard on the machine which sense the boom state. One is located on the side of the base boom and senses when the boom is fully telescoped in. The other sensor, which is mounted to the side of the upright, senses whether the main boom is elevated and is activated by a cam on the lift cylinder bushing.

Boom Elevation Limit Switch

BOOM

ELEVATION

LIMIT

SWITCH

Set the limit switch to trip at 3.8° above horizontal (Main

Boom Position).

Set the switch to reset at 1° below horizontal (Main

Boom Position).

Route harness through center of turntable and chassis plug harness into connector labeled transport limit switch provided with frame harness.

4-16

3121200

SECTION 4 - BOOM & PLATFORM

4.10 BOOM CLEANLINESS GUIDELINES

The following are guidelines for internal boom cleanliness for machines used in excessively dirty environments.

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.

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.

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.

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.

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.

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.

4.11 PLATFORM CONTROL ENABLE SYSTEM

(TRIGGER)

The platform controls make use of a time dependent enable circuit to limit the time availability of “live” or enabled controls.

To operate any directional function, the trigger switch on the joystick must be depressed before activation of the function.

When the switch is depressed, the controls are enabled and the operator has 7 seconds to operate any function. While the controls are “live”, the enabled light will be illuminated in the platform display panel. When the time limit has been reached, the enabled light will turn off and the controls will be “dead” or disabled. To continue use of the machine the controls must be re-enabled to start the timer system over again. This is done by releasing all functions, then releasing and re-depressing the trigger switch.

4.12 SIDE ENTRY PLATFORM

The aluminum side entry platform is the common platform for all markets. It is 30” X 48” and has a drop bar gate.

4.13 HYDRAULIC MANUAL DESCENT SYSTEM

The manual descent allows retrieval of an elevated boom in the event of a power failure. The valves are manually operated and fluid is moved with a hand pump to charge the system to allow lift down and to operate telescope in or out. The swing motor can be actuated using a ½” drive ratchet.

3121200

4-17

SECTION 4 - BOOM & PLATFORM

4.14 POWERTRACK MAINTENANCE

Remove Link

NOTE:

Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different.

Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack.

Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a



T-20 Torx bit, remove 8-32 x 0.500 screw from one side.

REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT

DAMAGE.

4-18

3121200

SECTION 4 - BOOM & PLATFORM

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.

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.

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.

3121200

4-19

SECTION 4 - BOOM & PLATFORM

Insert flat head screwdriver between links. Twist and pull links apart.

Remove link from other section of powertrack using screwdriver.

4-20

3121200

Install New Link

Squeeze cut-out end of new link into half-shear (female) end of track section.

SECTION 4 - BOOM & PLATFORM

Spread half-shear (female) end of new link and slide cutout end of track section into it. Use screwdriver if necessary.

3121200

Round half-shears will not fit properly in cut-outs after new link is installed.

4-21

SECTION 4 - BOOM & PLATFORM

Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will rotate into cut-outs.

Push pin through center hole. Slide washer on pin.

Parts shown below connect new link to powertrack.

Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.

4-22

3121200

SECTION 4 - BOOM & PLATFORM

NOTE:

Make sure snap rings are seated in pin groove and closed properly.

Pull up on other end of round bar. Slide new poly roller on bar.

Correct

Incorrect

Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar. Torque to



18-20 in-lb (2-2.25 Nm).

3121200

4-23

SECTION 4 - BOOM & PLATFORM

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

NOTE:

When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head.

REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT

DAMAGE.

Remove rivets as shown in link removal instructions.

4-24

3121200

SECTION 4 - BOOM & PLATFORM

Parts used: Bracket Center Pin and Center Pin Snap Ring.

Replace Moving End Brackets

Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it.

REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PRE-

VENT DAMAGE.

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.

3121200

Correct

Incorrect

4-25

SECTION 4 - BOOM & PLATFORM

Install center pin with snap ring in new bracket.

NOTE:

Ensure snap rings are seated in pin groove and closed properly.

Correct

Incorrect

Install radius pins and snap rings in original locations.

Repeat with other moving end if replaced.

Make sure both brackets rotate correctly.

4-26

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

SECTION 5. BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.1 LUBRICATING O-RINGS IN THE HYDRAULIC

SYSTEM

When assembling connectors in the hydraulic that use o-ring fittings, it is necessary to lubricate all fittings with hydraulic oil prior to assembly. To lubricate the fittings, use one of the following procedures.

NOTE:

All o-ring fittings must be pre-lubricated with hydraulic oil prior to assembly.

Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated.

Cup and Brush

The following is needed to correctly oil the o-ring in this manner:

• A small container for hydraulic oil

• Small paint brush

Turn the o-ring on the other side of the fitting and repeat the previous step, ensuring the entire o-ring is coated with hydraulic oil.

Hold the fitting in one hand while using the brush with the other hand to dip into the container. Remove excess hydraulic oil from the brush so an even film of oil is applied on the o-ring.

3121200

5-1

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Dip Method

NOTE:

This method works best with Face Seal o-rings, but will work for all o-ring fitting types.

The following is needed to correctly oil the o-ring in this manner:

• A small leak proof container

• Sponge cut to fit inside the container

• A small amount of hydraulic oil to saturate the sponge.

Place the sponge inside the container and add hydraulic oil to the sponge until it is fully saturated.

Dip the fitting into the sponge using firm pressure.

Upon lifting the fitting, a small droplet will form and drip from the bottom of the fitting. This should signify an even coating of oil on the fitting.

Spray Method

This method requires a pump or trigger spray bottle.

Fill the spray bottle with hydraulic oil.

Hold the fitting over a suitable catch can.

Spray the entire o-ring surface with a medium coat of oil.

O-ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated sponge. This will also cause more oil to be dispersed from the sponge.



Brush-on Method

This method requires a sealed bottle brush.

Fill the bottle with hydraulic oil.

Using slight pressure to the body of the spray bottle, invert the bottle so the brush end is in the downward position.

Brush hydraulic oil on the entire o-ring, applying an even coat of oil.

5-2

3121200

5.2 HYDRAULIC CYLINDERS

Cylinder Locations

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Figure 5-1. Cylinder Locations - Sheet 1 of 2

MAE30490

5-3

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-4

Outrigger Cylinder

Brake Release Cylinder

Drive Engage Cylinder

Jib Cylinder

Telescope Cylinder

Master Cylinder

Figure 5-2. Cylinder Locations - Sheet 2 of 2

Main Lift Cylinder

Platform Level Cylinder

MAE30460

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Disassembly

Mark the orientation of the rod, gland, and barrel with a permanent marker or paint pen. Do not apply any paint on the chromed surface of the rod. Unscrew the head gland from the cylinder assembly using a spanner wrench in the holes provided in the OD of the head gland.

DO NOT AT TEMPT TO SERVICE A HYDRAULIC C YLINDER WHILE IT IS

INSTALLED. THE CYLINDER MUST BE REMOVED FROM THE MACHINE AND ALL

PRESSURE MUST BE RELIEVED. AIR MUST NOT BE USED TO EXTEND OR

RETRACT THE CYLINDER. SAFETY GLASSES MUST BE WORN AT ALL TIMES BY

SERVICE PERSONNEL.

The cylinder should be secured in such a way as to prevent rotation of the barrel while unscrewing the head gland. Care should be taken to avoid damaging the rod surface and to avoid excessive deformation of the barrel, which could permanently damage the unit. Make sure to support the rod during removal.

ROD SUPPORT

PROTECTED ROD CLAMP

BARREL CLAMP

MAE29480

Figure 5-4. Cylinder Head Removal

NOTE:

The threads are locked with a non-permanent thread adhesive during assembly. A quick tug on the wrench may be necessary to release the thread adhesive.

Remove the rod assembly from the barrel using care not to damage the threads or any other component surface.

ROD SUPPORT

SUPPORT TABLE

Figure 5-3. Cylinder Barrel Support

Remove all dirt, grease, and other contaminants from around the ports and the head gland. Drain all oil from the unit. Extending and retracting the rod manually can help purge the bulk of the remaining oil.

3121200

Figure 5-5. Cylinder Rod Support

Clamp the rod mount and support the rod assembly with the chrome surface protected. Remove the piston assembly either by unthreading the locknut with a socket wrench or the piston itself from the rod using a spanner wrench depending on the cylinder model.

5-5

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-6

*Torque 350 ft-lbs (475.5 Nm)

Head

Rod

Piston

Barrel

O-Ring

Rod Seal

Backup Ring

Wiper Seal

10. Wear Ring

11. Piston Seal

12. Locknut

Figure 5-6. Platform Level Cylinder

13. Bushing

14. Counterbalance Valve

15. Counterbalance Valve

1684397-C

MAE28830

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

*Torque 19-21 ft-lbs (25.5 - 28.5 Nm)

**Torque 18-20 ft-lbs (24.4 - 27 Nm)

*** Torque 30-35 ft-lbs (40.7 - 47.5 Nm)

****Torque 150 ft-lbs (203.3 Nm)

Head

Rod

Piston

Barrel

O-ring

Backup Ring

Rod Seal

Wiper Seal

10. Wear Ring

11. Piston Seal

12. Locknut

13. Spacer

14. Bushing

15. Solenoid Valve

Figure 5-7. Lift Cylinder

16. Check Valve

17. Pilot Check Valve

18. Relief Valve

19. Plug

20. Orifice

1684434-C

MAE30450

5-7

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Rod

Barrel

Piston

Head

5-8

Retainer

Wear Ring

O-ring

Spacer

10. Piston Seal

11. Backup Ring

12. Wear Ring

Figure 5-8. Telescope Cylinder

13. Rod Seal

14. Wiper Seal

15. Counterbalance Valve

16. Counterbalance Valve

17. Plug

18. Shuttle Valve

19. Wear Pad

1684402-E

MAE30420

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

*Torque 350 ft-lbs (475.5 Nm)

1684398

MAE30430

Head

Rod

Piston

Barrel

O-ring

Rod Seal

Backup Ring

Wiper Seal

Figure 5-9. Master Cylinder

10. Wear Ring

11. Piston Seal

12. Locknut

13. Bushing

3121200

5-9

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-10

1684494-B

MAE28810

Head

Rod

Piston

Barrel

O-ring

Rod Seal

Backup Ring

Wiper Rod

10. Wear Ring

11. Wear Ring

12. Piston Seal

Figure 5-10. Jib Cylinder

13. Locknut

14. Cartridge

15. Plug

16. Bushing

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Cleaning and Inspection

Inspect all seals, backup rings, wipers, and wear rings for tears, grooves, foreign matter, and excessive wear. Deep grooves may be an indication of damage to the barrel bore, rod chrome, or the presence of large particle contamination.

Remove the seals, backup rings, wipers, and wear rings using a soft metal tool (brass or aluminum) with rounded edges. Use care not to nick or score the surfaces of any component, especially the seal grooves.

Wipe all components with a lint-free cloth. Plug the barrel opening with a lint-free cloth. Remove any adhesive remnants from the head gland, barrel, rod, and piston threads (where applicable) using a soft wire brush. Use care not to scratch or otherwise damage the critical surfaces of any component including seal grooves, barrel bore, rod chrome, etc.

Inspect the piston and head gland for excessive wear, cracks, scoring, or any other damage. If wear is present on the OD of the piston or the ID of the head gland, check to ensure that the circularity of both dimensions is within 0.007" (0.177 mm). Beyond this limit the seal performance is compromised and the components must be replaced.

If equipped, the stop tube should be inspected for cracking and excessive flaring of the ends.

Closely inspect the chrome surface of the rod. Any nicks, gouges, or scratches that penetrate the chrome plating or result in a sharp edge, which may damage seals, are cause for rod assembly replacement.

Flush the barrel and fluid tube (if equipped), drain, and wipe dry with a lint-free cloth. Closely inspect bore for nicks, gouges, or scratches. Replace the barrel assembly if any of these are present.

3121200

5-11

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Assembly

INSPECT ALL COMPONENTS AS DESCRIBED UNDER INSPECTION. CLEAN ALL

COMPONENTS WITH A LINT-FREE CLOTH. THE BARREL SHOULD BE FLUSHED

OUT AND DRAINED. COMPRESSED AIR MUST BE USED TO BLOW OUT THE BAR-

REL BORE AND ALL PORTS. LUBRICATE ALL SEALS WITH HYDRAULIC FLUID

PRIOR TO ASSEMBLY.

HEAD GLAND ASSEMBLY

Install rod seal. Check for proper orientation.

Install wear rings on gland ID if required.

Rod wipers are installed by snapping the wiper into the groove.

Install the backup ring and o-ring with the backup ring nearest the head gland threads.

PISTON ASSEMBLY

Install wear rings onto piston.

Install piston seal into central groove on piston OD. A clean, small cross-section o-ring or a thin elastic bland may be wrapped around seal to help stretch it over the piston.

Install piston seal backup rings on both sides of seal.

Make sure the backup rings are oriented so that lips on the side lock into grooves in the sides of the seal.

ROD, GLAND, PISTON ASSEMBLY

Lubricate ID of head gland assembly with hydraulic fluid, and slide onto rod (rod wiper end first) using caution not to damage rod wiper or seal on rod end.

Slide stop tube (if equipped) onto rod. Do not scratch rod chrome.

Apply Loctite #7471 (Primer-T) to piston and rod threads. Allow primer to evaporate then apply two beads of Loctite #222 Thread Adhesive axially across the threads of the piston ID.

Screw threaded piston onto rod end and torque to 100 ft. lbs. (136 Nm). An optional method for tightening the threaded piston is to turn until the piston bottoms out, then set in place by hitting the spanner wrench handle with a hammer; the piston should rotate slightly.

For all non-threaded pistons, install the piston assembly onto the threaded end of the rod. Torque the locknut to the following specification:

Table 5-1. Torques of Locknut

Cylinder

Telescope, Platform Level, Master

Lift

Torque

350 ft.lbs. (475 Nm)

150 ft.lbs. (203 nm)

FINAL ASSEMBLY

Ensure all rags, etc. are removed from the barrel bore.

Apply Loctite #7471 (Primer-T) to the barrel bore and gland threads. Lubricate the barrel bore and piston assembly with hydraulic fluid. Avoid getting any oil on the barrel threads.

Align the rod with the barrel assembly. Insert the piston into the barrel opening. Use care to avoid damaging the wear rings, seals, and piston surface on the barrel.

Lubricate the o-ring and backup ring on the head gland using hydraulic fluid. Avoid getting oil on the threads.

Apply two beads of Loctite #222 Thread Adhesive axially across the head gland threads. Screw the gland into the barrel and torque to 100 ft.lbs. (135 Nm). An optional method for tightening the head gland is to turn until the head gland bottoms out, then set in place by hitting the spanner wrench handle with a hammer, the head gland should rotate slightly.

TESTING

Set the test apparatus to test the pressures as listed below.

Cylinder

Telescope

Platform Level

Master

JIB

Lift

Outrigger

Working Pressure

PSI

1000

1050

1600

2500

2400

Bar

110

172

165

Connect pressure lines to the proper ports.

Extend and retract the cylinder to full stroke position three times.

Check for leakage in each position at all weld joints, between the head gland and the barrel, and between the head gland and rod.

Drain all hydraulic fluid and cap or plug all ports.

5-12

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Outrigger Cylinder

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

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.

Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately support cylinder rod, if applicable.

If applicable, remove solenoid valve and fittings from cylinder port block. Discard o-rings.

Place cylinder barrel in a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to break thread-locking compound.

ROD SUPPORT

PROTECTED ROD CLAMP

BARREL CLAMP

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND C YLINDER BARREL

SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND

PISTON.

Clamp barrel securely. Pull rod assembly and cylinder head from barrel.

Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible.

ROD SUPPORT

SUPPORT TABLE

Figure 5-11. Cylinder Barrel Support

Figure 5-12. Cylinder Head Removal

MAE28960

Mark cylinder head and barrel with a center punch for easy realignment. Unscrew cylinder head (1) with pin face spanner wrench.

3121200

Figure 5-13. Cylinder Rod Support

5-13

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

16*

5-14

Head

Rod

Piston

*Torque to 18-20 ft. lbs (24.4 -27 Nm)

Barrel

T-Seal

Wear Ring

O-ring

Backup Ring

Rod Seal

10. Wear Ring

11. Wiper Seal

12. O-ring

Figure 5-14. Outrigger Cylinder

13. Backup Ring

14. Locknut

15. Bushing

1684442-E

MAE28860

16. Solenoid Valve

17. Plug

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,

SHARP OBJECT, OR SCREW DRIVER. NOTE SEAL ORIENTATION BEFORE REMOV-

ING FOR PROPER INSTALLATION.

Remove Locknut (14) from the rod (2).

Screw piston counterclockwise and remove from rod.

10.

Remove and discard wear ring (6) and T-seal (5) from piston (3).

11.

Remove and discard backup rings (8) and o-ring (7) from piston (3).

MAE29230

Figure 5-15. Piston Disassembly

12.

Remove rod from holding fixture.

10.

Remove cylinder head assembly (1) from rod (2).

10.

Remove and discard backup ring (13), o-ring (12), wear ring (10) from cylinder head (1).

11.

Remove and discard rod seal (9) and wiper seal (11) from cylinder head (1).

MAE29240

Figure 5-16. Cylinder Head Disassembly

CLEANING AND INSPECTION

Clean parts thoroughly with approved cleaning solvent.

Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.

Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

Inspect threaded portion of barrel for damage. Dress threads as necessary.

Inspect piston surface for damage, scoring, or distortion.

Dress piston surface or replace piston as necessary.

Inspect threaded portion of piston for damage. Dress threads as necessary.

Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary.

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.

3121200

5-15

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

13.

If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.

Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation.

Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced.

Lubricate inner side of the steel bushing prior to bearing installation.

Press composite bushing into barrel or rod bushing with correct size arbor.

NOTE:

Lubrication is not required with nickel plated pins and bearings. Install pin in composite bushing dry.

ASSEMBLY

INCORRECT SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER

C YLINDER OPERATION. ENSURE ALL PISTON SEALS ARE CORREC TLY

INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL

ORIENTATION.

NOTE:

Use proper cylinder seal kit for cylinder assembly. See your

JLG Parts Manual.

NOTE:

Apply a light film of hydraulic oil to all components before assembly.

Install rod seal (9), wiper seal (11) and wear ring (10) inside the cylinder head.

Install o-ring (12) on cylinder head.

Figure 5-17. Composite Bushing Installation

14.

If applicable, inspect port block fittings and holding valve. Replace as necessary.

