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Service and Maintenance Manual

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1. DRIVE MOTORS E I ff j gt UPPER MASTER i i 1 SP LTW As TE 2 1 alll pb DRIVE BRAKES V2 L e A LOWER MASTER ROTATOR MOTOR 2 Z B i a rer 19 050 ORIFICE SWIVEL B de 4 Tii 2 1 osos m 2 SPOOL gt SOLENOID kaq LI LUTU S E LEVEL ROTATE Hj aXe ZETE MAIN DRIVE zn _ _ _ _ pe Her ES 19 Lg B 1 MAIN DRIVE RELIEF amp DUMP i 25 gh R Fo Pd 1 HI DRIVE DUMP e T lH FE NE n SA eua x LKH 1 8 ca 22 IN m ui e usce Deu H H e is I 8 S 9 s _ T x ub C an SEQUENCE da VALVE Ld Tom grive flow 18 gom 08 lom 9 Q norm fow to GMX 100 11 42 Tem lt Norm flow io bang bang futttions 6 5 gpm 28 ipm AUX PUMP 2 8 L ENGINE 1 2 3 l T 5 MM T 5 SPOOL PROPORTIONAL SIRE l I B MAIN TELE MAIN PUMP MAIN LIFT 21 L Hower LIFT 7 SWING pls Hid
2. Bho fe ama k or oA L 3LIHM Bo 5 z di M 5 8 t i z B 8 9 3LIHM 4 585 5 5 5 ii B naa nao 3 SC 3LIHM 2 a or E t 5 z RAAR T 215 E ii u S naaznie 3 E e dg ES 1 E 1 8 28 8 d TT ECCE f A u 1 E 2 r s z px zh 5 2 Ed L mao E 585 Exo gt x B 2 n i gt 81 134 ms g TU 5 5 E s 1 R 134 034 3 131 038 geri 9 t 8 25 BR sione avna gans 5 Bug 2 hoe o 5 2 B LL MOTIJA a ANS 3 RH NN0 134 1 N E E 8 s e RK 2 55 8 E 2 grs dz 5 8 al 8 N N 56 N L 295 4 x aH manaa A manaa gt x 5 lt S a zt 25 s mana 018 7134 8 M g S I Qo BB 5 manuo 2 gt 3 a Pu a 5 I 5 a 2 2 5 80 c0
3. INTERVAL Deli 2 4 s eene oq See Maintenance Maintenance Inspection Inspection Ground Controls 5 5 6 6 Function Control Locks Guards or Detents 1 5 1 5 5 5 Footswitch 1 5 5 5 Emergency Stop Switches Ground amp Platform 5 5 5 Function Limit Cutout Switch Systems 5 5 5 Capacity Indicator 5 Drive Brakes 5 Swing Brakes 5 Boom Synchronization Sequencing Systems 5 Manual Descentor Auxiliary Power 5 5 Power System 9 Engine Idle Throttle and RPM 3 3 Engine Fluids Coolant Fuel 11 9 11 11 11 Air Fuel Filter 1 7 7 7 Exhaust System 1 9 9 9 Batteries 5 1 9 19 Battery Fluid 11 11 11 Battery Charger 5 5 Fuel Reservoir Cap and Breather 11 9 2 1 5 1 5 Hydraulic Electric System 9 Hydraulic Pumps 1 9 1 2 9 Hydraulic Cylinders 1 9 7 2 1 2 9 1 2 9 Cylinder Attachment Pins and Pin Retainers 1 9 1 2 1 2 Hydraulic Hoses Lines Fittings 1 9 12 1 2 9 12 1 2 9 12 Hydraulic Reservoir Cap and Breather 11 1 9 2 1 5 1 5 24 Hydraulic Filter 1 9 7 7 Hydraulic Fluid 11 7 11 7 11 Electrical Connections 1 20 20 Instruments Gauges Switches Lights Horn 1 5 23 General Operators and Safety Manuals in Storage Box 21 21 21 ANSI and AEM Manuals Handbooks Installed 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 3120679 JLG Lift 2 7 SECTION 2 GENERAL
4. 3 26 Assembly aussi RU PR u p dala 3 27 3 8 Swing Brake Ausco Machines Built To 1992 3 29 Disassembly es etd O REC 3 29 Cleaning and 1 3 29 Assembly 2 ERREUR EUR huu du 3 29 3 9 Swing Brake Mico Machines Built To 1992 3 31 DisassSembly suxa a Rr e ex es Ere butt gre iuge a ulum s 3 31 Cleaning and 2 1 3 31 Assembly x ee oe ET c 3 33 ii JLG Lift 3120679 TABLE CONTENTS 3 10 Swing Brake Machines Built 1992 To 3 33 DisassemblVy Re arta as ne y Satipu 3 33 Cleaning and 1 3 35 Assembly iust pda oe Roa aL RORGUR RR ea asa 3 35 3 11 em 3 36 Disassembly d pio koe dee UM RO RADEON SelM RAG eee 3 36 Assembly ua cb ed eene we cepe hat N deese Ow cad e acp deren ie een 3 36 3 12 PQ Controllers ueber eU ai wee 3 38 TRIM Adjustmeri