15.

Inspect oil ports for blockage or presence of dirt or other foreign material. Repair as necessary.

16.

If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

MAE29240

Figure 5-18. Cylinder Head Assembly

Install backup ring (13) on cylinder head.

Slide cylinder head assembly onto rod (2). Do not dislodge or damage seals.

Support rod in holding fixture.

Install backup rings (8) and o-ring (7) inside the piston assembly.

5-16

3121200

Install T-seal (5) and wear ring (6) on piston (3).

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

MAE29230

Figure 5-19. Piston Disassembly

Screw the piston (3) on to rod end. Do not dislodge or damage seals.

Install locknut (14) on the rod.

10.

Remove cylinder rod from holding fixture.

11.

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.

12.

Clamp barrel securely and support rod. Insert piston end into barrel cylinder. Do not damage or dislodge seal.

13.

Continue pushing rod into barrel until cylinder head gland can be inserted into barrel cylinder.

14.

Screw the cylinder head gland into the barrel using a tool and tighten until punch mark matches.

MAE29530

Figure 5-20. Cylinder Head Installation

15.

After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

16.

Install the solenoid valve and fittings in the rod port block, using new o-rings as applicable.

3121200

5-17

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Brake Release Cylinder

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

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.

Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately support cylinder rod, if applicable.

If applicable, remove cartridge-type counterbalance valve and fittings from cylinder port block. Discard orings.

Place cylinder barrel in a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to break thread-locking compound.

ROD SUPPORT

PROTECTED ROD CLAMP

BARREL CLAMP

MAE29770

Figure 5-22. Cylinder Head Removal

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND C YLINDER BARREL

SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND

PISTON.

Clamp barrel securely. Pull rod (2) assembly from barrel

(1).

Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible.

ROD SUPPORT

SUPPORT TABLE

Figure 5-21. Cylinder Barrel Support

Mark cylinder head and barrel with a center punch for easy realignment. Unscrew cylinder head (3) with spanner wrench.

Remove and discard o-ring (9) and backup ring (10) from barrel.

Figure 5-23. Cylinder Rod Support

5-18

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Barrel

Rod

Head

Piston

Spring

Nut

O-ring

10. Backup Ring

Figure 5-24. Brake Release Cylinder

11. Rod Seal

12. Wiper Seal

13. Spacer

14. Backup Ring

1001193948-B

MAE28790

5-19

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,

SHARP OBJECT, OR SCREW DRIVER. NOTE SEAL ORIENTATION BEFORE REMOV-

ING FOR PROPER INSTALLATION.

Remove locknut (6) from the rod (2).

10.

Screw piston counterclockwise and remove from rod.

11.

Remove and discard o-ring (7), backup rings (14) and

 o-ring (8) from piston (4).

Figure 5-25. Piston Disassembly

MAE29310

12.

Remove spring (5) and spacer (13) from rod (2).

13.

Remove rod from holding fixture.

14.

Remove and discard wiper seal (12), rod seal (11) from cylinder head (3).

CLEANING AND INSPECTION

Clean parts thoroughly with approved cleaning solvent.

Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.

Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

Inspect threaded portion of barrel for damage. Dress threads as necessary.

Inspect piston surface for damage, scoring, or distortion.

Dress piston surface or replace piston as necessary.

Inspect threaded portion of piston for damage. Dress threads as necessary.

Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary.

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.

Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

14.

If applicable, inspect port block fittings and holding valve. Replace as necessary.

15.

Inspect oil ports for blockage or presence of dirt or other foreign material. Repair as necessary.

16.

If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

MAE29320

Figure 5-26. Cylinder Head Disassembly

5-20

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

ASSEMBLY

INCORRECT SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER

C YLINDER OPERATION. ENSURE ALL PISTON SEALS ARE CORREC TLY

INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL

ORIENTATION.

NOTE:

Use proper cylinder seal kit for cylinder assembly. See your

JLG Parts Manual.

NOTE:

Apply a light film of hydraulic oil to all components before assembly.

Support rod in holding fixture.

Slide spacer (13) on the rod (2).

Install spring (5) onto the spacer and rod.

Install o-ring (8) inside the piston (4).

Install o-ring (7) and backup ring (14) on the piston.

Install rod seal (11) and wiper seal (12) inside the cylinder head.

MAE29320

Figure 5-28. Cylinder Head Assembly

Remove cylinder rod from holding fixture.

10.

Position cylinder barrel in suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN INSTALLING C YLINDER ROD, HEAD,

AND PISTON.

11.

Clamp barrel securely and support rod. Insert piston end into barrel. Do not damage or dislodge piston loading oring and seal ring.

12.

Screw the cylinder head gland into the barrel using a spanner wrench. and tighten until punch mark matches.

Figure 5-27. Piston Disassembly

MAE29310

Screw the piston (4) onto rod. Do not dislodge or damage seals.

Install locknut (6) on the rod.

MAE29760

Figure 5-29. Cylinder Head Installation

13.

After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

3121200

5-21

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Drive Engage Cylinder

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER

SLIGHTLY TO AVOID TRAPPING PRESSURE.

Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.

Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately support cylinder rod, if applicable.

If applicable, remove cartridge-type counterbalance valve and fittings from cylinder port block. Discard orings.

Place cylinder barrel in a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to break thread-locking compound.

ROD SUPPORT

PROTECTED ROD CLAMP

BARREL CLAMP

Figure 5-31. Cylinder Head Removal

MAE29480

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND C YLINDER BARREL

SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND

PISTON.

Clamp barrel securely. Pull rod assembly and cylinder head from barrel.

Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible.

ROD SUPPORT

SUPPORT TABLE

Figure 5-30. Cylinder Barrel Support

Mark cylinder head and barrel with a center punch for easy realignment. Unscrew cylinder head (4) with spanner wrench.

Figure 5-32. Cylinder Rod Support

5-22

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Barrel

Rod piston

Head

Spring

Locknut

Wear Ring

Piston Seal

O-ring

10. O-ring

11. Seal

12. O-ring

Figure 5-33. Drive Engage Cylinder

13. Rod Seal

14. Wiper Seal

15. Spacer

16. Bushing

1684468-A

MAE30510

5-23

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE,

SHARP OBJECT, OR SCREW DRIVER. NOTE SEAL ORIENTATION BEFORE REMOV-

ING FOR PROPER INSTALLATION.

Remove locknut (6) from rod(2).

Screw piston counterclockwise and remove from rod.

10.

Remove and discard piston seal (8) and wear ring (7) from piston (3).

11.

Remove and discard o-ring (9) from piston.

16.

Remove and discard rod seal (13) and wiper seal (14) from head assembly.

Figure 5-34. Piston Disassembly

MAE29330

12.

Remove spring (5) and spacer (15) from rod.

13.

Remove rod from holding fixture.

14.

Remove cylinder head assembly (4) from rod (2).

15.

Remove and discard o-rings (10 & 12) and seal (11) from cylinder head (4).

MAE29340

Figure 5-35. Cylinder Head Disassembly

CLEANING AND INSPECTION

Clean parts thoroughly with approved cleaning solvent.

Inspect cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.

Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

Inspect threaded portion of barrel for damage. Dress threads as necessary.

Inspect piston surface for damage, scoring, or distortion.

Dress piston surface or replace piston as necessary.

Inspect threaded portion of piston for damage. Dress threads as necessary.

Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress surfaces as necessary.

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.

5-24

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

13.

If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.

Thoroughly clean hole, (steel bushing) of burrs, dirt etc. to facilitate bearing installation.

Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced.

Lubricate inner side of the steel bushing prior to bearing installation.

Press composite bushing into barrel or rod bushing with correct size arbor.

NOTE:

Lubrication is not required with nickel plated pins and bearings. Install pin in composite bushing dry.

ASSEMBLY

INCORRECT SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER

C YLINDER OPERATION. ENSURE ALL PISTON SEALS ARE CORREC TLY

INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL

ORIENTATION.

NOTE:

Use proper cylinder seal kit for cylinder assembly. See your

JLG Parts Manual.

NOTE:

Apply a light film of hydraulic oil to all components before assembly.

Install rod seal (13) and wiper seal (14) inside the cylinder head.

Install o-rings (10 & 12) and seal (11) on cylinder head.

Slide cylinder head assembly onto rod (2). Do not dislodge or damage seals.

Figure 5-36. Composite Bushing Installation

14.

If applicable, inspect port block fittings and holding valve. Replace as necessary.

15.

Inspect oil ports for blockage or presence of dirt or other foreign material. Repair as necessary.

16.

If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

MAE29340

Figure 5-37. Cylinder Head Assembly

Support rod in holding fixture.

Carefully slide the spacer (15) onto the rod.

Insert spring (5) onto the rod.

Install o-ring (9) inside piston (3).

3121200

5-25

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

Install piston seal (8) and wear ring (7) onto piston (3).

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN INSTALLING C YLINDER ROD, HEAD,

AND PISTON.

13.

Clamp barrel securely and support rod. Insert piston end into barrel cylinder. Do not damage or dislodge piston loading o-ring and seal ring.

14.

Screw the cylinder head gland into the barrel using a tool and tighten until punch mark matches.

Figure 5-38. Piston Disassembly

MAE29330

Carefully install piston on cylinder rod. Do not damage or dislodge o-ring and backup rings.

10.

Install locknut (6) onto the rod.

11.

Remove cylinder rod from holding fixture.

12.

Position cylinder barrel in suitable holding fixture.

Figure 5-39. Cylinder Head Installation

MAE29520

15.

After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

5-26

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.3 HYDRAULIC PUMP

Removal

(GEAR)

Carefully place the gear pump on the clean working surface.

Installation

ENSURE THE PRESSURE IS PROPERLY RELIEVED FROM THE HYDRAULIC SYS-

TEM BEFORE PROCEEDING TO REMOVAL OF THE PUMP MOTOR.

Disconnect the hydraulic hoses from inlet and outlet ports of the gear pump.

CAP OR PLUG ALL THE HYDRAULIC HOSES TO PREVENT ENTRAPPING OF THE

DUST AND DIRT INTO IT.

Remove bolts and washers secured on the gear pump.

Carefully remove gear pump from the rear piston pump assembly.

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.

Apply thin film of spline grease on the gear shaft.

Carefully insert the shaft into the piston pump and secure the gear pump using two bolts and washers.

Apply JLG Threadlocker P/N 0100011 to end of bolts.

Torque bolts to 20-24 ft.lbs (27-33 Nm).

Remove cap from the hydraulic hoses and re-connect to their original locations.

PUMP COUPING KIT

GEAR PUMP

WASHER

BOLT

Figure 5-40. Hydraulic Pump Installation

MAE29370

3121200

5-27

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.4 PRESSURE SETTING PROCEDURE

Main Relief

Install a pressure gauge at the port marker "G" located on top of the valve block.

The telescope “In” relief valve is located below the hand pump. Screw this in (clockwise) 2 turns.

Telescope out about 5 feet. Then telescope in until it bottoms out. The gauge should read 2700 psi. (186 bar).

If adjustment is needed, the main relief adjustment is located below the “TA” and “TB” ports. To increase, screw clockwise, to decrease screw counterclockwise.

Telescope In

Install a pressure gauge at the port marked “G” located on top of the valve block.

Locate the telescope “In” relief valve below the hand pump.

Telescope out about 5 feet. Then telescope in until it bottoms out. The gauge should read 2200 psi. (152 bar).

To increase, screw clockwise, to decrease screw counterclockwise.

Telescope Out

Install a pressure gauge at the port marked "G" located on top of the valve block.

Locate the telescope "Out" relief valve located below the

"GA" gauge port.

Telescope out until it bottoms out. The gauge should read 2400 psi. (166 bar).

To increase, screw clockwise, to decrease screw counterclockwise.

Platform Level Up

Install a pressure gauge at the port marked “GA” located on the left side of the block right next to the telescope directional valve.

Both level relief valves are located on top of the valve block. The one toward the center is level up.

Level up until it bottoms out. The gauge should read

2200 psi (152 Bar).

To increase, screw clockwise, to decrease screw counterclockwise.

Platform Level Down

Install a pressure gauge at the port marked "GB" located on the front side of the block right below the hand pump.

Both level relief valves are located on top of the valve block. The one toward the out side is level down.

Level down until it bottoms out. The gauge should read

2000 psi. (138 bar).

To increase, screw clockwise, to decrease screw counterclockwise.

Swing Right

Install a pressure gauge at the port marked "G" located on top of the block.

Lower the boom down into the boom rest to lock the boom.

Activate swing right. The gauge should read



600 - 800 psi. (41 - 55 bar).

The swing right relief valve is located on the left face next to the swing directional valve. To increase, screw clockwise, to decrease screw counterclockwise.

Swing Left

Install a pressure gauge at the port marked "G" located on top of the block.

Lower the boom down into the boom rest to lock the boom.

Activate swing left. The gauge should read 600 - 800 psi.

(41 - 55 bar).

The swing left relief valve is located on the front face next to the suction port. To increase, screw clockwise, to decrease screw counterclockwise.

Outrigger Up

Install a pressure gauge at the port marked “G” located on top of the block.

Activate jacks up until the cylinders are all bottomed out. The gauge should read 2500 psi. (172.5 bar).

The outrigger relief valve is located on the front face below the lift push button manual descent valve. To increase, screw clockwise, to decrease screw counterclockwise.

5-28

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Figure 5-41. Hydraulic Test Ports

MAE29300

5-29

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.5 HYDRAULIC OIL FILL AT STARTUP

Fill the tank.

NOTE:

Step 2 applies to Gas Engine equipped models only.

Loosen the outlet port hose of the pump until oil is seen.

This ensures that air has been bled from the suction line.

Without doing this step, there could be an air lock up on start-up, which can damage the pump

Manually lay the outriggers out so the pads are on the ground.

Retract the outriggers.

Extend the outriggers.

Refill the hydraulic tank.

Raise the boom up to horizontal.

Raise the Jib (if applicable) to full stroke. Lower the Jib with manual descent. (Needle valve at the Jib cylinder).

Close the needle valve when the Jib is fully retracted.

Extend and retract platform level to full stroke in both directions. Level the platform.

10.

Lift up the boom to full stroke (or as high as the boom will go).

11.

Extend and retract platform level, then back to level.

12.

Lift down the boom using manual descent. Bring the boom down to the boom rest.

13.

Repeat the lift up and down function using the switch, not manual descent.

14.

Telescope the boom out to full stroke.

15.

Telescope the boom in to the end of stroke.

16.

Swing the turn-table1/8th turn in both directions.

17.

Retract the outriggers.

18.

Refill the tank to the full mark on the dipstick.

5.6 HYDRAULIC HOSES

When replacing any of the hoses that run through the center of the turntable, make sure the boom is positioned 180° opposite from the tongue and not over the tongue. Failure to have the boom properly positioned will cause the hoses to experience excessive twisting during swing operations and will cause premature failure of the hose.

5.7 HYDRAULIC FILTER AND BREATHER

When changing the hydraulic filter, inspect the o-ring on the cap for any nicks or tears. Replace the o-ring if there is any damage. Check the breather line (clear line) that runs from the hydraulic tank to the breather to ensure it is free from oil and not pinched or damaged. If oil has ever entered the breather, it must be changed. This can happen if the hydraulic tank is overfilled or the breather line gets pinched.

NOTE:

The cap securing the filter must be torqued



154 to 170 ft.lbs. (209 to 230.5 Nm).

5-30

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Platform Level Cartridge Valve

Telescope Cartridge Valve

MAE29440

Swing Cartridge Valve

Lift Cartridge Valve

Figure 5-42. Control Valve Identification

Manual Descent Cartridge Valve

Outrigger Cartridge Valve

5-31

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-32

MAE29280

Ft-Lbs.

11-14

154-170

15-18.5

15-20

209-230.5

20-25

Table 5-2. Control Valve Torque Values

Ft-Lbs.

13-15

17-19

18.5-22

17.5-20

23-26

25-30

Ft-Lbs.

25-28

28-33

Figure 5-43. Control Valve Torque Values (Engine Powered Machines) - Sheet 1 of 2

34-38

38-45

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

MAE29290

Table 5-3. Control Valve Torque Values

Ft-Lbs.

11-14

154-170

15-18.5

15-20

209-230.5

20-25

Ft-Lbs.

13-15

17-19

18.5-22

17.5-20

23-26

25-30

Ft-Lbs.

25-28

28-33

Figure 5-44. Control Valve Torque Values (Engine Powered Machines) - Sheet 2 of 2

34-38

38-45

5-33

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-34

MAE29460

Ft-Lbs.

28-33

154-170

38-45

209-230.5

Table 5-4. Control Valve Torque Values

Ft-Lbs.

13-15

17-19

18.5-22

17.5-20

23-26

25-30

Ft-Lbs.

25-28

Figure 5-45. Control Valve Torque Values (Electric Powered Machines) - Sheet 1 of 2

34-38

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

MAE29470

Ft-Lbs.

28-33

154-170

38-45

209-230.5

Table 5-5. Control Valve Torque Values

Ft-Lbs.

13-15

17-19

18.5-22

17.5-20

23-26

25-30

Ft-Lbs.

25-28

Figure 5-46. Control Valve Torque Values (Electric Powered Machines) - Sheet 2 of 2

34-38

5-35

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-36

1. Left Drive Valve



2. Shuttle Valve (LS2)



3. Right Drive Valve



4. EP2



5. EP1

6. Pressure Check



7. Shuttle Valve (LS1)

8. Shuttle Valve (LS3)



9. Counterbalance Valves

Figure 5-47. Drive Directional Valve Identification - Drive & Set Option

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

Ft-Lbs.

18-20

30-35

35-40

24-27

41-47

47-54

Figure 5-48. Drive Directional Valve Torque Values - Drive & Set Option

5-37

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-38

NOTE:

All cartridges are torqued 18-20 ft.lbs. (24-27 Nm). The solenoid valve is to be torqued 25-27 ft.lbs. (34-36.5 Nm). There is no torque specification for the filter.

1. Pressure Regulator (PR1)



2. Check Valve (CV1)



3. Relief Valve (RV1)



4. Relief Valve (RV2)



5. Solenoid Valve (SV1)



6. Filter (F1)

Figure 5-49. Drive Enable Valve Identification - Drive & Set Option

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

This page left blank intentionally.

5-39

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.8 HYDRAULIC SCHEMATICS

5-40

Figure 5-50. Hydraulic Schematic - Electric Machines - Sheet 1 of 2

SHEET 1

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

SHEET 1

Figure 5-51. Hydraulic Schematic - Electric Machines - Sheet 2 of 2

2792642-G

5-41

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-42

Figure 5-52. Hydraulic Schematic - Gas Machines - Sheet 1 of 2

SHEET 2

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

SHEET 2

Figure 5-53. Hydraulic Schematic - Gas Machines - Sheet 2 of 2

2792642-G

5-43

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-44

Figure 5-54. Hydraulic Schematic - Drive Option (Gas) - Sheet 1 of 2

SHEET 3

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

SHEET 3

Figure 5-55. Hydraulic Schematic - Drive Option (Gas) - Sheet 2 of 2

2792642-G

5-45

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-46

Figure 5-56. Hydraulic Schematic - Drive Option Electric Motor - Sheet 1 of 2

SHEET 4

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

SHEET 4

Figure 5-57. Hydraulic Schematic - Drive Option Electric Motor - Sheet 2 of 2

2792642-G

5-47

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5.9 HYDRAULIC DIAGRAM

8 7

SLAVE CYLINDER

V1 V2

JIB CYLINDER

BOOM CIRCUIT

SEE SHEET #4

MASTER CYLINDER

OUTRIGGER

LEFT REAR

OUTRIGGER MANIFOLD

(FACING REAR OF TRAILER)

1 2 3

4 5 6

OUTRIGGER MANIFOLD

(FACING FRONT OF TRAILER)

7 8

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

5-48

OUTRIGGER

RIGHT REAR

PAGE

NO.

SWING MOTOR

CHARTED P/L DESCRIPTION

CHART

CHASSIS CIRCUIT ELECTRIC

CE CHASSIS CIRCUIT ELECTRIC

CHASSIS CIRCUIT GAS

CE CHASSIS CIRCUIT GAS

BOOM CIRCUIT

DRIVE & SET CIRCUIT GAS

DRIVE & SET CIRCUIT GAS CE

DRIVE & SET CIRCUIT ELECTRIC

DRIVE & SET CIRCUIT ELECTRIC CE

Figure 5-58. Machine - Sheet 1 of 12

P/L

P/N

N/A

OUTRIGGER

RIGHT FRONT

SHEET 1

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

BOOM CIRCUIT

SEE SHEET #4

4 3

X X X

LIFT CYLINDER

2 1

TELE CYLINDER

POWER UNIT

LEFT SIDE VIEW

SHEET 1

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

EA RA

POWER UNIT

RESERVOIR SIDE

OUTRIGGER

RIGHT FRONT

CHASSIS CIRCUIT

SEE SHEET #2-#3

NOTE: ALL CYLINDER PORTS MARKED "V1" ARE EXTEND

ALL CYLINDER PORTS MARKED "V2" ARE RETRACT

INLET

OUTLET

GAS VERSION

POWER UNIT

MOTOR SIDE

JIB BLOCK

Suction

1283401-F

MAE31080

4 3

Figure 5-59. Machine - Sheet 2 of 12

3121200

5-49

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

8 7

OUTRIGGER

LEFT REAR

OUTRIGGER MANIFOLD

(FACING REAR OF TRAILER)

1 2 3

4 5

5-50

OUTRIGGER

RIGHT REAR

SWING MOTOR

OUTRIGGER

RIGHT FRONT

7 6 5

Figure 5-60. Chassis Circuit (Electric) - Sheet 3 of 12

CHASSIS CIRCUIT

ELECTRIC

OUTRIGGER MANIFOLD

(FACING FRONT OF TRAILER)

7 8

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

SHEET 2

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

CHASSIS CIRCUIT

ELECTRIC

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

3 2

MALE/FEMALE CONNECTIONS

SEE TOWER BOOM CIR.

REFERENCE SHEET #4

POWER UNIT

LEFT SIDE VIEW

MALE/FEMALE CONNECTIONS

SEE TOWER BOOM CIR.

REFERENCE SHEET #4

POWER UNIT

RESERVOIR SIDE

PA PB

POWER UNIT

MOTOR SIDE

JIB BLOCK

Suction T2

OUTRIGGER

RIGHT FRONT

SHEET 2

5 4 3 2

Figure 5-61. Chassis Circuit (Electric) - Sheet 4 of 12

1283401-F

MAE31090

5-51

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

8 7 6 5

CHASSIS CIRCUIT

GAS

5-52

OUTRIGGER

LEFT REAR

OUTRIGGER MANIFOLD

(FACING REAR OF TRAILER)

1 2

4 5 6

OUTRIGGER

RIGHT REAR

SWING MOTOR

OUTRIGGER MANIFOLD

(FACING FRONT OF TRAILER)

7 8

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

OUTRIGGER

RIGHT FRONT

7 6 5

Figure 5-62. Chassis Circuit (Gas) - Sheet 5 of 12

SHEET 3

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

CHASSIS CIRCUIT

GAS

OUTRIGGER

LEFT FRONT

OUTRIGGER MANIFOLD

(FACING LEFT OF TRAILER)

3 2

MALE/FEMALE CONNECTIONS

SEE TOWER BOOM CIR.

REFERENCE SHEET #4

POWER UNIT

LEFT SIDE VIEW

MALE/FEMALE CONNECTIONS

SEE TOWER BOOM CIR.

REFERENCE SHEET #4

EA RA

POWER UNIT

RESERVOIR SIDE

PA PB

INLET

OUTLET

GAS VERSION

POWER UNIT

MOTOR SIDE

JIB BLOCK

Suction T2

OUTRIGGER

RIGHT FRONT

SHEET 3

5 4 3 2

Figure 5-63. Chassis Circuit (Gas) - Sheet 6 of 12

1283401-F

MAE31100

5-53

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-54

MASTER CYLINDER

SLAVE CYLINDER

V1 V2

JIB CYLINDER

7 6

Figure 5-64. Boom Circuit - Sheet 7 of 12

BOOM CIRCUIT

TELE CYLINDER

SHEET 4

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

BOOM CIRCUIT

4 3 2 1

TELE CYLINDER

X X X

LIFT CYLINDER

SEE CHASSIS CIR.

REFERENCE SHEET #2-#3

MALE/FEMALE CONNECTIONS

BULKHEAD PLATE

(AS VIEWED FROM FRONT

OF TURNTABLE)

PP PB

TURNTABLE BASE

CABLES,

AIR LINE,

PRESSURE

WASHER HOSE

SEE CHASSIS CIR.

REFERENCE SHEET #2-#3

MALE/FEMALE CONNECTIONS

SHEET 4

5 4 3

Figure 5-65. Boom Circuit - Sheet 8 of 12

1283401-F

MAE31110

5-55

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

8 7 6

RIGHT DRIVE

MOTOR

DRIVE & SET CIRCUIT

GAS

5-56

NOTE: RIGHT AND LEFT MOTORS

DESIGNATION ARE DETERMINED

BY THE OPERATOR STANDING IN

THE PLATFORM

WHEEL ENGAGEMENT

CYLINDER

LEFT DRIVE

MOTOR

M4 P2

DRIVE VALVE

SEE PORT AND

ADAPTER LOCATION

CHART BELOW

INSIDE

PORT

FLOWDIVIDER

PORT AND ADAPTER LOCATION

PORTS SEQ #

B,M1,M2,M3,4M #1

T #2

P1,P2 #4

G1,G2 #10

8 7 6 5

Figure 5-66. Drive and Set Circuit (Gas) - Sheet 9 of 12

WHEEL ENGAGEMENT

RELEASE VALVE

SHEET 5

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121200

DRIVE & SET CIRCUIT

GAS

WHEEL ENGAGEMENT

CYLINDER

3 2

PORT AND ADAPTER LOCATION

PORTS SEQ #

C,D,P,P1,T,T1 #4

G,GC #10

ENABLE

VALVE

BRAKE CYLINDER

POWER UNIT

MOTOR SIDE

Suction

PUMP

WHEEL ENGAGEMENT

RELEASE VALVE

SHEET 5

5 4 3 2

Figure 5-67. Drive and Set Circuit (Gas) - Sheet 10 of 12

1283401-F

MAE31120

5-57

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

5-58

8 7

RIGHT DRIVE

MOTOR

DRIVE & SET CIRCUIT

ELECTRIC

NOTE: RIGHT AND LEFT MOTORS

DESIGNATION ARE DETERMINED

BY THE OPERATOR STANDING IN

THE PLATFORM

WHEEL ENGAGEMENT

CYLINDER

LEFT DRIVE

MOTOR

DRIVE VALVE

SEE PORT AND

ADAPTER LOCATION

CHART BELOW

INSIDE

PORT

WHEEL ENGAGEMENT

RELEASE VALVE

FLOWDIVIDER

PORT AND ADAPTER LOCATION

PORTS SEQ #

B,M1,M2,M3,4M #1

T #2

P1,P2 #4

G1,G2 #10

8 7 6 5

Figure 5-68. Drive and Set Circuit (Electric) - Sheet 11 of 12

SHEET 6

3121200

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

DRIVE & SET CIRCUIT

ELECTRIC

4 3

PORT AND ADAPTER LOCATION

PORTS SEQ #

C,D,P,T,T1 #4

G,GC #10

P1 #21

2 1

ENABLE VALVE

BRAKE CYLINDER

POWER UNIT

MOTOR SIDE

WHEEL ENGAGEMENT

RELEASE VALVE

3121200

SHEET 6

5 4 3 2

Figure 5-69. Drive and Set Circuit (Electric) - Sheet 12 of 12

1283401-F

MAE31130

5-59

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

NOTES:

5-60

3121200

SECTION 6 - JLG CONTROL SYSTEM

6.1 INTRODUCTION

SECTION 6. JLG CONTROL SYSTEM

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 PERI-

ODS TO AVOID HEAVY SATURATION.

The JLG designed Control System is a 12 volt based 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, minimum speed, and maximum speed for all boom, drive, and steering functions.

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 into the control system.

The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubleshooting.

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.

Analyzer Display

Escape Key

To return home or access previous menu

Up & Down Arrow Keys

Value Selector menu:

HELP:PRESS ENTER

ESC ENTER

Enter Key

Stores and selects Top Level, Sub

Level, and item menus

Left & Right Arrow Keys

Used to move between Top Level,

Sub Level, and item menus

Figure 6-1. Hand Held Analyzer

3121200

6-1

SECTION 6 - JLG CONTROL SYSTEM

6.2 TO CONNECT THE JLG CONTROL SYSTEM

ANALYZER

Connect the cable supplied with the analyzer, to the controller module in the ground control box and connect the remaining end of the cable to the analyzer.

Using the Analyzer

With the machine power on and the analyzer connected properly, the analyzer will display the following:

HELP: PRESS ENTER

ESC ENTER

NOTE:

The cable has a four pin connector at each end of the cable; the cable cannot be connected backwards.

Power up the Control System by turning the key to the ground position and pulling the emergency stop button on.

MAE19060

MENU:

HELP:PRESS ENTER

Move between top level menu items using

RIGHT

and

LEFT

played menu item, press

ENTER

arrow keys. To select a dis-

To cancel a selected menu item, press

ESC

then you will be able to scroll using the right and left arrow keys to select a different menu item.

The top level menus are as follows:

HELP



DIAGNOSTICS



SYSTEM TEST



ACCESS LEVEL



PERSONALITIES



MACHINE SETUP



CALIBRATIONS (view only)

6-2

3121200

SECTION 6 - JLG CONTROL SYSTEM

If you press

ENTER

, at the

HELP: PRESS ENTER

display, and a fault is present, the analyzer display will scroll the fault across the screen. If there was no fault detected, the display will read:

HELP: EVERYTHING OK.

If powered up at the ground station, the display will read:

GROUND OK.

ENTER

lowing display:

is pressed again, the display moves to the fol-

HELP:

1:POWERCYCLE(0/0)

ESC ENTER

Pressing

ENTER

with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases, such as

DRIVE

, the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the

ESC

key.



6.3 CHANGING ACCESS LEVEL

When the analyzer is first connected, you will be in access level

2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the

ACCESS LEVEL

menu. For example:

Access level 2

ESC ENTER

MAE19060

LOGGED HELP



1: POWER CYCLE (0/0

)

At this point, the analyzer will display the last fault the system has seen, if any are present. You may scroll through the fault logs to view what the last 25 faults were. Use the right and left arrow keys to scroll through the fault logs. To return to the beginning, press

ESC

indicates a power up.

two times.

POWER CYCLE (0/0)

When a top level menu is selected, a new set of menu items may be offered: for example:

PLATFORM



GROUND



PUMP



ENGINE



SYSTEM



VALVES



DATALOG



VERSIONS

MAE19060

MENU:



ACCESS LEVEL 2

Press

ENTER

Using the

to select the

ACCESS LEVEL

menu.

DOWN

digit of the password, 3.

arrow keys, enter the first

Then using the

RIGHT

arrow key, position the cursor to the right one space to enter the second digit of the password.

3121200

6-3

SECTION 6 - JLG CONTROL SYSTEM

Use the

DOWN

arrow key to enter the second digit of the password which is 33271.

Continue using the arrow keys until all the remaining digits of the password is shown.

6.4 ADJUST PARAMETERS

Once you have gained access to level 1, and a personality item is selected, press the

adjust its value, for example:

DOWN

arrow keys to

Once the correct password is displayed, press

ENTER

The access level should display the following, if the password was entered correctly:

PERSONALITIES:

LIFT ACCEL 1.0

ESC ENTER

ACCESS LEVEL 1

ESC ENTER

MAE19060

MENU:



ACCESS LEVEL 1

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.

MAE19060

PERSONALITIES:



LIFT ACCEL 1.0s

There will be a minimum and maximum for the value to ensure efficient operation. The Value will not increase if the

arrow is pressed when at the maximum value nor will the value decrease if the

DOWN

arrow is pressed and the value is at the minimum value for any particular personality. If the value does not change when pressing the up and down arrows, check the access level to ensure you are at access level 1.

6-4

3121200

SECTION 6 - JLG CONTROL SYSTEM

6.5 MACHINE SETUP

Level Vehicle Description

When a machine digit item is selected, press

DOWN

arrow keys to adjust its value, for example:

DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.

GROUND ALARM:

2 = MOTION

ESC



ENTER

LEVEL Vehicle:

YES:ENTER, NO:ESC

ESC ENTER

MAE19060

LEVEL VEHICLE

YES:ENTER, NO:ESC

GROUND ALARM:



2 = MOTION



The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when lifting down. There are certain settings allowed to install optional features or select the machine model.

When selection the machine model to match the size of the machine, the personality settings will all default to the factory recommended setting.

NOTE:

Refer to Table 6-3, Machine Model Adjustments and Speeds

- ANSI & CSA and Table 6-4, Machine Model Adjustments and Speeds - CE Only for the recommended factory set-

tings.

NOTE:

Password 33271 will give you access to level 1, which will permit you to change all machine personality settings.



Not available at password level 2.

ENTER

confirms vehicle is currently level, and zeroes the tilt sensor measurements.

3121200

6-5

SECTION 6 - JLG CONTROL SYSTEM

ABBREVIATION

DOS

DRV

E&T

DWN

DEG.

C/O

CONT(S)

COOR

CRK PT

CRP

CUT

CYL

DECEL

BLAM

BSK

CAL

CNTL

CNTRL

ANG

AUX

BCS

ACCEL

ACT

A/D

AMB.

FNT

FOR

FWD

ELEV

ENG

EXT

FSW

FUNC

Table 6-1. Analyzer Abbreviations

MEANING

ACCELERATE

ACTIVE

ANALOG DIGITAL CONVERTER COUNT

AMBIENT

ANGLE

AUXILIARY

BOOM CONTROL SYSTEM

BOOM LENGTH ANGLE MODULE

BROKEN

BASKET

CALIBRATION

CLOSED

CHASSIS MODULE

CONTROL

CUT OUT

CONTRACTOR(S)

COORDINATED

CRACK POINT

CREEP

CUTOUT

CYLINDER

DECELERATE

DOWN

DEGREE

DRIVE ORIENTATION SYSTEM

DRIVE

ERROR

ELEVATED & TILTED

ELEVATION

ENGINE

EXTEND

FRONT

FLOW

FRONT

FORWARD

FOOT SWITCH

FUNCTION

GROUND

6-6

PCV

PLAT

O/R

O//R

OSC

OVRD

O/C

MAX

LVL

MIN

LEN

LIM

GND

GRN

HWFS

JOY

PRS

REV

PLT

POT

PRES

RET

ROT.

ABBREVIATION

Table 6-1. Analyzer Abbreviations

MEANING

GROUND

GREEN

GROUND MODULE

HOURS

HARDWARE

HARDWARE FAILSAFE

IN or CURRENT

JOYSTICK

LEFT

POUND

LENGTH

LIMIT

LEFT

LEVEL

MINUTES

MINIMUM

MAXIMUM

MAIN

NORMALLY OPEN or NO

NORMALLY CLOSED

OUT

OPEN CIRCUIT

OPEN

OVERRIDE or OUTRIGGER

OVERRIDE

OSCILLATING

OVERRIDE

PLATFORM

PRESSURE

PROPORTIONAL CONTROL VALVE

PLATFORM

PLATFORM MODULE

POTENTIOMETER

PRESSURE

POINT

REAR or RIGHT

REVERSE or REVISION

RETRACT

ROTATE

RIGHT

3121200

ABBREVIATION

VER

VLV

WIT

YEL

TEMP

TORQ.

TRN

T/T

TURNTBL

TWR

S/C

SEL

SPD

STOW

STOWD

TELE

Table 6-1. Analyzer Abbreviations

MEANING

SHORT CIRCUIT

SELECTOR

SERIAL NUMBER

SPEED

STOWED

SWITCH or SOFTWARE

TELESCOPE

TEMPERATURE

TORQUE

TRANSPORT

TURNTABLE

TOWER

TURNTABLE

TOWER

UPPER or UP

VOLT

VERSION

VALVE

WITNESS

YELLOW

SECTION 6 - JLG CONTROL SYSTEM

3121200

6-7

SECTION 6 - JLG CONTROL SYSTEM

6-8

3121200

SECTION 6 - JLG CONTROL SYSTEM

3121200

6-9

SECTION 6 - JLG CONTROL SYSTEM

6-10

3121200

SECTION 6 - JLG CONTROL SYSTEM

6.6 SYSTEM TEST

The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures.

Platform Test

Position the Platform/Ground select switch to the Platform position.

Plug the analyzer into the connector at the base of the platform control box.

The analyzer screen should read.