5. 2 2 General i wed vu DEI etr veau DE WE pire uq REALE 2 2 Safety and Workmanship 1 2 2 e ctrs PC hina a wd cons nee 2 2 Components Removal and 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts oue m Ph tne TERR usakuna ERE cd 2 3 Bearlngs u ae cte es Dod epu Pe e ir cad pq vds AE d bre 2 3 Gaskets y sted E eeu pu P degree eM egeta e Rd da See ee 2 3 Bolt Usage Torque Application 2 3 Hydraulic Lines and Electrical Wiring 4 2 3 Hydraulic System sanete c Eee ROO RID RU Ce RR RN Ge 2 3 Eubrication quud crt PEE II CRI EUR Y Wee qe wu qd 2 3 Baitery A eee ee ae eae pate ah eee AGGER 2 3 Lubrication and Servicing 2 3 2 3 Lubrication and Information 1 1 4 2 3 FIVOFAUliGk Syston 3 5 do m ete e t stt a a m a starts 2 3 Hydraulic 2 l avr d P PRO SURE E REOR 2 4 Changing Hydraulic 2 4 Lubrication Specificati
6. 6 1 JLG Lift 3120679 LIST OF FIGURES LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Operator Maintenance amp Lubrication 1 5 1 2 Torque Chart SAE Fasteners Sheet 1 7 1 11 1 3 Torque Chart SAE Fasteners Sheet 2 7 1 12 1 4 Torque Chart SAE Fasteners Sheet 3 7 1 13 1 5 Torque Chart SAE Fasteners Sheet 4 7 1 14 1 6 Torque Chart METRIC Fasteners Sheet 5 7 1 15 1 7 Torque Chart METRIC Fasteners Sheet 6 7 1 16 1 8 Torque Chart METRIC Fasteners Sheet 7 7 1 17 2 1 Engine Operating Temperature Specifications 2 9 3 1 Drive Torque Hub eR tee ak RR MES me bh ac 3 3 3 2 Torque Hub Carrier 0 1 244 4 4 3 13 3 3 Drive Brake Mico March 1992 to S N 33746 3 15 3 4 Drive Brake Mico S N 33476 to 3 18 3 19 Swing Bearing Tolerance Boom 3 20 3 18
7. SWING MOTOR zu Lu MANUAL DESCENT VALVES 1 TOWER TELE CYL i HYD fo M CAM n I VALVE n ni Vb IET I pi 1 amp Lift Down ig Flow Control Y ral Sun Hydraulics P N M FDCB LAN DAK d EE 1 o I ay Qm 2 MAIN TELE CYL VALVE R P Li 1 a 2 gc VI 9 DUAL p COUNTERBALANCE n LIFT DOWN i CREEP VALVE 1 liz 5 zi CAM VALVE A OUTLET o wy 1 1 r Swing Section Tower Lift Section _ Tower_Tele Section_ Main Tele Section BLA PRESSURE I I 4 4 ILE R Es L4 H1 H LL J a E I l I I l 1 Jis lb 1 PILOT PRESS X T T E Ld T I T m 9 E bor 29 lr E l 1 118 INL I t 1 18 11 e 11 ex E 1 SENSE 6 28 JLG Lift 3120679 SECTION 6 SCHEMATICS
8. iS an dee abe gerne ee AS 3 4 3 3 Drive Brake Mico Machines Built March 1992 To S N 33476 3 14 DISASSEMDIY ateti eae eade dae ate 3 14 Cleaning and 3 14 Assembly umu e ert etu eate eu 3 14 3 4 Drive Brake Mico Machines Built S N 33476 To 3 16 Disassembly 23 5 6e ree Hx dee AS PR e Te e AGO Tue SA gunt 3 16 INSPECTION ec TTD 3 17 Assembly zUzsores5ucefqqp Sia SUE quei 3 17 3 5 Free Wheeling Option us pu RR Se RR ERREUR o g REEL 3 19 To Disengage Drive Motors and Brakes Free Wheel for Towing 3 19 To Engage Drive Motors and Brakes Normal 3 19 3 6 Swing Bearing 2 teer REI BER NEW a IW eee td A 3 19 Turntable Bearing Mounting Bolt Condition 3 19 Wear Tolerance ahus UNUS aa d ed d a RUE a 3 21 Replacement and Devcon Application Procedures 3 21 Swing Bearing Torque 3 24 3 7 Swing Torque deret eee Pase ede qure dte IR NR Y AR 3 24 Disassembly tete ode ebd nee dul odas e aa dae th n Mensa ewe a e Rue a a 3 24 Cleaning and
9. ub 1001110253 B B i Hd LEF NM isl 3120679 Figure 6 7 Hydraulic Schematic Sheet 2 of 2 JLG Lift 6 29 SECTION 6 SCHEMATICS LS NOTES 6 30 JLG Lift 3120679 PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 3120679 Corporate JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 JLG Worldwide Locations JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 61265 811111 61 2 65813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 A amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater
10. Cylinder Bore Diameter rns 4 inches mm inches mm 3 76 2 0 026 0 66 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 152 4 0 006 0 15 7 177 8 0 005 0 13 8 203 2 0 0038 0 10 9 228 6 0 0030 0 08 Drift is to be measured at the cylinder rod with a calibrated dial indicator The cylinder oil must be at ambient temper ature and temperature stabilized The cylinder must have the normal load which is the nor mal platform load applied If the cylinder passes this test it is acceptable NOTE This information is based on 6 drops per minute inder leakage 2 5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings 1 Pinned joints should be disassembled inspected if the following occurs a Excessive sloppiness in joints b Noise originating from the joint during operation 2 Filament wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface 3 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 3120679 b Flaking pealing scoring or scratches on the pin surface c Rusting of the pin in the bearing area 4 Re assembly of pinned joints using filament wound
11. o NuO 1HM c lt lt lt H lt lt BONYEO lt lt 9 lt 034 134 lt o lt lt NMONB 8 318 134 lt in lt E NYO 1HM lt lt 1 Avo lt lt lt lt 2 ol aay lt a lt s 33 134 lt 0 F xo Nug I 318 134 lt Na 134 M Dsi 13 NNO 1HM c lt 3 8 13A N30 g N 134 078 al B 5 0 x z bo edd 8 re x E z 6 ana H 8 ls D s ma8 134 018 134 wr i go l N3 LHM E 18 Au9 a o 00 ot 933 8 T lt i 8 2 033 134 lt dot IL 318 134 o 1 8 I 187134 J Doy lt lt lt 5 i m Y elc Y z S 31IHM BH 8 x ER 5 NHO 038 FTT Te axons 1 03947734 T3A LHM amp ZS JLIHM 1 311HM 713A NH8 NuB A
12. 17 27 1 Capscrew 10 Shaft 19 Bearing 2 End Cover 11 Disc 20 Dowel Pin 3 Bleeder Screw 12 Friction Disc 21 Housing 4 Case Seal 13 Separators 22 Retaining Ring 5 O ring 14 Return Plate 23 Rotary Oil Seal 6 Back Up Ring 15 Spring 24 O ring 7 Piston 16 Spring 25 Gasket 8 O ring 17 Spring Guide 26 Pin 9 Backup Ring 18 Retaining Ring Figure 3 4 Drive Brake Mico S N 33476 to Present 3 18 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE 3 5 FREE WHEELING OPTION 3 6 SWING BEARING To Disengage Drive Motors and Brakes Turntable Bearing Mounting Bolt Condition Free Wheel for Towing etc Check 1 Chock wheels securely if not on a flat level surface NOTE This check is designed to replace the existing bear 2 Disconnect all drive hubs by inverting disconnect caps in center of hubs To Engage Drive Motors and Brakes Normal Operation 1 Connect all drive hubs by inverting disconnect cap in center of hub 2 Remove chocks from wheels as required ing 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 JLG Threadlocker P N 0100019 After replacing
13. RII 4 12 Main Boom Installation 4 13 4 2 Boom Chairs RR CURE Os PO 4 13 Adjusting Procedures Main Boom 4 13 Inspection ProCedure EIE EV EM ae eed 4 14 4 3 Wear Pads io iiaea e e a ee ar E 4 16 4 4 Platform Rotator Brake 1 2 4 16 SECTION 5 HYDRAULICS 5 1 Valves Theory 5 1 Solenoid Control Valves Bang Bang 5 1 Proportional Control Valves Vickers 5 1 Reliet Valvesix c pate ee REM ene E OU ES Ge aUi dees ceteris AUS hee ee etd 5 1 Crossover Relief 2 5 1 5 2 Cylinders Theory of Operation 5 1 3120679 JLG Lift TABLE CONTENTS 5 3 5 4 5 5 5 6 5 7 SECTION 6 SCHEMATICS 6 1 6 2 6 3 Cylinder Checking 5 2 Cylinders w o Counterbalance Valves Front and Rear Steer Cylinders Front and Rear Frame Lift Cylinders Upper Master Cylinder Lower Master Cylinder Front and Rear Axle Extension
14. Replenish oil as necessary Lubricate as required See Lubrication Chart Repair or replace swing control lever Replace gear s as required Repair or replace swing brake Repair or replace valve 3120679 JLG Lift SECTION 6 SCHEMATICS Table 6 3 Turntable Troubleshooting TROUBLE PROBABLE CAUSE REMEDY POWERPLANT Engine will not start Station power selector switch notin required position Circuitbreaker open Defective starter motor Fuelshutoff solenoid defective Damaged wiring in ignition circuit broken wire onstarter Ignition switch not functioning properly Defective start solenoid Starter relay defective Ignition circuit shorted