HELP:

PRESS ENTER

ESC ENTER

Pull out the Emergency Stop switch.

MAE19060

Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate.

Follow the flow path in Figure 6-5., System Test Flow

Chart - Platform Tests and go through the component

tests. Hit the ESC key during any part of the test to return to the main menu without completing all tests or wait until all tests are complete. During the TEST ALL

INPUTS sequence, the analyzer allows control switches to be operated and shows if they are closed (CL) or open

(OP).

3121200

6-11

SECTION 6 - JLG CONTROL SYSTEM

6-12

3121200

SECTION 6 - JLG CONTROL SYSTEM

Ground Test

Position the Platform/Ground select switch to the

Ground position.

Plug the analyzer into the connector inside the Ground control box.

The analyzer screen should read:



HELP:

PRESS ENTER

ESC

ENTER

Pull out the Emergency Stop switch.

MAE19060

Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate.

Follow the flow path in Figure 6-6., System Test Flow

Chart - Ground Station Tests and go through the compo-

nent tests. Hit the ESC key during any part of the test to return to the main menu without completing all tests or wait until all tests are complete. During the TEST ALL

INPUTS sequence, the analyzer allows control switches to be operated and shows if they are closed (CL) or open

(OP).

3121200

6-13

SECTION 6 - JLG CONTROL SYSTEM

6-14

3121200

SECTION 6 - JLG CONTROL SYSTEM

6.7 LEVELING, TILT SENSOR CALIBRATION

When all outriggers are set, the leveling system looks at the angle reported by the bi-directional tilt sensor mounted on the ground board. The system automatically adjusts the outriggers until the chassis is level within 1.0° compound angle before allowing operation of the boom above elevation.

When Machine Is on a Firm Level Surface

Place the empty, stowed machine on a firm level surface.

Place a digital level on the frame as shown and level as well as possible in both x (left Wheel to right wheel) and y (tongue to tail lights) direction by adjusting tongue jack, being careful not to set the level on welds or adjacent plates (On later frames the fork pocket will be forward of the level).

If the board has been replaced or the tilt sensor is not calibrated, connect an analyzer to the machine at the ground control console and calibrate tilt sensor. Enter

Level 2 in Analyzer and use the right arrow key to scroll to Calibrations. Next use the down arrow reach TILT SENSOR. Then press the ENTER key .

3121200

Deploy the outriggers until the machine auto levels. The machine will indicate it has leveled by beeping three times and flashing the outrigger indicator lights on the ground control box.

Verify the machine is level using a digital level as shown in step 1. If not level within 0.5° in each direction, continue to Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure.

NOTE:

The tilt sensor reading may be accessed through the analyzer: Use the right arrow key

to reach DIAGNOSTICS down arrow key once , right arrow key scroll over to SYSTEM, then the down arrow key reach Tilt.

6-15

SECTION 6 - JLG CONTROL SYSTEM

Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure:

Connect an analyzer to the machine at the ground control console. Turn the machine power on and select the ground control mode. Go to service mode and adjust outriggers individually to level the machine:

On the analyzer, select "ACCESS LEVEL 2" and enter

33271. Use the right arrow key to scroll to CAL-

IBRATIONS. Press the ENTER key . Press the right arrow key then the down arrow key

OVERRIDE F-L.

once to reach AUTOLEVEL,

once to reach



Arrow down until you reach the desired outrigger. Use the outrigger deploy switch on the

Ground control to raise or lower the outrigger.

Verify the reading from digital level. Must not exceed

0.2° in both the X- direction (left Wheel to right wheel) and Y-direction (tongue to tail lights).

Calibrate tilt sensor. Enter Level 2 in Analyzer and use the right arrow key

Press the down arrow key

to scroll to CALIBRATIONS.

once to reach TILT SEN-

SOR. Then hit ENTER .

Recycle emergency stop switch. Retract leveling jacks until the set lights go out. Set leveling jacks and wait until the machine signals it is level. Verify machine auto levels within 1.0°.

6-16

3121200

SECTION 6 - JLG CONTROL SYSTEM

6.8 USER FAULT CODES

A single digit fault code blinks on the Platform and the Ground control panel to signal the operator of a procedure fault. Refer

to Table 6-2, User Fault Codes.

Code

Table 6-2. User Fault Codes

Message

Chassis Tilt Sensor Out Of Range

Running At Creep - Material Hook Mode

Function Locked Out - Joystick Not Centered At Startup

Function Locked Out - Trigger Permanently Closed

Function Problem - Engine Choke Permanently Selected

Function Problem - Engine Start Permanently Selected

Function Problem - Jib Down Permanently Selected

Function Problem - Jib Up Permanently Selected

Function Problem - Level Down Permanently Selected

Function Problem - Level Up Permanently Selected

Function Problem - Lift Down Permanently Selected

Function Problem - Lift Up Permanently Selected

Function Problem - Outrigger Set Permanently Selected

Function Problem - Outrigger Stow Permanently Selected

Function Problem - Swing Left Permanently Selected

Function Problem - Swing Right Permanently Selected

Function Problem - Telescope In Permanently Selected

Function Problem - Telescope Out Permanently Selected

Joystick Moved But Trigger Switch Open

Trigger Closed Too Long While In Neutral

Drive & O/R Prevented - Operate From Platform

Drive & O/R Prevented - Place Boom On Rest

Drive & O/R Prevented - Set Hand Brake

Drive Prevented - Lift Down

Drive Prevented - Stow Outriggers

Drive Prevented - Telescope In

Lift Down Prevented - Tele In First

Lift Up & Tele Out Prevented - Tilted & Above Elevation

"Lift Up & Tele Out Prevented - Tilted, Unset,& Above Elevation "

Lift Up & Tele Out Prevented - Unset & Above Elevation

Lift Up Prevented - Check Outriggers

Lift Up Prevented - Lift Down Then Set Outriggers

Lift Up Prevented - Tilted

Model Changed - Hydraulics Suspended - Cycle EMS

Outrigger Stow Prevented - Tele In First

Outriggers Prevented - Elevated

Running At Creep - Tilted & Above Elevation

Running At Creep - Unset & Above Elevation

Tele Out Prevented - Set Outriggers

Tele Out Prevented - Tilted

Table 6-2. User Fault Codes

Code Message

A 2 user flash code indicates a problem with the machine set up, such as an outrigger not properly set. If this occurs while the boom is elevated, all functions will operate at a reduced speed. Immediately return the platform to the stowed position and reposition the machine or reset the outriggers, as required. If the problem still exists, troubleshoot with a JLG analyzer.

A 2 user flash code and tilt alarm warning indicator activated at the same time indicates a potential tipping condition. If this occurs while boom is elevated, the lift up and telescope out functions will not operate. Telescope in, lift down and swing functions will operate at reduced speed. THE BOOM MUST BE FULLY RETRACTED BEFORE LOWERING.

Immediately return the platform to the stowed position and reposition the machine or reset the outriggers, as required. If the problem still exists, troubleshoot with a JLG analyzer.

Battery Voltage Too High - System Shutdown

Battery Voltage Too Low - System Shutdown

No Charge System Output

Functions At Cutback - Power Module Current Limit

Power Module Too Hot - Please Wait

Battery Voltage Too High - System Shutdown

Battery Voltage Too Low - System Shutdown

Engine Not Running

Vehicle Requires Service

3121200

6-17

SECTION 6 - JLG CONTROL SYSTEM

6-18

NATURAL 35 PIN

GREY 35 PIN

BLACK 14 PIN

INTEGRAL AMBIENT

TEMP SENSOR

BLACK 4 PIN

BLACK 35 PIN

BLUE 35 PIN

Figure 6-7. Ground Module

1600370-J

MAE29880

3121200

SECTION 6 - JLG CONTROL SYSTEM

Connector Pin Tagname

1 N/C

N/C

GND

N/C

Function

NOT CONNECTED

GROUND

NOT CONNECTED

Type

Power Output

GND

N/C

GROUND

NOT CONNECTED

Power Output

Power Input

N/C

NOT CONNECTED

ANALOG INPUT 0 (0-10V; 10 Bit;

AI0 Analog Input

200K pull-down)

ANALOG INPUT 1 (0-10V; 10 Bit;

AI1 Analog Input

200K pull-down)

ENGS ENGINE MAGNETO (SPEED PICKUP) Analog Input

(Natural)

GND

N/C

DI0

DO0

GROUND

NOT CONNECTED

Power Output

DIGITAL INPUT 0 (Low-Sensing) Digital Input

DIGITAL OUTPUT 0 (High-Side; 4A;

Digital Output

PWM; Exclusive with J4-12 & J2-27)

NOT CONNECTED

CONSTANT BATTERY Power Input

N/C

CBAT

N/C

GND

APWR

AGND

N/C

GND

DI1

DI2

NOT CONNECTED

GROUND

ANALYZER POWER (+9.5V)

RS-232 RECEIVE

RS-232 TRANSMIT

ANALYZER RETURN

NOT CONNECTED

Power Output

Serial

Input

Output

Power Output

GROUND Power Output

DIGITAL INPUT 1 (Low-Sensing) Digital Input

DIGITAL INPUT 2 (Low-Sensing) Digital Input

Connector Pin Tagname

1 N/C

Function

NOT CONNECTED

N/C

PWRS

TELEIN

LVLUP

GND

LVLDN

NOT CONNECTED

POWER MODULE LOGIC & LINE

CONTACTOR COIL SUPPLY

TELESCOPE IN VALVE

LEVEL UP VALVE

GROUND

LEVEL DOWN VALVE

Digital Output

Power Output

Digital Output

OGALR OPTIONAL GROUND ALARM (PWM) Digital Output

DUMP DUMP VALVE (PWM)

DIGITAL OUTPUT 7 (High-Side; 4A;

Type

Digital Output

10 DO7 Digital Output

LFTUP

JIBU

N/C

GND

Exclusive with J2-21)

LIFT UP VALVE

JIB UP VALVE

NOT CONNECTED

GROUND

DIGITAL OUTPUT 10 (High-Side; 4A;

Digital Output

Power Output

15 DO10 Digital Output

(Grey)

TELEOUT

GND

GALR

JIBD

Exclusive with J2-3)

TELESCOPE OUT VALVE

GROUND

GROUND ALARM

JIB DOWN VALVE (PWM)

Digital Output

Power Output

Digital Output

DO14

22 LFTDN

STRO

DI3

DIGITAL OUTPUT 14 (High-Side; 4A;

Digital Output

Exclusive with J2-10)

LIFT DOWN VALVE (PWM)

ENGINE START

Digital Output

DIGITAL INPUT 3 (Low-Sensing) Digital Input

ANALOG INPUT 3 (0-10V; 10 Bit;

AI3 Analog Input

200K pull-down)

OVLDI PLATFORM OVERLOAD INDICATOR Digital Output

SYSDI

GND

N/C

HMTR

SYSTEM DISTRESS INDICATOR

GROUND

NOT CONNECTED

HOURMETER

Digital Output

Power Output

Digital Output

DIGITAL OUTPUT 19 (High-Side; 4A;

33 DO19 Digital Output

SWGL

SWGR

Exclusive with J2-32)

SWING LEFT VALVE

SWING RIGHT VALVE

Digital Output

3121200

6-19

SECTION 6 - JLG CONTROL SYSTEM

Connector Pin Tagname

1 N/C

FLLJ

GND

CHKR

N/C

FRLJ

CHKS

(Black)

RLLJ

THTR

RRLJ

THRH

GND

EXTLJ

RETLJ

Function

NOT CONNECTED

FRONT-LEFT L/J VALVE

GROUND

CHOKE PULL RELAY

NOT CONNECTED

FRONT-LEFT L/J VALVE

CHOKE HOLD SOLENOID

REAR-LEFT L/J VALVE

THROTTLE PULL RELAY

REAR-RIGHT L/J VALVE

THROTTLE HOLD SOLENOID

GROUND

EXTEND L/J VALVE

RETRACT L/J VALVE

Type

Digital Output

Power Output

Digital Output

Power Output

Digital Output

Power Output

Connector Pin Tagname Function

DIGITAL OUTPUT 32 (High-Side; 4A;

Type

1 DO32 Digital Output

Exclusive with J4-2 & J4-14)

DIGITAL OUTPUT 33 (High-Side; 4A;

DO33

N/C

STRS

LVLDS

DI6

7 TELEINS

JIBDS

Exclusive with J4-1 & J4-13)

NOT CONNECTED

ENGINE START SWITCH

LEVEL DOWN SWITCH

Digital Output

Digital

Input

DIGITAL INPUT 6 (High-Sensing) Digital Input

TELESCOPE IN SWITCH

JIB DOWN SWITCH

Digital Input

LJSTW LEVELING JACK STOW SWITCH Digital Input

10 DI10 DIGITAL INPUT 10 (High-Sensing) Digital Input

11 TRANS TRANSPORT LIMIT SWITCH Digital Input

(Blue)

DO17

RLLJI

RRLJI

DIGITAL OUTPUT 17 (High-Side;4A;

Digital Output

PWM; Exclusive with J1-22&J2-26)

REAR-LEFT L/J INDICATOR Digital Output

REAR-RIGHT L/J INDICATOR Digital Output

N/C

CHKSW

17 LVLUPS

DI14

NOT CONNECTED

ENGINE CHOKE SWITCH

LEVEL UP SWITCH

Digital Input

Digital

DIGITAL INPUT 14 (High-Sensing) Digital

Input

JIBUS

LJSET

JIB UP SWITCH Digital Input

LEVELING JACK SET SWITCH Digital Input

21 TELELMT TELESCOPE IN LIMIT SWITCH Digital Input

22 DI18 DIGITAL INPUT 18 (High-Sensing) Digital Input

23 LFTUPS

24 IGN

IGN

FRLJI

DO34

DO35

FLLJI

30 TELOUTS

GND

33 LFTDNS

34 SWLS

35 SWRS

LIFT UP SWITCH

IGNITION

IGNITION Power Output

FRONT-RIGHT L/J INDICATOR Digital Output

DIGITAL OUTPUT 34 (High-Side; 4A;

Digital Input

Power Output

Digital Output

Exclusive with J4-28 & J4-29)

DIGITAL OUTPUT 35 (High-Side; 4A;

Digital Output

Exclusive with J4-26 & J4-27)

FRONT-LEFT L/J INDICATOR

TELESCOPE OUT SWITCH

GROUND

LIFT DOWN SWITCH

SWING LEFT SWITCH

SWING RIGHT SWITCH

Digital Output

Digital Input

Power Output

Digital

Digital Input

Digital

Input

Connector Pin Tagname

1 PLTE

PLTM

Function

PLATFORM EMS

PLATFORM MODE

Type

Power Input

GNDE GROUND MODE (Connect to J7-14) Power Input

ANALOG INPUT 4 (0-10V; 10 Bit; 200K

AI4 Analog Input pull-down)

7EXC +7V ANALOG EXCITATION VOLTAGE Power Output

CANT

PLTP1

PLTP2

GND

FLSET

CANBUS TERMINATOR (Connect to

J7-17 to engage)

PLATFORM POSITION 1

PLATFORM POSITION 2

GROUND

FRONT-LEFT L/J SET LIMIT SWITCH

Serial I/O

Analog

Digital

Input

Power Output

Input

12 RRSET REAR-RIGHT L/J SET LIMIT SWITCH Digital Input

(Black)

CANH

GNDE

DI26

7EXC

CANT

CANS

CANBUS HIGH

GROUND MODE (Connects to J7-3)

DIGITAL INPUT 26 (High-Sensing)

CANBUS TERMINATOR

CANBUS SHIELD

Serial

Digital

Serial

Power

I/O

Power Output

Input

+7V ANALOG EXCITATION VOLTAGE Power Output

I/O

Input

GND GROUND

ANALOG INPUT 7 (0-10V; 10 Bit; 200K

Power Input

AI7 Analog Input pull-down)

DI27 DIGITAL INPUT 27 (High-Sensing) Digital Input

DI28 DIGITAL INPUT 28 (High-Sensing) Digital Input

FRSET FRONT-RIGHT L/J SET LIMIT SWITCH Digital Input

CANL

GND

CANBUS LOW

GROUND

Serial I/O

Power Output

7EXC +7V ANALOG EXCITATION VOLTAGE Power Output

GND

IGN

GROUND

IGNITION

Power Output

IGN

IGNITION

Power Output

IGN IGNITION Power Output

RLSET REAR-LEFT L/J SET LIMIT SWITCH Digital Input

Connector Pin Tagname

(Black)

MGND

MIGN

PGND

PIGN

Function

MASTER GROUND CONNECTION

(Connect to J8-3)

MASTER IGNITION CONNECTION

(Connect to J8-4)

PASSTHROUGH GROUND CONNEC-

TION (Connect to J8-1)

PASSTHROUGH IGNITION CONNEC-

TION (Connect to J8-2)

Type

Power Input

Power Output

6-20

3121200

SECTION 6 - JLG CONTROL SYSTEM

FUNCTION

Table 6-3. Machine Model Adjustments and Speeds - ANSI & CSA

ADJUSTMENT

1,4

RANGES

Electric

MODEL DEFAULTS

Gas

MODEL TIME RANGE (SECONDS)

Electric Gas

2,3

DRIVE

FORWARD (25’ COURSE)

REVERSE (25’ COURSE)

ACCEL

DECEL

L FWD MIN

L FWD MAX

L REV MIN

L REV MAX

R FWD MIN

R FWD MAX

R REV MIN

R REV MAX

LIFT

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

CREEP

SWING

ACCEL

DECEL

MIN LEFT

MAX LEFT

MIN RIGHT

MAX RIGHT

CREEP

TELESCOPE

ACCEL

DECEL

MIN IN

MAX IN

MIN OUT

MAX OUT

CREEP

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (50%)

0 to 35% (65%)

0 to 50%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (75%)

0 to 100% (85%)

0 to 35%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 100%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

0 to 35%

1.0

0.5

2.5

0.8

2.7

1.0

1.5

0.8

100

1.0

0.5

2.5

0.8

2.7

1.0

1.5

0.8

20-28

40-50

35-46

65-105

19-26

19-22

40-50

35-46

65-105

19-26

3121200

6-21

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Machine Model Adjustments and Speeds - ANSI & CSA

ADJUSTMENT

1,4

RANGES

Electric

MODEL DEFAULTS

Gas

MODEL TIME RANGE (SECONDS)

Electric Gas

2,3

2.25

0.65

2.75

4.35

2.75

4.35

2.25

0.65

0.5

107

2.5

0.8

0.1

2.25

0.65

2.75

4.35

2.75

4.35

2.25

0.65

0.5

100

2.5

0.8

0.1

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (75%)