to ground Battery cable s not making contact Actuate switch as required Determine and correct cause reset circuit breaker Replace starter motor Replace solenoid Repair or replace wiring Replace switch Replace start solenoid Replace starter relay Repair circuitas required Clean and tighten cable s Engine will not start Ignition Engine will not accelerate above low speed No fuel Restricted or broken fuel line Battery defective or discharged Fuel pump not working Damaged wiring on speed control switch or gov ernor solenoid Speed control switch not functioning properly Governor not functioning properly Boom horizontal limit sw
15. achieved without rotation decreases delay time ther trimpot adjustments 12 Release footswitch c Operate machine drive function and adjust ramp pot so that machine will stop within 8 to 12 in 13 Connect ORANGE RED dump wire to applicable 20 to 30 cm when the control handle is terminal strip in platform console released from the full extent of its travel d Operate machine drive function in the opposite direction and check that stopping distance of 8 to 12 in 20 to 30 cm is maintained 3 38 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE 2 3120679 Release footswitch stop machine f Seal ramp pot adjustment screw with a drop of enamel paint to prevent maladjustment due to vibration g Install controller and secure machine Swing Controller a Using all applicable safety precautions start machine and ensure that adequate space is available to maneuver machine b Fully extend boom at horizontal c Position ENGINE SPEED switch to LOW d Operate SWING controller at full speed to the left and then quickly move controller to the full speed RIGHT position The platform should slow stop and then swing right in one smooth and continuous operation e If control valve initiates swing right motion before platform momentum is stopped the ramp poten tiometer adjust screw should be rotated clock wise to increase ramp time and the test repeated f If aft
16. 2 4 5 4 4 Tower BOOm pl QR Re Ex Scene 4 8 5 1 Poly Pak Seal Installation 1 5 9 5 2 Valve Locations Turntable Mounted 5 14 5 3 Valve Locations Frame Mounted 5 15 5 4 Recommended Tool 2 5 20 5 5 Main Gear Pump 4 5 21 6 1 Electrical Schematic Sheet 1 5 1 21 6 22 6 2 Electrical Schematic Sheet 2 5 6 23 6 3 Electrical Schematic Sheet 3 5 2 6 24 6 4 Electrical Schematic Sheet 4 5 1 6 25 6 5 Electrical Schematic Sheet 5 5 6 26 6 6 Hydraulic Schematic Sheet 1 2 6 28 6 7 Hydraulic Schematic Sheet 2 2 6 29 3120679 JLG Lift V LIST OF TABLES LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Capacities wu array NU Rs eee ee A Eden 1 1 1 2 Engine R
17. Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL AREA Pre Start Inspection Weekly Preventive Maintenance Monthly Preventive Maintenance Pre Delivery2 or Frequent3 Inspection Annual Yearly Inspection Every 2 Years Walk Around Inspection Perlormed 21 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 1 2 Grease andLubricate to Specifications 22 22 Function Test of All Systems 21 21 21 22 Paintand Appearance 7 Stamp Inspection Date on Frame 22 Notify JLG of Machine Ownership 22 Footnotes 1 Prior to use each day or at each Operator change 2 Prior to each sale lease or delivery 3 In service for 3 months or 150 Hours or Out of service for 3 months or more or Purchased used Annually no later than 13 months from the date of the prior inspection Performance Codes 1 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Checkfor proper and secure installation Visualinspection for damage cracks distortion or excessive wear Check for proper adjustment Checkfor cracked or broken welds Operates P
18. 1 10 JLG Lift 3120679 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Tensile Torque Loctite 2427 or 271 M bes Size Bolt Dia CAT Clamp Load Vibra TITETM111 or or Vibra TITE 131 140 Exi zr ol zu 4 40 0 1120 0 00604 380 8 0 9 6 0 7 48 01120 000661 420 9 10 7 08 40 0 1380 0 01015 610 18 20 13 1 5 8 32 01640 0 01400 90 30 34 2 25 36 01640 0014 4 90 5 35 26 10 24 0190 0 01750 10 43 48 3 35 32 0190 0 02000 185 49 5 36 4 T 1 4 20 02500 0 0318 2020 96 108 75 9 15 12 128 02500 0 0364 2320 120 135 se 10 135 15 m san tB Nm Nm FB Nm Fr Nm 22 24 03125 0 0580 370 179 6 4 19 a 9 17 23 38 24 03750 0078 560 5 47 25 34 59 54 3 43 20 0 4375 0 1187 7550 55 75 40 54 60 82 50 68 2 13 0500 0 1419 9050 75 12 5 75 8 16 68 92 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 118 05625 02030 12950 0 163 90 122 15 14 109 148 5 8 183 8 0 6250 0 2560 16300 10 230 10 16 190 28 153 207 325 16 0 7500 0 3730 23800 300 47 20 28 2
19. 3 29 SECTION 3 CHASSIS amp TURNTABLE 3 30 23 37265 MODEL 28653 Gasket Bolt Model 28653 Flanged Bolt Model 37265V Lockwasher Model 28653 Only Power Plate Bleeder Ball Bearing Model 37265V Only O ring Backup Ring O ring Backup Ring Piston Stationary Disc Compression Spring Rotating Disc Primary Disc Torque Pin Splined Shaft Compression Spring Spring Retainer Model 37265V Figure 3 22 Swing Brake Ausco Machines Built to 1992 Oil Seal Ball Bearing Gasket Housing Retaining Ring Model 28653 Only Retaining Ring Model 28653 Only Gasket Pressure Relief Valve JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE 5 Before installing seal 4 lubricate lip of seal with system hydraulic fluid or other suitable lubricant Face lip of seal toward outside of brake in order to keep gear box oil or other external contaminants out of brake Using a shop press install seal 4 by pressing evenly around OD of seal Use care to avoid cocking seal 6 Install shaft 7 into housing Support inner race of bearing 3 when pressing bearing onto shaft 7 Install gasket 2 Align properly After installing all remaining brake components install bearing 18 Properly support shaft when pressing bearing onto shaft 8 Install power plate sub assembly Use a shop press to evenly lower plate into position There shoul
20. 3120679 11 Install capscrews 31 lockwashers 32 Tighten evenly to draw end cover 34 to housing and bear ing 37 onto shaft 45 Torque capscrews to 68 Nm NOTE If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening capscrews 12 Press on inner ring of bearing 37 until it shoulders on shaft 45 to eliminate binding on bearings Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing 54 NOTICE PRESS FORCE SHOULD BE LIMITED TO 2 000 LB 907 KG MAXI MUM TO AVOID POSSIBLE DAMAGE TO SNAP RING 44 NOTICE IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING 3 10 SWING BRAKE MACHINES BUILT 1992 TO PRESENT Disassembly 1 Separate end cover 2 from housing 21 by remov ing capscrews 1 A CAUTION END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3 000 LB 1 360 KG MINIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASH ERS 2 Remove case seal 4 from the housing 21 then remove bleeder screw 3 from the end cover 2 Remove piston 7 from end cover 2 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9