0 to 100% (85%)

0.50-4.50V

87 to 107dB

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

FUNCTION

PLATFORM LEVEL

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

JIB LIFT

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

OUTRIGGERS

ACCEL

DECEL

MIN SET

MAX SET

MIN STOW

MAX STOW

JOYSTICK

FWD IN

FWD MAX

REV IN

REV MAX

LEFT IN

LEFT MAX

RIGHT IN

RIGHT MAX

GROUND

ALARM

20-25

13-18

20-25

15-21

4150561-H

6-22

3121200

SECTION 6 - JLG CONTROL SYSTEM

FUNCTION

Table 6-4. Machine Model Adjustments and Speeds - CE Only

ADJUSTMENT

1,4

RANGES

Electric

MODEL DEFAULTS

Gas

MODEL TIME RANGE (SECONDS)

Electric Gas

2,3

DRIVE

FORWARD (25’ COURSE)

REVERSE (25’ COURSE)

ACCEL

DECEL

L FWD MIN

L FWD MAX

L REV MIN

L REV MAX

R FWD MIN

R FWD MAX

R REV MIN

R REV MAX

LIFT

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

CREEP

SWING

ACCEL

DECEL

MIN LEFT

MAX LEFT

MIN RIGHT

MAX RIGHT

CREEP

TELESCOPE

ACCEL

DECEL

MIN IN

MAX IN

MIN OUT

MAX OUT

CREEP

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (50%)

0 to 35% (65%)

0 to 50%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (75%)

0 to 100% (85%)

0 to 35%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 100%

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

0 to 35%

1.0

0.5

2.5

1.3

2.7

1.0

1.5

0.8

100

1.0

0.5

2.5

1.3

2.7

1.0

1.5

0.8

20-28

40-50

43-53

65-105

19-26

19-22

40-50

43-53

65-105

19-26

3121200

6-23

SECTION 6 - JLG CONTROL SYSTEM

FUNCTION

Table 6-4. Machine Model Adjustments and Speeds - CE Only

ADJUSTMENT

1,4

RANGES

Electric

MODEL DEFAULTS

Gas

MODEL TIME RANGE (SECONDS)

Electric Gas

2,3

PLATFORM LEVEL

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

JIB LIFT

ACCEL

DECEL

MIN UP

MAX UP

MIN DOWN

MAX DOWN

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 50% (85%)

0 to 25% (75%)

0 to 50% (85%)

OUTRIGGERS

ACCEL

DECEL

MIN SET

MAX SET

MIN STOW

MAX STOW

JOYSTICK

FWD MIN

FWD MAX

REV MIN

REV MAX

LEFT MIN

LEFT MAX

RIGHT MIN

RIGHT MAX

0.1 to 5.0 sec

0.1 to 3.0 sec

0 to 25% (75%)

0 to 100% (85%)

0 to 25% (75%)

0 to 100% (85%)

0.50-4.50V

GROUND

ALARM 87 to 107dB

* See Section 6.9 for orientation when setting speeds.

0.1

2.5

0.8

0.5

100

2.75

4.35

2.25

0.65

2.25

0.65

2.75

4.35

0.1

2.5

0.8

0.5

2.75

4.35

2.25

0.65

2.25

0.65

2.75

4.35

107

20-25

13-18

20-25

15-21

6-24

3121200

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Model Adjustments and Speeds - CE Only

ADJUSTMENT

1,4

MODEL DEFAULTS

MODEL TIME RANGE (SECONDS)

2,3

FUNCTION

RANGES

Electric Gas Electric Gas

Note 1: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.

Note 2: Stop watch should be start when function starts. The exception is the drive function.The machine should have a running start.Stop watch as you cross the start line.



The drive distance is 25 feet.

Note 3: Unless noted, function speeds should be measured from the platform with one operator.

Note 4: All test should be done with the oil temp above 65°F (15.5°C).

Note 5: Ranges shown in "( )" are exceptions for Gas-powered machines.

Note 3: With swing motor P/N 3160182 optimum performance is achieved with these settings:



SWING, MAX (RT OR LT): Electric = 18%, gas = 61%, time = 85-105 seconds

With swing motor P/N 3160331 optimum performance is achieved with these settings:

SWING, MAX (RT OR LT): Electric = 34%, time=75-95; gas = 60%, time = 65-85 seconds

4150561-H

3121200

6-25

SECTION 6 - JLG CONTROL SYSTEM

6.9 MACHINE ORIENTATION WHEN SETTING

SPEEDS

LIFT:

Telescope retracted, lift up, and record time. Lift down and record time.

SWING:

Boom lift at full elevation, telescope retracted, swing

360 degrees and record time Swing opposite 360 degrees and record time.

TELESCOPE

: Boom lift at full elevation, telescope out and record time. Tele in and record time.

DRIVE

: The machine should be in the stowed position.

Test Notes

Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.

Stop watch should be start when function starts.

Unless noted, function speeds should be measured from the platform with one operator.

All test should be done with the oil temp above 65°F

(15.5°C).

Table 6-5. Machine Configuration Programming Information

Market Default

Configuration

Digit

Setting Description

0 1 2 3

(MODEL#)

(POWER)

(DRIVE)

(MARKET)

T350 - 35ft.

T500 - 50ft.

Electric - 24V Battery

Engine - Honda Gasoline

NO - Drive option not installed.

YES - Drive option is installed.

ANSI USA

ANSI EXPORT

CSA

AUSTRALIA

(GROUND ALARM)

Not installed - Optional Ground Alarm shall not sound

Descent - Optional Ground Alarm shall sound for 1000mS On, 1000mS Off during lift down operations.

MOTION - Optional Ground Alarm shall sound for 1000mS On, 1000mS Off during drive, lift, swing, telescope, level jib and L/J operations.

1 1

NOTE:

1. When configuring a T-Series vehicle, the Machine Configuration must be completed before any Personality settings can be changed.



Changing the Personality settings first and then changing the Model of the Machine Configuration will cause the Personality settings to return to default value.



2. Shaded entries are not available (adjustable) for the selected Market.



3. DRIVE Machine Configuration Setting only available when POWER is set to 1= ENGINE (Ground Module Version P1.3).

4150562-B

6-26

3121200

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Help Messages

Help Message

RUNNING AT CREEP – TILTED &

ABOVE ELEVATION

Index

Service

Flash

Code

None

User

Flash

Code

RUNNING AT CREEP – UNSET &

ABOVE ELEVATION

ENGINE NOT RUNNING

JOYSTICK MOVED BUT TRIGGER

SWITCH OPEN

None

Function in Creep Mode

Lift Up, Lift Down, Swing Left,

Swing Right, Telescope In, Telescope Out

Lift Up, Lift Down, Swing Left,

Swing Right, Telescope In, Telescope Out

Function Locked Out from Ground

Control

Function Locked Out from

Platform Control

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

CHASSIS TILT SENSOR OUT OF

RANGE

5 None None

6 RUNNING AT CREEP – MATE-

RIAL HOOK MODE

POWER CYCLE 7

None

2-1

None Lift Up, Lift Down, Swing Left,

Swing Right, Telescope In, Telescope Out

None

KEYSWITCH FAULTY 8 2-1 9 Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

PLATFORM POSITION DETEC-

TION FAULTY

FUNCTION PROBLEM – ROTARY

SELECTOR SWITCH

2-1

2-2

9 Lift Up, Lift Down, Swing Left,

Swing Right, Telescope In, Telescope Out

JOYSTICK FAULTY -- X-AXIS

WIPER OUT OF RANGE

11 2-2 9

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Swing Left, Swing Right, Telescope In,

Telescope Out, Front Left L/J, Front Right

L/J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

3121200

6-27

SECTION 6 - JLG CONTROL SYSTEM

Help Message

JOYSTICK FAULTY -- Y-AXIS

WIPER OUT OF RANGE

Index

Service

Flash

Code

2-2

User

Flash

Code

FUNCTION LOCKED OUT – JOY-

STICK NOT CENTERED AT

STARTUP

FUNCTION LOCKED OUT –TRIG-

GER PERMANENTLY CLOSED

TRIGGER CLOSED TOO LONG

WHILE IN NEUTRAL

2-2

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Function Locked Out from

Platform Control

Lift Up, Lift Down, Jib Up, Jib Down,

Level Up, Level Down, Front Left L/J,

Front Right L/J, Rear Left L/J, Rear Right

L/J, Set (Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Engine Choke Pull, Engine Choke Hold FUNCTION PROBLEM – ENGINE

CHOKE PERMANENTLY

SELECTED

FUNCTION PROBLEM – ENGINE

START PERMANENTLY

SELECTED

FUNCTION PROBLEM – LEVEL

UP AND DOWN BOTH SELECTED

FUNCTION PROBLEM – TELE-

SCOPE IN AND OUT BOTH

SELECTED

FUNCTION PROBLEM – JIB UP

AND DOWN BOTH SELECTED

FUNCTION PROBLEM – LEVEL-

ING JACK SET AND STOW BOTH

SELECTED

FUNCTION PROBLEM – LIFT UP

AND DOWN BOTH SELECTED

FUNCTION PROBLEM – SWING

LEFT AND RIGHT BOTH

SELECTED

FUNCTION PROBLEM – ENGINE

CHOKE PERMANENTLY

SELECTED

2-2

2-3

Level Up, Level Down

Telescope In, Telescope Out

Jib Up, Jib Down

Lift Up, Lift Down

Swing Left, Swing Right

Engine Choke Pull, Engine Choke Hold

Engine Start, Engine Throttle Pull,

Engine Throttle Hold

Engine Choke Pull, Engine Choke Hold

6-28

3121200

SECTION 6 - JLG CONTROL SYSTEM

Help Message

FUNCTION PROBLEM – ENGINE

START PERMANENTLY

SELECTED

FUNCTION PROBLEM – LEVEL

UP PERMANENTLY SELECTED

Index

Service

Flash

Code

2-3

26 2-3

User

Flash

Code

2-3 1 FUNCTION PROBLEM – LEVEL

DOWN PERMANENTLY

SELECTED

FUNCTION PROBLEM – TELE-

SCOPE IN PERMANENTLY

SELECTED

FUNCTION PROBLEM – TELE-

SCOPE OUT PERMANENTLY

SELECTED

FUNCTION PROBLEM – JIB UP

PERMANENTLY SELECTED

2-3

2-3 1 FUNCTION PROBLEM – JIB

DOWN PERMANENTLY

SELECTED

FUNCTION PROBLEM – LEVEL-

ING JACK SET PERMANENTLY

SELECTED

FUNCTION PROBLEM – LEVEL-

ING JACK STOW PERMANENTLY

SELECTED

FUNCTION PROBLEM – LIFT UP

PERMANENTLY SELECTED

FUNCTION PROBLEM – LIFT

DOWN PERMANENTLY

SELECTED

FUNCTION PROBLEM – SWING

LEFT PERMANENTLY SELECTED

FUNCTION PROBLEM – SWING

RIGHT PERMANENTLY

SELECTED

LIFT DOWN PREVENTED – TELE

IN FIRST

2-3

2-5

TELE OUT PREVENTED – SET

LEVELING JACKS

TELE OUT PREVENTED – TILTED 40

2-5

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Engine Start, Engine Throttle Pull,

Engine Throttle Hold

Function Locked Out from

Platform Control

Engine Start, Engine Throttle Pull,

Engine Throttle Hold

Level Up

Level Down

Telescope In

Telescope Out

Jib Up

Jib Down

Set (Extend L/J)

Stow (Retract L/J)

Lift Up

Lift Down

Swing Left

Swing Right

Lift Down

Telescope Out

Lift Down

Telescope Out

3121200

6-29

SECTION 6 - JLG CONTROL SYSTEM

Help Message

LIFT UP & TELE OUT PREVENTED

– TILTED & ABOVE ELEVATION

Index

Service

Flash

Code

2-5

User

Flash

Code

LIFT UP & TELE OUT PREVENTED

– UNSET & ABOVE ELEVATION

42 2-5 2

2-5 2 LIFT UP & TELE OUT

PREVENTED – TILTED, UNSET &

ABOVE ELEVATION

LIFT UP PREVENTED – LIFT

DOWN THEN SET LEVELING

JACKS

LIFT UP PREVENTED – STOW

LEVELING JACKS

LIFT UP PREVENTED – TILTED 46

2-5

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Lift Up, Telescope Out

Lift Up

Function Locked Out from

Platform Control

Lift Up, Telescope Out

Lift Up

LEVELING JACKS

PREVENTED – ELEVATED

LEVELING JACK STOW

PREVENTED – TELE IN FIRST

MODEL CHANGED – HYDRAU-

LICS SUSPENDED – CYCLE EMS

2-5

LIFT UP SOLENOID - SHORT TO

BATTERY

LIFT UP SOLENOID - SHORT TO

GROUND

LIFT UP SOLENOID - OPEN CIR-

CUIT

LIFT DOWN SOLENOID - SHORT

TO BATTERY

LIFT DOWN SOLENOID - OPEN

CIRCUIT

TELESCOPE IN SOLENOID -

SHORT TO BATTERY

3-3

Set (Extend L/J)

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up

Lift Down

Telescope In

Set (Extend L/J)

Stow (Retract L/J)

Lift Up

Lift Down

Telescope In

6-30

3121200

SECTION 6 - JLG CONTROL SYSTEM

Help Message

TELESCOPE IN SOLENOID -

SHORT TO GROUND

Index

Service

Flash

Code

3-3

User

Flash

Code

TELESCOPE IN SOLENOID -

OPEN CIRCUIT

57 3-3 9

3-3 9 TELESCOPE OUT SOLENOID -

SHORT TO BATTERY

TELESCOPE OUT SOLENOID -

SHORT TO GROUND

59 3-3 9

3-3 9 TELESCOPE OUT SOLENOID -

OPEN CIRCUIT

SWING LEFT SOLENOID - SHORT

TO BATTERY

SWING LEFT SOLENOID - SHORT

TO GROUND

SWING LEFT SOLENOID - OPEN

CIRCUIT

64 SWING RIGHT SOLENOID -

SHORT TO BATTERY

SWING RIGHT SOLENOID -

SHORT TO GROUND

SWING RIGHT SOLENOID - OPEN

CIRCUIT

LEVEL UP SOLENOID - SHORT TO

BATTERY

LEVEL UP SOLENOID - SHORT TO

GROUND

LEVEL UP SOLENOID - OPEN

CIRCUIT

70 LEVEL DOWN SOLENOID -

SHORT TO BATTERY

LEVEL DOWN SOLENOID -

SHORT TO GROUND

3-3

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Telescope In

Telescope Out

Swing Left

Swing Right

Level Up

Level Down

Function Locked Out from

Platform Control

Telescope In

Telescope Out

Swing Left

Swing Right

Level Up

Level Down

3121200

6-31

SECTION 6 - JLG CONTROL SYSTEM

Help Message

LEVEL DOWN SOLENOID - OPEN

CIRCUIT

Index

Service

Flash

Code

3-3

User

Flash

Code

JIB UP SOLENOID - SHORT TO

BATTERY

73 3-3 9

3-3 9 JIB UP SOLENOID - SHORT TO

GROUND

JIB UP SOLENOID - OPEN CIR-

CUIT

JIB DOWN SOLENOID - SHORT

TO BATTERY

3-3

3-3 9 JIB DOWN SOLENOID - OPEN

CIRCUIT

F-L L/J SOLENOID - SHORT TO

BATTERY

F-L L/J SOLENOID - SHORT TO

GROUND

3-3

3-3 9 F-L L/J SOLENOID - OPEN CIR-

CUIT

F-R L/J SOLENOID - SHORT TO

BATTERY

F-R L/J SOLENOID - SHORT TO

GROUND

F-R L/J SOLENOID - OPEN CIR-

CUIT

R-L L/J SOLENOID - SHORT TO

BATTERY

R-L L/J SOLENOID - SHORT TO

GROUND

R-L L/J SOLENOID - OPEN CIR-

CUIT

R-R L/J SOLENOID - SHORT TO

BATTERY

3-3

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Level Down

Jib Up

Jib Down

Front Left L/J

Front Right L/J

Rear Left L/J

Rear Right L/J

Function Locked Out from

Platform Control

Level Down

Jib Up

Jib Down

Front Left L/J

Front Right L/J

Rear Left L/J

Rear Right L/J

6-32

3121200

SECTION 6 - JLG CONTROL SYSTEM

Help Message

R-R L/J SOLENOID - SHORT TO

GROUND

Index

Service

Flash

Code

3-3

User

Flash

Code

R-R L/J SOLENOID - OPEN CIR-

CUIT

89 3-3 9

3-3 9 EXTEND L/J SOLENOID - SHORT

TO BATTERY

EXTEND L/J SOLENOID - SHORT

TO GROUND

91 3-3 9

3-3 9 EXTEND L/J SOLENOID - OPEN

CIRCUIT

RETRACT L/J SOLENOID - SHORT

TO BATTERY

RETRACT L/J SOLENOID - SHORT

TO GROUND

3-3

RETRACT L/J SOLENOID - OPEN

CIRCUIT

GROUND ALARM - SHORT TO

BATTERY

GROUND ALARM - SHORT TO

GROUND

OPTIONAL GROUND ALARM -

SHORT TO BATTERY

3-3

OPTIONAL GROUND ALARM -

SHORT TO GROUND

HOURMETER - SHORT TO BAT-

TERY

100

HOURMETER - SHORT TO

GROUND

101

START SOLENOID - SHORT TO

BATTERY

102

START SOLENOID - SHORT TO

GROUND

103

3-3

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Rear Right L/J

Set (Extend L/J)

Stow (Retract L/J)

Engine Start

Function Locked Out from

Platform Control

Rear Right L/J

Set (Extend L/J)

Stow (Retract L/J)

Engine Start

3121200

6-33

SECTION 6 - JLG CONTROL SYSTEM

Help Message

START SOLENOID - OPEN CIR-

CUIT

Index

104

Service

Flash

Code

3-3

User

Flash

Code

THROTTLE PULL RELAY - SHORT

TO BATTERY

105 3-3 9

3-3 9 THROTTLE PULL RELAY - SHORT

TO GROUND

106

THROTTLE PULL RELAY - OPEN

CIRCUIT

107 3-3 9

THROTTLE HOLD SOLENOID -

SHORT TO BATTERY

108

THROTTLE HOLD SOLENOID -

SHORT TO GROUND

109

3-3

3-3 9 THROTTLE HOLD SOLENOID -

OPEN CIRCUIT

110

CHOKE PULL RELAY - SHORT TO

BATTERY

111

CHOKE PULL RELAY - SHORT TO

GROUND

112

CHOKE PULL RELAY - OPEN CIR-

CUIT

113

114 CHOKE HOLD SOLENOID -

SHORT TO BATTERY

CHOKE HOLD SOLENOID -

SHORT TO GROUND

115

CHOKE HOLD SOLENOID - OPEN

CIRCUIT

116

DUMP SOLENOID - SHORT TO

BATTERY

117

3-3

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Engine Start

Engine Throttle Pull

Engine Throttle Hold

Engine Choke Pull

Engine Choke Hold

Function Locked Out from

Platform Control

Engine Start

Engine Throttle Pull

Engine Throttle Hold

Engine Choke Pull

Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

6-34

3121200

SECTION 6 - JLG CONTROL SYSTEM

Help Message

DUMP SOLENOID - SHORT TO

GROUND

Index

118

Service

Flash

Code

3-3

User

Flash

Code

DUMP SOLENOID - OPEN CIR-

CUIT

119 3-3 9

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Function Locked Out from

Platform Control

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

DRIVE LEFT FWD SOLENOID -

SHORT TO BATTERY

120

DRIVE LEFT FWD SOLENOID -

SHORT TO GROUND

121

DRIVE LEFT FWD SOLENOID -

OPEN CIRCUIT

122

DRIVE LEFT REV SOLENOID -

SHORT TO BATTERY

123

DRIVE LEFT REV SOLENOID -

SHORT TO GROUND

124

DRIVE LEFT REV SOLENOID -

OPEN CIRCUIT

125

DRIVE RIGHT FWD SOLENOID -

SHORT TO BATTERY

126

DRIVE RIGHT FWD SOLENOID -

SHORT TO GROUND

127

DRIVE RIGHT FWD SOLENOID -

OPEN CIRCUIT

128

DRIVE RIGHT REV SOLENOID -

SHORT TO BATTERY

129

DRIVE RIGHT REV SOLENOID -

SHORT TO GROUND

130

DRIVE RIGHT REV SOLENOID -

OPEN CIRCUIT

131

3-3

3121200

6-35

SECTION 6 - JLG CONTROL SYSTEM

Help Message

DRIVE ENABLE SOLENOID -

SHORT TO BATTERY

Index

132

Service

Flash

Code

3-3

User

Flash

Code

DRIVE ENABLE SOLENOID -

SHORT TO GROUND

133 3-3 9

3-3 9 DRIVE ENABLE SOLENOID -

OPEN CIRCUIT

134

POWER MODULE TOO HOT –

PLEASE WAIT

135 4-2 4

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Function Locked Out from

Platform Control

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

FUNCTIONS AT CUTBACK --

POWER MODULE CURRENT

LIMIT

136

NO CHARGE SYSTEM OUTPUT 137

4-2

4-3

BATTERY VOLTAGE TOO LOW –

SYSTEM SHUTDOWN

BATTERY VOLTAGE TOO HIGH –

SYSTEM SHUTDOWN

CANBUS FAILURE: POWER

MODULE

138

139

140

4-4

6-6

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

6-36

3121200

SECTION 6 - JLG CONTROL SYSTEM

Help Message

CANBUS FAILURE: PLATFORM

MODULE

Index

141

Service

Flash

Code

6-6

User

Flash

Code

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Function Locked Out from

Platform Control

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

CANBUS FAILURE: DRIVE MOD-

ULE

142

ACCESSORY CAN COMMUNICA-

TION LOST

143

ACCESSORY FAULT 144

6-6

6-7

CHASSIS TILT SENSOR NOT CAL-

IBRATED

145

POWER MODULE FAILURE: PER-

SONALITY RANGE ERROR

146

8-1

9-9

POWER MODULE FAILURE:

INTERNAL ERROR

POWER MODULE FAILURE:

CHECK POWER CIRCUITS OR

MOSFET SHORT CIRCUIT

147

148

EEPROM FAILURE – CHECK ALL

SETTINGS

149

9-9

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

3121200

6-37

SECTION 6 - JLG CONTROL SYSTEM

Help Message

FUNCTIONS LOCKED OUT –

PLATFORM MODULE SOFT-

WARE VERSION IMPROPER

Index

150

Service

Flash

Code

9-9

User

Flash

Code

FUNCTIONS LOCKED OUT –

POWER MODULE SOFTWARE

VERSION IMPROPER

FUNCTIONS LOCKED OUT –

DRIVE MODULE SOFTWARE

VERSION IMPROPER

GROUND MODULE FAILURE:

VLOW FET FAILURE

151

152

153

9-9

Table 6-6. Help Messages

Function in Creep Mode

Function Locked Out from Ground

Control

Function Locked Out from

Platform Control

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up,

Level Down, Front Left L/J, Front Right L/

J, Rear Left L/J, Rear Right L/J, Set

(Extend L/J), Stow (Retract L/J)

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

GROUND MODULE FAILURE:

REF VOLTAGE OUT OF RANGE

154

CHASSIS TILT SENSOR GAIN OUT

OF RANGE

155

CHASSIS TILT SENSOR NOT GAIN

CALIBRATED

156

FUNCTIONS LOCKED OUT –

CONSTANT DATA VERSION

IMPROPER

157

9-9

9 Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

Lift Up, Lift Down, Swing Left, Swing

Right, Telescope In, Telescope Out, Jib

Up, Jib Down, Level Up, Level Down,

Front Left L/J, Front Right L/J, Rear Left

L/J, Rear Right L/J, Set (Extend L/J),

Stow (Retract L/J), Engine Start, Engine

Throttle Pull, Engine Throttle Hold,

Engine Choke Pull, Engine Choke Hold

6-38

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL

This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.

7.2 MULTIMETER BASICS

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.

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

Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read the Voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down.

Polarity

Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads are reversed.

Check what reading is expected, the location of the signal and that the leads are connected to the device under test correctly.

Also check that the lead on the "COM" port goes to the Ground or negative side of the signal and the 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) m = milli = (Displayed Number) / 1,000

μ = micro = (Displayed Number) / 1,000,000

Example: 1.2 kW = 1200 W

Example: 50 mA = 0.05 A

Voltage Measurement

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.



3121200 7-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Resistance Measurement Continuity Measurement

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.

• If meter is not auto ranging, set it to the correct range

(See multimeter’s operation manual)

• Use firm contact with meter leads.

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.

• 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.

7-2

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Current Measurement

Figure 7-4. Current Measurement (DC)

• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correct jacks for the current range you have selected

• If meter is not auto ranging, set it to the correct range

(See multi meter’s operation manual)

• Use firm contact with meter leads.

7.3 CHECKING SWITCHES

Basic Check

The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected.

De-energize the circuit.

Isolate the switch from the rest of the circuit if possible.

If not possible, keep in mind it may affect readings.

Access the terminals to the switch.

If the switch has two terminals: a. Measure resistance across the terminals. b. Change the switch position.

c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short.

If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will be connected. The test is similar to testing a switch with two terminals. a. Place one meter lead on the common contact and the other on a different contact in the same circuit. b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two terminals and open otherwise. c. If the switch has more than one common contact repeat the process for that circuit.

3121200 7-3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Limit Switches

Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually operated switches except that the moving object operates the switch.

These switches can be tested the same way as a standard switch by manually operating the sensing arm.

Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch as follows:

Remove prox switch from its mount.

Reconnect harness if it was disconnected for step a, and turn on machine.

Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See vehicle or control system documentation on how to do this.

Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous metal physically similar to it. The switch state in the control system diagnostics should change.

When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed.

Automatic Switches

If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.

Connect instrumentation to monitor and/or control the parameter the switch is measuring.

Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do this.

Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for example. The state indicated in the control system should change.

Switch Wiring - Low Side, High Side

When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.

A low side switch will allow voltage to be present on the load.

No power is applied because the switch is stopping current flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can measure the voltage at both power terminals with respect to battery



 ground. The difference between those two measurements is the voltage applied to the load.



7-4

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.4 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS

Silicone Dielectric Compound must be used on all electrical connections for the following reasons:

• To prevent oxidation at the mechanical joint between male and female pins.

• 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.

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.

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.

Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only.

NOTE:

Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal more difficult.

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).

Installation of Dielectric Grease

Before following these instructions, refer to excluded connector types (See Exclusions below).

Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors.

Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals.

Leave a thin layer of dielectric grease on the face of the connector.

Assemble connector system immediately to prevent moisture or dust contamination.

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.

Figure 7-5. Applying Dielectric Grease

3121200 7-5

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Deutsch HD, DT, DTM, DRC Series

The Deutsch connector system is commonly used for harsh environments. Follow installation instructions.

Figure 7-6. Deutsch Connector

AMP Seal

The AMP Seal connector system is used on Control ADE Platform and Ground Modules.

Apply dielectric grease to the plug/male connector housing which typically contains socket contacts/female terminals. If trapped air prevents the connector from latching, pierce one of the unused wire seals. After assembly, install a seal plug (JLG

#4460905) in that location to prevent moisture ingress.

Note that seal plugs may be installed by the wire harness manufacturer if an unused wire seal becomes compromised (wire inserted in the wrong cavity during assembly and the corrected).

Figure 7-8. Use of Seal Plugs

AMP Mate-N-Lok

Follow manufacturer installation instructions.

Figure 7-9. AMP Mate-N-Lok Connector

Figure 7-7. Application to plug/male connector housing

7-6

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

DIN Connectors

This connector is typically used on hydraulic valves. Follow manufacturer installation instructions.

Figure 7-10. DIN Connector

Exclusions

A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application.

Dielectric grease may not be required in properly sealed enclosures.

Brad Harrison/phoenix Contact M12

The connector uses gold contact material to resist corrosion and an o-ring seal for moisture integrity. If dielectric grease is mistakenly applied to this connector system, the low-force contacts cannot displace the grease to achieve electrical contact. Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required).

Engine Control Unit Connectors

Many times, these types of connectors use back-seals for moisture integrity. However, the low-force contacts cannot displace dielectric grease and create electrical contact. It is possible to use solvents (i.e. contact cleaner or mineral spirits) for the removal of improperly applied dielectric grease. The EMR4 engine control module from Deutz employs this connector system (for example).

3121200 7-7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5 AMP CONNECTOR

Applying Silicone Dielectric Compound to AMP

Connectors

Silicone Dielectric Compound must be used on the AMP connections for the following reasons:

• To prevent oxidation at the mechanical joint between male and female pins.

• To prevent electrical malfunction caused by low level conductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.

To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus preventing the housing latch from engaging.

Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.

Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.

Assembly

Check to be sure the wedge lock is in the open, or as-shipped,

position (See Figure 7-11.). Proceed as follows:

Figure 7-11. Connector Assembly Figure 1

To insert a contact, push it straight into the appropriate

circuit cavity as far as it will go (See Figure 7-13.).

Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact

(See Figure 7-13.).

7-8

Figure 7-12. AMP Connector

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

After all required contacts have been inserted, the wedge lock must be closed to its locked position.

(See Figure 7-14.).

Figure 7-13. Connector Assembly Figure 2

Slide the wedge lock into the housing until it is flush

with the housing (See Figure 7-15.).

Release the locking latches by squeezing them inward

3121200

Figure 7-14. Connector Assembly Figure 3

Figure 7-15. Connector Assembly Figure 4

7-9

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Disassembly

Figure 7-16. Connector Disassembly

Service - Voltage Reading

Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs.

Pry open the wedge lock to the open position.

While rotating the wire back and forth over a half turn

(1/4 turn in each direction), gently pull the wire until the contact is removed.

NOTE:

The wedge lock should never be removed from the housing for insertion or removal of the contacts.

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE

READINGS.

It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the

AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.

This nullifies the effectiveness of the connector seals and could result in system failure.

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.



7-10

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

3121200

Figure 7-17. Connector Installation

7-11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.6 DEUTSCH CONNECTORS

DT/DTP Series Assembly

DT/DTP Series Disassembly

Figure 7-18. DT/DTP Contact Installation

Grasp crimped contact about 25mm behind the contact barrel.

Hold connector with rear grommet facing you.

Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.

NOTE:

The receptacle is shown - use the same procedure for plug.

Figure 7-19. DT/DTP Contact Removal

Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.

To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.

Hold the rear seal in place, as removing the contact may displace the seal.

7-12

3121200

HD30/HDP20 Series Assembly

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Disassembly

A B

Figure 7-20. HD/HDP Contact Installation

Grasp contact about 25mm behind the contact crimp barrel.

Hold connector with rear grommet facing you.

10.

Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place.

Figure 7-22. HD/HDP Contact Removal

11.

With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.

12.

Slide tool along into the insert cavity until it engages contact and resistance is felt.

13.

Pull contact-wire assembly out of connector.

Figure 7-21. HD/HDP Locking Contacts Into Position

NOTE:

For unused wire cavities, insert sealing plugs for full environmental sealing

Figure 7-23. HD/HDP Unlocking Contacts

NOTE:

Do Not twist or insert tool at an angle.

3121200 7-13

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.7 ELECTRICAL COMPONENT

GROUND CONTROL BOX

STROBE

LIGHT

OUTLET

BOX

DRIVE PROXIMITY

SWITCHES (OPTIONAL)

DRIVE DIRECTIONAL

VALVE (OPTIONAL)

MOTION

ALARM

LIFT

DOWN

PROP

VALVE

IGNITION

RELAY

TRANSPORT / ABOVE

LEVEL LIMIT SWITCH

J3 J4

TELESCOPE

LIMIT SWITCH

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

VALVE/MOTOR/TANK

(MOTOR SIDE)

VALVE/MOTOR/TANK

(TANK SIDE)

7-14

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

MAE28730

Figure 7-24. Electrical Components Installation - Electric Powered Machines (Prior to SN 00300001804) - Sheet 1 of 2

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM CONSOLE

LOCATED ON T/T AT

LIFT HOOK STOW

DRIVE ENABLE

VALVE

(OPTIONAL)

TO ANALYZER

DRIVE

MODULE

(OPTIONAL)

JIB

VALVE

(T500J)

ONLY

LOCATED AT

PLATFORM

PIVOT

CONTACTOR

SEVCON

MODULE

B-

B+

BATTERY

CHARGER

WITH DRIVE

OPTION ONLY

LEFT SIDE

MARKER LIGHT

ON TOW

VEHICLE

TOW

VEHICLE

RIGHT SIDE

MARKER

LIGHT

CENTER

BRAKE

LIGHT

AUSTRALIAN,

CE SPECS & SOUTH AFRICA

ELECTRIC BRAKES

(WHEN EQUIOOED)

LEFT SIDE

TAILLIGHT

RIGHT SIDE

TAILLIGHT

BATTERIES

BREAKEWAY SWITCH

BATTERY CHARGER

(ELECTRIC BRAKES)

LEFT

TAILLIGHT

REAR

FOGLIGHT

PLATE

LIGHT

LEFT

TAILLIGHT

RIGHT

TAILLIGHT

ANSI EXPORT

SPECS

LEFT SIDE

MARKER LIGHT

ANSI &

BREAKAWAY SWITCH

(ELECTRIC BRAKES)

WITH

ELECTRIC

BRAKES

ON TOW

VEHICLE

CENTER

BRAKE

LIGHT

RIGHT

TAILLIGHT

RIGHT SIDE

MARKER LIGHT

ON TOW

VEHICLE

WITH

HYDRAULIC

BRAKES

MAE28740

Figure 7-25. Electrical Components Installation - Electric Powered Machines (Prior to SN 00300001804) - Sheet 2 of 2

3121200 7-15

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GROUND CONTROL BOX

STROBE

LIGHT

OUTLET

BOX

DRIVE PROXIMITY

SWITCHES (OPTIONAL)

DRIVE DIRECTIONAL

VALVE (OPTIONAL)

TELEMATIC

MOTION

ALARM

LIFT

DOWN

PROP

VALVE

IGNITION

RELAY

TRANSPORT/ABOVE

LEVEL LIMIT SWITCH

J3 J4

TELESCOPE

LIMIT SWITCH

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

VALVE/MOTOR/TANK

(TANK SIDE)

VALVE/MOTOR/TANK

(TANK SIDE)

7-16

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

MAE28750

Figure 7-26. Electrical Components Installation - Electric Powered Machines (Prior to SN 00300001804) - Sheet 1 of 2

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM CONSOLE

LOCATED ON T/T AT

LIFT HOOK STOW

DRIVE ENABLE

VALVE

(OPTIONAL)

TO ANALYZER

DRIVE

MODULE

(OPTIONAL)

JIB

VALVE

(T500J

ONLY)

LOCATED AT

PLATFORM

PIVOT

CONTACTOR

BATTERY

CHARGER

(ELECTRIC

POWERED)

BATTERIES

SEVCON

MODULE

LEFT SIDE

MARKER LIGHT

CENTER

BRAKE

LIGHT

AUSTRALIAN,

CE SPECS & SOUTH AFRICA

ON TOW

VEHICLE

TOW

VEHICLE

RIGHT SIDE

MARKER

LIGHT

ELECTRIC BRAKES

(WHEN EQUIPPED)

LEFT SIDE

TAILLIGHT

RIGHT SIDE

TAILLIGHT

BREAKAWAY SWITCH

BATTERY CHARGER

(ELECTRIC BRAKES)

LEFT

TAILLIGHT

REAR

FOGLIGHT

PLATE

RIGHT

LIGHT TAILLIGHT

LEFT

TAILLIGHT

ANSI &

ANSI EXPORT

SPECS

LEFT SIDE

MARKER LIGHT

BREAKAWAY SWITCH

(ELECTRIC BRAKES)

WITH

ELECTRIC

BRAKES

ON TOW

VEHICLE

CENTER

BRAKE

LIGHT

RIGHT

TAILLIGHT

RIGHT SIDE

MARKER LIGHT

ON TOW

VEHICLE

WITH

HYDRAULIC

BRAKES

MAE28760

Figure 7-27. Electrical Components Installation - Electric Powered Machines (SN 00300001804 to Present) - Sheet 2 of 2

3121200 7-17

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GROUND CONTROL BOX

STROBE

LIGHT

OUTLET

BOX

PRIOR TO

SN 003001804

DRIVE PROXIMITY

SWITCHES (OPTIONAL)

DRIVE DIRECTIONAL

VALVE (OPTIONAL)