21. 7 7 gt D E24 i 27 BLU ORN 87 l i 5 z S 8 a lt amp FRONT E STEER 3 5 RIGHT gt 9 a REAR SPEED 5 STEER lp DRIVE p DRIVE 87 RIGHT 86 A 307 838 lt 30 pe a z u t i Y E I WHITE 235 235 YELLOW IOS Eis 3 3 STEI ra a HORN 3 5 ZEB A 87 RELAY 87 p sss 8558 2 5 3 357 ROTATE a 3 30 0 S 3 WHT YEL Qu L wot ROTATE ii i e at RIGHT 32 189 89 E D a 6 E a8 2 5 3 3 56 g 56 GRY YEL p PROP DUMP Dae BH 307 3 x 4 73 ius L RED 12 j30 eG 5 DUMP RED 12 5 WHT Y cn EL g WHT YEL OTEN WHT BRN 42 9 RED ORN y nee p sena EX BRN BLK start BLACK 12 GRN WHT ETIB RELAY 1 E WATER OIL 8 ALT TEMP PRESS RED 10 amp RED 1O 9 x 9 gt Yr amp 1 CABLE PRIMARY x 8 PRIMARY BLACK 10 32 3 HORZ LIMIT SWT gt d THROTTLE amp BLK HT BLACK BAT CABLE 508 ACTUATOR L BLUE BROWN z 5 GRN YEL REAR AXLE FRONT AXLE LIMIT SWT LIMIT SWT LIMIT SWT FRONT AXLE WHT VIO gia 13 14 13 14 13 14 13 14 z 214 GRN BLK P43 x N x uia 11 12 111712 11 12 rw 1 A gt WHT YEL o lt T WHT BLK lt 9 WHT RED lt WATER RED 10 O RED10205
22. bushing pullers similar to those manufactured by Owatonna Tool Co The table below illustrates the modifications necessary to adapt the OTC collets to this task Equivalent pullers from other suppliers may be modified in similar fashion 015 R Maximum Typical Collet CA A For 365 use 2 1 2 dia x 2 bar Special steel sleeve see sketch Special Steel Sleeve The special steel sleeve is used to insert the drive shaft through the lip seal without damage and can be made from bar stock For the P315 use 1 dia x 3 1 8 bar for the P330 use a 1 1 8 1 1 4 dia x 4 5 8 bar for the P350 use a 1 3 8 dia x 4 5 8 bar forthe P365 use a 1 1 2 dia x 4 5 8 bar The drawing and chart give details for making this special tool C Rad Make From Pump Motor OTC Collet No 1122 0 990 1372 1250 1 4 Hole Drill Through 000 002 P315 1 7 8 em 9 16 944 002 885 900 000 002 4 1 2 9 16 1 065 0421 0027 90 000 002 3 3 8 4 1 2 9 16 1 290 002 1 2507 000 chamfer 050 x 60 015 x 45 015 x 60 000 002 3 3 8 4 1 27 9 16 1 377 002 1 2507 ooo All external surfaces must be free of scratches and burrs Figure 5 4 Recommended Tool List Lift 3120679 SECTION 5 HYDRAULICS Lip Seal Mounting End Not Used Plug Dowel Pin Thrust Plate Chan
23. 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 7 Torque Chart METRIC Fasteners Sheet 6 of 7 Lift 3120679 SECTION 1 SPECIFICATIONS 3120679 Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS 6 AND ABOVE Torque Tensile Dry or Loctite 242 or 2717 Loctite 2627 Size PITCH Stress OR Vibra TITE Vibra TITE Sl pos or Pi i K 15 EPS SSES L 6 SE ono 3 19 a 125 z28 54 95 150 255 325 20 2 5 245 460 22 2 5 303 625 24 3 353 790 27 3 459 1160 1575 33 2140 2750 4395 NO 5000059 J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Fi
24. 3 000 LBS 1 360 KG MINIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASH ERS 2 Remove case seal 4 from the housing 21 then remove bleeder screw 3 from the end cover 2 Remove piston 7 from end cover 2 4 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9 from piston 7 Remove separators 13 from housing 21 6 Remove stack assembly consisting of discs 11 return plate 14 and friction discs 12 from housing 21 NOTE Not all models use the same number of springs or spring pattern Record this information for assembly purposes Spring retainer 17 was not used in ear lier models 7 Remove dowel pins 20 springs 15 amp 16 and spring retainer 17 from housing 21 Remove retaining ring 18 from housing 21 9 Remove shaft by pressing or using a soft mallet on male end of shaft 10 NOTE Earlier models did not use retaining ring 22 10 Remove retaining ring 22 and bearing 19 from shaft 10 Press Rotary oil seal 23 from housing 21 3 14 Lift Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary Discard seals and o rings Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are found to be in good condition