TELEMATIC

MOTION

ALARM

LIFT DOWN

PROP VALVE

IGNITION

RELAY

J3 J4

TRANSPORT / ABOVE

LEVEL LIMIT SWITCH

TELESCOPE

LIMIT SWITCH

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

VALVE/MOTOR/TANK

(MOTOR SIDE)

VALVE/MOTOR/TANK

(TANK SIDE)

7-18

O/R JACK

LIMIT

SWITCH

O/R JACK

VALVE

O/R JACK

VALVE

O/R JACK

LIMIT

SWITCH

BATTERY

(ENGINE POWERED)

STARTER

(ENGINE POWERED)

MAE28770

Figure 7-28. Electrical Components Installation - Engine Powered Machines - Sheet 1 of 2

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM CONSOLE

LOCATED ON T/T AT

LIFT HOOK STOW

DRIVE ENABLE

VALVE

(OPTIONAL)

ANALYZER

J2 DRIVE

MODULE

(OPTIONAL)

JIB

VALVE

(T500J

ONLY)

LOCATED AT

PLATFORM

CHOKE

COIL

RECTIFIER

THROTTLE

COIL

LEFT SIDE

MARKER LIGHT ON TOW

VEHICLE

TOW

VEHICLE

RIGHT SIDE

MARKER

LIGHT

CENTER

BRAKE

LIGHT

AUSTRALIAN

CE SPECS & SOUTH AFRICA

ELECTRIC BRAKES

(WHEN EQUIPPED)

BREAKAWAY SWITCH

BATTERY CHARGER

(ELECTRIC BRAKES)

MAGNETIC

PICKUP

ENGINE

THROTTLE

VALVE

LEFT SIDE

TAILLIGHT

RIGHT SIDE

TAILLIGHT

OIL

LEVEL

SWITCH

LEFT

TAILLIGHT

REAR

FOGLIGHT

PLATE

LIGHT

RIGHT

TAILLIGHT

LEFT

TAILIGHT

LEFT SIDE

MARKER LIGHT

ANSI &

ANSI EXPORT

SPECS

ENGINE

CHOKE PULL

RELAY

ON TOW

VEHICLE

ENGINE

STOP

RELAY

CENTER

BRAKE

LIGHT

RIGHT

TAILLIGHT

RIGHT SIDE

MARKER LIGHT

BREAKAWAY SWITCH

(ELECTRIC BRAKES)

WITH

ELECTRIC

BRAKES

ON TOW

VEHICLE

WITH

HYDRAULIC

BRAKES

MAE28780

Figure 7-29. Electrical Components Installation - Engine Powered Machines - Sheet 2 of 2

3121200 7-19

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

X009

X011

(Electric Pwr. Only)

B-

B +

X101

X102

Main Harness

X008

X001

X010

X103

X104

X002

X007

X003

X004

X080

LEVEL UP

X081

LEVEL

DOWN

X082

TELE. OUT

X083

TELE. IN

X084

LIFT UP

X086

L/J SET

X078

SWING RT.

X077

SWING LF.

X079

JIB UP

(T500J ONLY)

X086

L/J STOW

X115

Pump Negative (-)

X114

Pump Positive (+)

MAE28950

Figure 7-30. Controller and Valve Body Connector Locations - Electrical Machine without Drive (Prior to SN 0030001804)

7-20

3121200

BATTERY (+)

PUMP (+)

PUMP (-)

RELAY

BATTERY (-)

GROUND BOARD (-)

BLACK (12)

CHARGER (-)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

WHITE (J1)

GREY (J2)

BLACK (J3)

BLACK (J7)

BLACK (J8)

BLUE (J4)

PUMP (-)

LIFT UP

PUMP (+)

LEVEL UP

LEVEL DOWN

TELE OUT

TELE IN

SWING RIGHT

L/J SET

L/J STOW

SWING LEFT

JIB UP (T500J ONLY)

0275776-F

MAE29800

Figure 7-31. Controller and Valve Body Connector Locations - Electrical Machine without Drive (SN 0030001804 to Present)

3121200 7-21

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

WHITE (J1)

GREY (J2)

BLACK (J3)

BLACK (J7)

BLUE (J4)

7-22

GROUND MODULE MOUNTED AT

ALL FIVE MOUNTING POINTS

BLACK (J8)

DUMP VALVE

X087

LIFT UP

LEVEL UP

LEVEL DOWN

TELE OUT

TELE IN

SWING RIGHT

SWING LEFT

JIB UP (T500J ONLY)

L/J SET

L/J STOW

Figure 7-32. Controller and Valve Body Connector Locations - Engine Machine without Drive

0273794-F

MAE29810

3121200

CONNECTR

X031

X032

X033

X034

X027

X028

X029

X030

X023

X024

X025

X026

X019

X020

X021

X022

X015

X016

X017

X018

X011

X012

X013

X014

X007

X008

X009

X010

X001

X002

X003

X004

X043

X044

X045

X046

X047

X048

X039

X040

X041

X042

X035

X036

X037

X038

Table 7-1. Connector Identification

DESCRIPTION

Ground Module, J1

Ground Module, J2

Ground Module, J3

Ground Module, J4

Ground Module, J7

Ground Module, J8

IGN Relay

Power Module (Sevcon), P

Main Harness power

Drive Module

Ground Module Supply

Ground Control Pass-thru

Transport Limit Pass-thru

Lift Down Pass-thru

Strobe/Alarm Pass-thru

Tele Limit Pass-thru

Boom Cable

Jack Switches Pass-thru

Valves Pass-thru

Engine Pass-thru

Ground Outriggers Sw

Ground Swing Sw

Ground Enable Sw

Ground Key Sw

Ground Hour Meter

Ground Alarm

Ground Analyzer Port

Ground LED Board

Ground Lift Sw

Ground Jib Sw

Ground Tele Sw

Ground Level Sw

Ground Choke Sw

Ground Start Sw

Ground EMG Stop

Strobe Light

Lift Down Valve Coil

Transport Limit Sw

Tele Limit Sw

F/L Jack Limit Sw

F/R Jack Limit Sw

R/L Jack Limit Sw

R/R Jack Limit Sw

F/L Jack Valve Coil

F/R Jack Valve Coil

R/L Jack Valve Coil

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

CONNECTR

X077

X078

X079

X080

X073

X074

X075

X076

X069

X070

X071

X072

X065

X066

X067

X068

X061

X062

X063

X064

X057

X058

X059

X060

X053

X054

X055

X056

X049

X050

X051

X052

X089

X090

X091

X092

X093

X094

X095

X085

X086

X087

X088

X081

X082

X083

X084

Table 7-1. Connector Identification

DESCRIPTION

R/R Jack Valve Coil

Motion Alarm

Lift Hook Harness to X019

Lift Hook Harness to X054

Lift Hook Harness to Console X058

Platform Harness to X019

Platform Boom Connector

Jib Down Valve Coil

Platform Harness to console X058

Platform Console Main

Console Pass-Thru

Platform Module

Joystick

EMG Stop

Rotary Select Sw

Choke Sw

Start Sw

Alarm

Drive, L Forward

Drive, R Forward

Drive, L Reverse

Drive, R Reverse

Drive, Dump

Drive, Left Prox Sw

Drive, Right Prox Sw

Drive Module, A

Drive Module, B

Drive Module, Analyzer

Swing Left Coil

Swing Right Coil

Jib Up Coil

Level Up Coil

Level Down Coil

Tele Out Coil

Tele In Coil

Lift Up Coil

L/J Stow Coil

L/J Set Coil

Dump Valve Coil

Starter Sol. Fuse

Starter Sol.

Engine Stop Relay

Throttle Pull Relay

Engine Oil Level Switch

Engine Choke Pull Relay

Engine Oil Pressure Switch

Engine Mag Pickup

3121200 7-23

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

CONNECTR

X108

X109

X110

X111

X104

X105

X106

X107

X112

X113

X114

X115

X116

X100

X101

X102

X103

X096

X097

X098

X099

Table 7-1. Connector Identification

DESCRIPTION

Engine Rectifier

Engine Throttle Coil

Engine Choke Coil

Engine Powered, Battery Pos.

Engine Powered, Battery Neg.

Power Module (Sevcon), B-

Power Module (Sevcon), B+

Power Module (Sevcon), M1

Power Module (Sevcon), M2

Sevcon Power Cable In-line

6V Batt 1, Pos.

6V Batt 1, Neg.

6V Batt 2, Pos.

6V Batt 2, Neg.

6V Batt 3, Pos.

6V Batt 3, Neg.

6V Batt 4, Pos.

6V Batt 4, Neg.

Electric Pump Pos.

Electric Pump Neg.

Battery Charger Power

7-24

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

7-25

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.8 ELECTRICAL SCHEMATICS

L/J SET

ENABLE

SYSTEM DISTRESS

BATTERY

TILT

SPARE

PLATFORM

CONTROL

BOARD

8 7 6 5 4

BLACK

YEL/RED 2-20

RED

BLACK

YEL/RED 2-18

ORN/RED 49-22

BLACK

ORN/RED 49-21

ORN/RED 49-27

ORN/RED 49-28

YEL/RED 2-33

BLACK

WHT/YEL 48-1

ORN/RED 49-30

ORN/RED 49-29

ORN/RED 49-25

ALARM

START

ENG. ONLY

DRIVE

MODULE

CHOKE

ENG. ONLY

ORN/RED 58-1

BLACK

ORN/RED 59-1

ORN/RED 56-1

ORN RED 57-1

ORN 7-4

ORN 8-4

ORN 7-2

ORN 8-2

ORN 55-1

YEL/RED 2-33

ORN/RED 49-54

BLACK

YEL/RED 2-16-2

TURNTABLE POS.1

TURNTABLE POS.2

HAND BRAKE 1

HAND BRAKE 2

LEFT DRIVE FORWARD

LEFT DRIVE REVERSE

RIGHT DRIVE FORWARD

RIGHT DRIVE REVERSE

DRIVE DUMP

BLACK

DRIVE

PRESSURE

TRANSDUCER

4 3

2 1

YEL/RED 2-16

BLACK

MTB

SELECT

SWITCH

YEL/RED 2-4 1

YEL/RED 2-5

YEL/RED

2-1(12)

16 2

YEL/RED 2-5

12V OR 24V

IGN. RELAY

87a

MTB

EMS

30A

FRONT LEFT L/J

REAR LEFT L/J

FRONT RIGHT L/J

REAR RIGHT L/J

CHOKE

(ENG.ONLY)

TELE

LEVEL

JIB

DOWN

LIFT

SWING

JACKS

RIGHT

LEFT

SET

STOW

DOWN

TRANSPORT

LIMIT SWITCH

TELESCOPE

LIMIT SWITCH

BRN/WHT 47-25

BRN/WHT 47-24

BRN/WHT 47-22

BRN/WHT 47-23

OUT

DOWN

2-41-1

START

(ENGINE ONLY)

YEL/RED

2-40-1

YEL/RED 2-41

WHT/YEL 48-1

ENABLE

WHT/YEL 48-9

BROWN 13-2

GRN. IGN. RELAY

BROWN 14-2

PINK 25-2

PINK 26-2

2-40

BLUE 27-2

BLUE 28-2

TAN 3-2

TAN 4-2

WHITE 22-2

WHITE 21-2

ORN/WHT 55-2

ORN/WHT 55-1

BLACK

WHITE

BLACK

YEL/RED 2-26

YEL/RED 2-26-1

2 3 4 1

RED

BLACK/SHLD

WHITE

GREEN

POWER

GROUND

TRANSMIT

RECEIVE

ANALYZER

PLATFORM BOX

CONNECTOR

RED/BLK

BLUE

PLTF

EMS

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

NOT AVAIABLE

ON JIB MODEL

REMOTE

CONTROL CABLE

RED/BLK

BLUE

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

RED

SHIELD

BLACK

120

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

RED/BLK

BLUE

1/4 W

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BOOM

CABLE 2 1

GND FROM BATTERY

MTB EMS INPUT

N M L J

CAN HI

CAN LO

CAN SHIELD

G F

HOOK GND.

CONTROL REMOTE

(OPTIONAL)

YEL/RED 2-4

CAN BUS CABLE

B C A

RED/BLK

BLUE

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

HARNESS

GND TO PLATFORM

FRAME

MTB EMS TO PLATFORM

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

RED

BLACK

SHIELD

YEL/RED 2-4-1

YEL/RED 2-7

BROWN (SPARE)

ORN/RED 49-10

ORN/RED 49-9

BLUE 28-3-1

BLACK

BLK

YEL/RED 2-11

J2-20 (F-2)

TURNTABLE

CAN BUS TO

POWER MODULE

RED

BLACK

SHIELD CAN BUS CABLE

3 2 1 5 6 7 8 9 10

JIB DOWN (PWM)

IGNITION COIL CIRCUIT FOR CONNECTOR TERMINAL HARNESS

PREVIOUS TO SN 030004208

BLACK

FRONT/LEFT OUTRIGGERS SET LIMIT SWITCH

FRONT/RIGHT OUTRIGGERS SET LIMIT SWITCH

REAR/LEFT OUTRIGGERS SET LIMIT SWITCH

REAR/RIGHT OUTRIGGERS SET LIMIT SWITCH

BLACK

WHITE

BLACK

IGNITION COIL CIRCUIT FOR ENGINE HARNESS

AFTER SN 030004208

SPARK

PLUG

C/D OUT "X"

HALL EFFECT

SENSOR

A/B OUT "Y"

HALL EFFECT

SENSOR

PLATFORM

JOYSTICK

BLACK

YEL

RED

SPARK

PLUG

IGN.

COIL

THROTTLE PULL

THROTTLE SOLENOID

BLACK (12)

THROTTLE HOLD

CHOKE PULL

N.O.

OIL LEVEL

SWITCH

BLACK

87a

WHT/YEL 48-2-1(12)

WHT/YEL 48-4-1(12)

87a

CHOKE HOLD

CHOKE SOLENOID

BLACK (12)

AMP

STARTER

MOTOR

SOL.

OPTIONAL 12V

HONDA ENGINE.

85 86

ENGINE STOP RELAY

85 86

ENGINE THROTTLE PULL RELAY

ENGINE CHOKE PULL RELAY

STARTER

MOTOR

LOADING VIEW

WHT/YEL 48-10

WHT/YEL 48-11

IGN.

COIL

N.O.

OIL LEVEL

SWITCH

BLACK

YEL/RED 2-3 IGN. RELAY 87

VOLTAGE REGULATOR

WHT/YEL 48-13

87a

85 86

ENGINE STOP RELAY

ENGINE SPEED PICK-UP

ENGINE START

USE JUMPER FROM 6 TO 17 ON

ENGINE POWERED MACHINES ONLY.

CHOKE PULL

THROTTLE HOLD

THROTTLE PULL

CHOKE HOLD

WHT/YEL 48-7

WHT/YEL 48-6

TO 30AMP FUSE IN

GROUND CNTL BOX

12V ENGINE

BATTERY

TO J8 PIN 1

ON GROUND BOARD

TO CHARGE COIL

GROUND BOLT ON

ENGINE HOUSING

7 6 5

Figure 7-33. Electrical Schematic (Boom Operations) - Sheet 1 of 2

SHEET 1

7-26

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3

MTB

SELECT

SWITCH

YEL/RED 2-5

12V OR 24V

IGN. RELAY

YEL/RED

2-1(12)

87a

GND FROM BATTERY

MTB EMS INPUT

15 YEL/RED 2-4

CAN BUS CABLE

CAN HI

CAN LO

CAN SHIELD

P N M L J

K G

F E

B C A D H

HOOK GND.

CONTROL REMOTE

(OPTIONAL)

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

RED/BLK

BLUE

TURNTABLE

CAN BUS TO

POWER MODULE

FRAME

HARNESS

GND TO PLATFORM

MTB EMS TO PLATFORM

RED

BLACK

SHIELD

ORANGE

YELLOW

BROWN

BLU/BLK

ORN/BLK

YEL/BLK

BRN/BLK

8 BLK

YEL/RED 2-11

RED

BLACK

SHIELD

YEL/RED 2-4-1

YEL/RED 2-7

BROWN (SPARE)

ORN/RED 49-10

ORN/RED 49-9

BLUE 28-3-1

BLACK

IGN. RELAY 86

J2-20 (F-2)

RED

BLACK

SHIELD CAN BUS CABLE

JIB DOWN (PWM)

BLACK

N.O.

OIL LEVEL

SWITCH

87a

85 86

ENGINE STOP RELAY

MTB

EMS

BLACK

30A

FRONT LEFT L/J

REAR LEFT L/J

FRONT RIGHT L/J

REAR RIGHT L/J

CHOKE

(ENG.ONLY)

TELE

LEVEL

BRN/WHT 47-25

BRN/WHT 47-24

BRN/WHT 47-25-1

BRN/WHT 47-24-1

BRN/WHT 47-22

BRN/WHT 47-22-1

BRN/WHT 47-23

10 BRN/WHT 47-23-1

OUT

DOWN

2-41-1

YEL/RED

2-40-1

YEL/RED 2-41

START

(ENGINE ONLY)

WHT/YEL 48-1

ENABLE

2-40

WHT/YEL 48-9

BROWN 13-2

BROWN 14-2

PINK 25-2

PINK 26-2

GRN. IGN. RELAY

1 YEL/RED 2-40

WHT/YEL 48-1-1

WHT/YEL 48-9-1

BLACK

BROWN 13-2-1

BROWN 14-2-1

PINK 25-2-1

PINK 26-2-1

LIFT

SWING

JACKS

JIB

DOWN

RIGHT

LEFT

DOWN

SET

STOW

TRANSPORT

LIMIT SWITCH

TELESCOPE

LIMIT SWITCH

BLUE 27-2

BLUE 28-2

TAN 3-2

TAN 4-2

WHITE 22-2

WHITE 21-2

ORN/WHT 55-2

ORN/WHT 55-1

BLACK

WHITE

BLACK

BLUE 27-2-1

BLUE 28-2-1

TAN 3-2-1

TAN 4-2-1

WHITE 22-2-1

WHITE 21-2-1

ORN/WHT 55-2-1 5

YEL/RED 2-26

YEL/RED 2-26-1

ORN/WHT 55-1-1

ORN/RED 49-53

ORN/RED 49-72

GROUND CONTROL BOX

+12 VDC OUTPUT WHEN

ON GROUND CONTROLS

THE FOLLOWING J4 POSITIONS ARE NOT USED:

1, 2, 3, 4, 5, 6, 10, 12,

15, 18, 22, 27, 28, 31.

THE FOLLOWING J2 POSITIONS ARE NOT USED:

1, 2, 3, 10, 13, 15, 17, 18,

21, 24, 25, 26, 27, 28.

FRONT/LEFT OUTRIGGERS SET LIMIT SWITCH

FRONT/RIGHT OUTRIGGERS SET LIMIT SWITCH

REAR/LEFT OUTRIGGERS SET LIMIT SWITCH

REAR/RIGHT OUTRIGGERS SET LIMIT SWITCH

BLACK

WHITE

BLACK

USE JUMPER FROM 6 TO 17 ON

ENGINE POWERED MACHINES ONLY.

ORN/RED 49-1

ORN/RED 49-2

ORN/RED 49-3

ORN/RED 49-4

YEL/RED 2-6

FOR ELECTRIC ONLY

FOR ENGINE ONLY

THE FOLLOWING J1 POSITIONS ARE NOT USED:

1, 2, 4, 5, 6, 7, 8, 9, 10, 11

12, 13, 14, 15, 17, 18, 19, 20, 21,

22, 23, 25, 26, 27, 32, 33, 34, 35.

THE FOLLOWING J7 POSITIONS ARE NOT USED:

4, 5, 9, 10, 14, 15, 16, 20, 21, 22,

25, 26, 27, 28, 30, 31, 32, 33, 34.

ENGINE SPEED PICK-UP

ENGINE START

CHOKE PULL

THROTTLE HOLD

THROTTLE PULL

CHOKE HOLD

WHT/YEL 48-4

WHT/YEL 48-3

WHT/YEL 48-2

WHT/YEL 48-5

WHT/YEL 48-7

WHT/YEL 48-6

J1-16 (D-2)

J2-23 (F-2)

THE FOLLOWING J3 POSITIONS

ARE NOT USED: 1, 5.

J3 (BLACK)

2 1

RED 1-4(12)

BRN/WHT 47-20-1

BRN/WHT 47-21-1

ORN/RED 49-11-1

PINK 25-3-1

PINK 26-3-1

BLUE 27-3-1

BROWN 13-3-1

BROWN 14-3-1

TAN 3-3-1

TAN 4-3-1

WHITE 22-3-1

WHITE 21-3-1

RED/WHT 50-1-1

BLACK

BLACK M

BLACK

BLUE 28-3-1

WHT/YEL 48-6

YEL/RED 2-13

IGN. RELAY 85

BLACK

YEL/RED 2-15-1 TO SEVCON PIN 1 & CONTACTOR PIN 1

BRN/WHT 47-7-2 BRN/WHT 47-7-1

BLACK 3

BRN/WHT 47-20

BRN/WHT 47-21

ORN/RED 49-11

BLACK

PINK 25-3

PINK 26-3

BLUE 27-3

BROWN 13-3

BROWN 14-3

TAN 4-3

TAN 3-3

WHITE 22-3

WHITE 21-3

RED/WHT 50-1

BLACK

BRN/WHT 47-7

JIB DOWN (PWM)-SEE BOOM CABLE AREA, E-4

ENGINE START- SEE ENGINE AREA B-6

IGN. RELAY 87

RED

GREEN

WHITE

BLACK/SHIELD

(HP) SEVCON

BATTERY -

BATTERY +

PUMP +

PUMP -

FOR CONNECTOR

WIRING SEE C2

J2-3

LOCATION.

YEL/RED 2-43

IGN. RELAY-87

WHT/YEL 48-7

ENGINE MAG. SPEED PICK-UP

(SEE ENGINE AREA B-6)

YEL/RED 2-15-1

YEL/RED 2-12

B-

B+

THIS 12 POSITION CONNECTOR

IS WIRED THE SAME FOR BOTH

SEVCONS.

CONTACTOR PIN-2

YEL/RED 2-16

1 GA.

POS

PUMP

NEG

RED

GREEN

WHITE

BLACK/SHIELD

BAT CHRGR B-

J7-13

J7-24

(CAN HI) RED

(CAN LO) BLACK

BLACK

ALARM

(OPTIONAL)

YEL/RED 2-12

BLACK

ANALYZER POWER

ANALYZER RECEIVE

ANALYZER TRANSMIT

ANALYZER GROUND

BLACK (12)

ALARM

GND ALARM

STD

HOURMETER

DOWN

LEVEL

JIB

TELE.

OUT

DOWN

LIFT

RIGHT

SWING

LEFT

DUMP VALVE (PWM)

(ENGINE ONLY)

YEL/RED 2-14

STROBE LIGHT

(OPTIONAL)

YEL/RED 2-15-3

SPLICE CONNECTION

WITHIN HARNESS

YEL/RED 2-15-2

J2-3 (GND BRD)

YEL/RED 2-15-1

SEVCON PIN-1

SYSTEM DISTRESS

SPARE

IGN. RELAY 87

YEL/RED 2-16 TO

SEVCON PIN 8

B-

B+

TERMINATED AT

SEVCON B-

TERMINAL

BAT CHRGR B-

BAT B-

CONTROL

SYS B-

(LP) SEVCON (P/N:1600412)

WIRE TERMINATIONS

SHOWN IN PHANTOM

POWER MODULE CONNECTOR

DETAIL AND LOCATION

(ELECTRIC ONLY)

BATTERY DISCONNECT

5A FUSE

TELEMATICS

RED 1-3

BLACK M

BRN/WHT 47-7-3

YEL/RED 2-4-2

#16GA FUSIBLE

LINK-FIRST 6"

300A

FUSE

B+

B-

BATTERY

CHARGER

B+

ORN/RED 49-5

ORN/RED 49-7

ORN/RED 49-6

ORN/WHT 55-3-1

ORN/WHT 55-4-1

ORN/RED 49-8

BLACK

WHITE

ORN/WHT 55-3

ORN/WHT 55-4

WHITE

BLACK

BLACK J2-14

RETRACT L/O

FRONT/LEFT

REAR/LEFT

FRONT/RIGHT

OUTRIGGERS

REAR

RIGHT

OUTRIGGERS

24V

18V

12V

24V MACHINE

BATTERY

EXTEND L/O

TO CHARGE COIL

SHEET 1

= M.T.B. 31 POS. CONNECTOR AT FRAME HARNESS.

= 12 POS. VALVE CONNECTOR IN FRAME HARNESS.

= 2 POS. CONNECTOR AT FRAME HARNESS.

= 8 POS. CONNECTOR AT GROUND CONTROL LED BOARD.

= 8 POS. CONNECTOR AT FRONT LEFT JACK.

= 12 POS. CONN. JACK VALVE/ LIMIT SWITCH

4 3 2

Figure 7-34. Electrical Schematic (Boom Operations) - Sheet 2 of 2

1870172-J

MAE28580

3121200 7-27

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7-28

8 7 6 5 4

RIGHT

BRAKE

LIGHT

RIGHT

TURN

SIGNAL

(RED)

R.TAIL

LIGHT

(RED)

FOG LAMP

TAIL LIGHT

AND

RUNNING LIGHT

(RED)

LOCATED IN BACK OF BOOM

LEFT

CENTER

TURN

BRAKE LIGHT

(RED)

3RD BRAKE LIGHT

SIGNAL

(RED)

HARNESS CONNECTOR

LICENSE

PLATE

LIGHT

L. TAIL

LIGHT

(RED)

LEFT

BRAKE

LIGHT

RIGHT

SIDE MARKER

(AMBER)

WHITE

BROWN

3RD BREAK LIGHT

HARNESS CONNECTOR

BLUE

LOGIC CIRCUIT FOR

CENTER BRAKE LIGHT

BROWN

YELLOW

GREEN

WHITE

BLACK

WHITE JUMPER IS ATTACHED

TO CENTER MOUNTING BOLT

HOLE WITH HARDWARE OF CHOICE.

LEFT

SIDE MARKER

(AMBER)

CHARGER

RIGHT

TURN

SIGNAL

(RED)

RIGHT

BRAKE

WHITE

BLACK

RIGHT

SIDE MARKER

(AMBER)

WHITE

BLACK

R.TAIL

LIGHT

(RED)

3RD BREAK LIGHT

HARNESS CONNECTOR

WHITE

BROWN

GREEN

TAIL LIGHT

AND

RUNNING LIGHT

(RED)

CENTER

BRAKE LIGHT

(RED)

BLUE

BROWN

YELLOW

GREEN

WHITE

1 2 4 3

WHITE

YELLOW

BROWN

LEFT

TURN

SIGNAL

(RED)

BLUE

WHITE

BLACK

WHITE

BLACK

WHITE

BLACK

CE STANDARD 7 POSITION BLACK CONNECTOR WIRING

1 3 5 6 4 2 7

7 POSITION TRAILER WIRING

4 POSITION STANDARD WIRING AND ELECTRIC BRAKE WIRING

ANSI, CSA, ANSI EXPORT W/ELECTRIC BRAKES

SHEET 1

8 7 6 5

Figure 7-35. Electrical Schematic (Trailer) - Sheet 1 of 4

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SHEET 1

3121200

5 4 3

RIGHT

TURN

SIGNAL

(RED)

R.TAIL

LIGHT

(RED)

3RD BREAK LIGHT

HARNESS CONNECTOR

WHITE

BROWN

GREEN

TAIL LIGHT

AND

RUNNING LIGHT

(RED)

1 2 4 3

CENTER

BRAKE LIGHT

(RED)

BLUE

BROWN

YELLOW

GREEN

WHITE

LOGIC CIRCUIT FOR

CENTER BRAKE LIGHT

WHITE

YELLOW

BROWN

LEFT

TURN

SIGNAL

(RED)

WHITE JUMPER IS ATTACHED

TO CENTER MOUNTING BOLT

HOLE WITH HARDWARE OF CHOICE.

L. TAIL

LIGHT

(RED)

RIGHT

TURN

SIGNAL

(RED)

2 1

3RD BRAKE LIGHT

HARNESS CONNECTOR

R.TAIL

LIGHT

(RED)

WHITE

BROWN

GREEN

TAIL LIGHT

AND

RUNNING LIGHT

(RED)

1 2 4

CENTER

BRAKE LIGHT

(RED)

BLUE

BROWN

YELLOW

GREEN

WHITE

YELLOW

WHITE

BROWN

LEFT

TURN

SIGNAL

(RED)

WHITE JUMPER IS ATTACHED

TO CENTER MOUNTING BOLT

HOLE WITH HARDWARE OF CHOICE.

LOGIC CIRCUIT FOR

CENTER BRAKE LIGHT

L. TAIL

LIGHT

(RED)

RIGHT

BRAKE

WHITE

BLACK

RIGHT

SIDE MARKER

(AMBER)

WHITE

BLACK

BLUE

WHITE

BLACK

WHITE

BLACK

WHITE

BLACK

LEFT

BRAKE

LEFT

SIDE MARKER

(AMBER)

RIGHT

SIDE MARKER

(AMBER)

WHITE

BLACK

WHITE

BLACK

LEFT

SIDE MARKER

(AMBER)

TRAILER WIRING

VEHICLE WIRING

4 POSITION STANDARD TRAILER WIRING

ANSI, CSA, ANSI EXPORT SURGE BRAKES

1 3 5 6 4 2 7

7 POSITION TRAILER WIRING

4 POSITION STANDARD WIRING AND ELECTRIC BRAKE WIRING

ANSI, CSA, ANSI EXPORT W/ELECTRIC BRAKES

4 3 2

Figure 7-36. Electrical Schematic (Trailer) - Sheet 2 of 4

1870185-D

MAE27370

7-29

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7-30

8 7 6 5 4

RIGHT SIDE MARKER

LIGHT

BROWN

WHITE

HARNESS TRAILER LIGHTS

12 POSITION CONNECTOR LOCATED

AT LEFT REAR O/R PLUG INTO

BUMPER ASSY 12 POSITION CONNECTOR

ORANGE

PINK

10 WHITE-2

11 GREY

12 VIOLET

YELLOW

BLACK

WHITE-1

GREEN

BLUE

RED

BROWN

FRONT RIGHT SIDE

MARKER LIGHT

RIGHT STOP/TURN

MARKER LIGHT

LICENSE

PLATE

LIGHT

LEFT STOP/TURN

MARKER LIGHT

BROWN

WHITE

4 6 3 7 1 2 5 8 9 10 11 12

LEFT SIDE MARKER

LIGHT

CENTER BRAKE AND

MARKER LIGHT

4 TERMINAL CONNECTOR

(STANDARD CONNECTOR WITH SURGE BRAKES)

TRAILER

COMMON GROUND

TAIL & RUNNING LIGHTS

LEFT STOP & TURN

RIGHT STOP & TURN

TOW VEHICLE

GD-TM-LT-RT

LOCATED AT BACK OF BOOM

HARNESS TRAILER LIGHTS

BLACK

WHITE

RED - STOP

BROWN - MARKER

WHITE - GROUND

RED

BROWN

WHITE

GREEN

BROWN

WHITE

HARNESS CENTER BRAKE LIGHT

BLACK

WHITE

FRONT LEFT SIDE

MARKER LIGHT

GD - COMMON GROUND

S - NOT USED

TM - TAIL & RUNNING LIGHTS

6 TERMINAL CONNECTOR

(STANDARD CONNECTOR WITH ELECTRIC BRAKES)

TOW VEHICLE TRAILER

A - ELECTRIC BRAKES

LT - LEFT STOP & TURN

RT - RIGHT STOP & TURN

4 6 3 5 1 2 7 8 9 10 11

7 POSITION TRAILER WIRING

AUS/SA SURGE

THE COLOR CODE WILL BE THE

SAME FOR BOTH AUS AND SA.

PLUG WIRING AND CONNECTOR

WILL BE INSTALLED BY AUS AND

SA DEALERS

7 POSITION CE TRAILER PLUG (12N)

1 - L - YELLOW - LEFT TURN

2 - 54G - BLUE - NOT USED

3 - 31 - WHITE-1 - GROUND

4 - R - GREEN - RIGHT TURN

5 - 58R - BROWN - MARKER/LICENSE PLATE/TAIL LIGHT

6 - 54 - RED - STOP

7 - 58L - BLACK - NOT USED

6 5

7 4

2 3

LOADING VIEW

7 6

1 - COMMON GROUND

2 - ELECTRIC BRAKES

3 - TAIL & RUNNING LIGHTS

4 - NOT USED

5 - LEFT STOP & TURN

6 - RIGHT STOP & TURN

7 - NOT USED

7 TERMINAL CONNECTOR

(SPECIAL REQUESTED CONNECTOR )

TOW VEHICLE TRAILER

Figure 7-37. Electrical Schematic (Trailer) - Sheet 3 of 4

SHEET 2

3121200

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

4 TERMINAL CONNECTOR

(STANDARD CONNECTOR WITH SURGE BRAKES)

TRAILER

COMMON GROUND

TAIL & RUNNING LIGHTS

LEFT STOP & TURN

RIGHT STOP & TURN

TOW VEHICLE

GD-TM-LT-RT

WHITE - GROUND TO FRAME

BROWN - TAIL & RUNNING LIGHTS

YELLOW - LEFT STOP & TURN

GREEN - RIGHT STOP & TURN

CHARGER

GD - COMMON GROUND

S - NOT USED

TM - TAIL & RUNNING LIGHTS

6 TERMINAL CONNECTOR

(STANDARD CONNECTOR WITH ELECTRIC BRAKES)

TOW VEHICLE TRAILER

A - ELECTRIC BRAKES

LT - LEFT STOP & TURN

RT - RIGHT STOP & TURN

GD - WHITE - COMMON GROUND

S - NOT USED

TM - BROWN - TAIL & RUNNING LIGHTS

A - BLACK - ELECTRIC BRAKES

LT - YELLOW - LEFT STOP & TURN

RT - GREEN - RIGHT STOP & TURN

RIGHT

SIDE MARKER

(AMBER)

RIGHT

BRAKE

LIGHT

RIGHT

TURN

SIGNAL

(RED)

RIGHT

BRAKE

BLUE

WHITE

BLACK

WHITE

BLACK

WHITE

R.TAIL

LIGHT

(RED)

TAIL LIGHT

AND

RUNNING LIGHT

(RED)

VIOLET

WHITE

ORANGE

LOCATED IN BACK OF BOOM

LEFT

TURN

LICENSE

SIGNAL

PLATE

(RED)

LIGHT

L. TAIL

LIGHT

(RED)

LEFT

BRAKE

LIGHT

12 POSITION CONNECTOR LOCATED

AT LEFT REAR O/R PLUG INTO

BUMPER ASSY 12 POSITION CONNECTOR

YELLOW

BLACK

3 WHITE-1

GREEN

BLUE

RED

BROWN

ORANGE

PINK

10 WHITE-2

GREY

VIOLET

BLUE

BROWN

YELLOW

GREEN

WHITE

LOGIC CIRCUIT FOR

CENTER BRAKE LIGHT

WHITE JUMPER IS ATTACHED

TO CENTER MOUNTING BOLT

HOLE WITH HARDWARE OF CHOICE.

LEFT

BRAKE

BLACK

WHITE

LEFT

SIDE MARKER

(AMBER)

BLACK

WHITE

1 - COMMON GROUND

2 - ELECTRIC BRAKES

3 - TAIL & RUNNING LIGHTS

4 - NOT USED

5 - LEFT STOP & TURN

6 - RIGHT STOP & TURN

7 - NOT USED

7 TERMINAL CONNECTOR

(SPECIAL REQUESTED CONNECTOR )

TOW VEHICLE TRAILER

3 4

1 - WHITE - COMMON GROUND FROM BRAKES

2 - BLACK - ELECTRIC BRAKES

3 - BROWN/YELLOW & BROWN GREEN -

TAIL & RUNNING LIGHTS

4 - NOT USED

5 - YELLOW - LEFT STOP & TURN

6 - GREEN - RIGHT STOP & TURN

7 - NOT USED

4 6 3 7 1 8 5 2 9 10 11 12

12 POSITION TRAILER WIRING

AUS/SA ELEC.

THE COLOR CODE WILL BE THE

SAME FOR BOTH AUS AND SA.

PLUG WIRING AND CONNECTOR

WILL BE INSTALLED BY AUS AND

SA DEALERS

SHEET 2

5 4 3 2

Figure 7-38. Electrical Schematic (Trailer) - Sheet 4 of 4

1870185-D

MAE27380

3121200 7-31

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-32

3121200

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg, PA 17233-9533 USA

(717) 485-5161 (Corporate)

(877) 554-5438 (Customer Support)

(717) 485-6417

Visit our website for JLG Worldwide Locations.

www.jlg.com

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