25. Cylinders w Single Counterbalance Valves Main Lift Cylinder Tower Telescope Cylinder NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE MAIN LIFT CYLINDER RAISE THE TOWER BOOM AND THEN RAISE THE MAIN BOOM TO HORIZON TAL SUPPORT THE MAIN BOOM USING A SUITABLE BOOM PROP OR OVERHEAD LIFTING DEVICE 2 JLG Lift If working on the main lift cylinder raise the tower boom and then raise the main boom to horizontal Place a suitable boom prop approximately 1 in 2 5 cm below the boom If working on the tower tele scope oylinder raise the tower boom above horizon tal and extend the fly section approximately 1 foot 30 5 cm Shut down hydraulic system and allow machine to sit for 10 15 minutes Turn ignition switch to ON move control switch or lever for applicable cylinder in each direction then turn ignition switch to OFF This is done to relieve excess pressure in the hydraulic lines Carefully remove hydraulic hoses from appropriate cylinder port block There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made If the retract port is leaking the piston seals are defective and m
26. 5 17 SECTION 5 HYDRAULICS to increase pressure counterclockwise to decrease to increase pressure counterclockwise to decrease pressure Tighten locknut pressure Tighten locknut FRONT AXLE RETRACT al REAR AXLE ae D 6 Bottom out Rear Axle Extend function 10 The two valve sections controlling the front and rear 7 Loosen locknut on applicable valve section and turn jack cylinders are controlled by system pressure adjusting screw to adjust valve section to 2000 psi and are non adjustable 138 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut REAR AXLE EXTEND Bottom out Rear Axle Retract function Loosen lock nut on opposite side of valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise 5 18 JLG Lift 3120679 SECTION 5 HYDRAULICS 5 7 HYDRAULIC GEAR PUMP 3 Lift off the port end cover If prying is necessary be careful not to damage the machined surfaces Dowel pins will remain in either port end cover or Disassembly gear housing Do not remove the dowel pins A CAUTION DO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURING ASSEMBLY OR DISASSEMBLY 1 Place the pump in a vise with the drive shaft pointing down Match mark all sections Be sure to align
27. 542 Nm 11 Nm 80 ft Ib 100 Ib Master Cylinder 108 Nm 11 Nm Platform Level 80 ft Ib 100 in Ib Cylinder 108 Nm 11 Nm 80 ft Ib 100 in Ib Steer Cylinder 108 Nm 11 Nm Axle Extend 100ft Ib 100 in Ib Cylinder 136 Nm 11 Nm Axle Lift 400 ft Ib Cylinder 542 Nm NOTE Self locking setscrews used on piston nuts should be discarded and replaced whenever they are removed 8 If applicable install the setscrew s which secure the piston attaching nut to the diameter groove 9 Remove the cylinder rod from the holding fixture JLG Lift 5 9 SECTION 5 HYDRAULICS 10 11 Place new o rings seals the applicable out side diameter grooves of both the piston and the cyl inder head Position the cylinder barrel in a suitable holding fix ture EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 12 13 14 15 16 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder or if applicable until the cylinder head threads engage the thr
28. Inspect extend chain and retract chain sheave pins for scoring tapering ovality and evidence of correct lubrication Replace pins as necessary Inspect telescope cylinder sheave pin for tapering scoring ovality and evidence of correct lubrication Replace pin as necessary Inspect boom pivot pin for wear scoring or other damage and for tapering or ovality Replace pin as necessary Inspect upper lift cylinder attach pin for tapering ovality scoring wear or other damage Ensure pin surfaces are protected prior to installation Replace pin as necessary Inspect telescope cylinder trunnion attach pins for tapering ovality scoring wear or other damage Replace pins as necessary Inspect extend chain attach clevis pins for wear scoring or other damage Replace pins as neces sary Inspect telescope cylinder rod attach pin for scoring wear or other damage Replace pin as necessary Inspect inner diameter of boom pivot bushing for Scoring distortion wear or other damage Replace bushing as necessary Inspect all wear pads for excessive wear or damage Replace pads when worn to within 1 8 in 3 2 mm of insert Inspect extend and retract chains and chain attach component for cracks stretching distortion or other damage Replace components as necessary Inspect all threaded components for damage such as stretching thread deformation or twisting Replace as necessary Inspect structural units of boom as
29. Install new bearing 54 in housing and press until bearing bottoms on shoulder in housing 3 Position new large diameter disc 50 in housing with tabs guided by dowel pins 53 until disc rests on springs 51 52 DISCS 46 50 AND FRICTION DISCS 48 SHOULD REMAIN DRY DURING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES 4 Place a new friction disc 48 on bottom disc 50 centering it as closely as possible Insert one spring 47 on each dowel pin 5 Add additional new discs 46 new friction discs 48 and springs 47 as required for specific model 6 Install snap ring 44 on shaft 45 Insert shaft 45 thru friction discs 48 until shaft contacts bearing 54 Press shaft 45 until it shoulders on inner race of bearing A small preload will exist on snap ring 44 at this point 7 Insert separators 49 over spiral pins in housing 56 Separators will contact top of bottom disc 50 when properly installed 8 Install new o ring 38 new back up ring 39 new ring 41 and new back up ring 42 on piston 40 Insert piston 40 into end cover 34 being careful not to shear o rings or back up rings Inserting 1 4 20 UNC bolts in piston may simplify installation 9 Install new o ring 36 new bearing 37 new square ring 35 pipe plug 33 and bleeder screw 43 in end cover 10 Position end cover 34 on housing aligning dowel pin 53 with holes in end cover
30. Lift or pry off the first section gear housing 11 Ifthe pump is equipped with an outboard bearing ful not to damage machined surfaces Examine and place the shaft end cover in the vise with the mount replace if necessary ing face up Remove the snap ring with snap ring pli ers If the unit is equipped with a spiral lock retaining ring remove with a small screwdriver or awl 10 Inspect all bushings for scoring or discoloration and replace if necessary Use a bushing puller as shown the tool list to remove bushings 12 Use a bearing puller to remove the outboard bear ing F 3120679 JLG Lift 5 23 SECTION 5 HYDRAULICS 13 Grip the shaft end cover vise with the mounting face down Remove the double lip seal by inserting the special seal removal tool into the notch between the double lip seal and the shaft end cover Tap the seal out and discard Remove and discard all rubber and polymer seals Assembly 1 Stone all machined surfaces with a medium grit car borundum stone t 5 24 JLG Lift If bushings have been removed deburr the bushing bores with emery cloth Rinse parts in solvent Air blast all parts and wipe with a clean lint less cloth before starting assembly Grip shaft end cover in a vise with the mounting face down Examine the plug or plugs to be sure they re tightly in place Replacement is necessary only if parts are damaged Remove wit
31. Swing Bearing Bolt Feeler Gauge 3 21 3 19 Swing Bearing Tolerance Measuring 3 23 3 20 Swing Bearing Torquing Sequence 4 3 24 3 21 Swing Torque HUD on ete yaa keane ahs a hoes ea chi saa 3 25 3 22 Swing Brake Ausco Machines Built to 1992 3 30 3 23 Swing Brake Mico Machines Built to 1992 3 32 3 24 Swing Brake Machines Built 1992 to 3 34 3 25 SWING Motor ees Ie ter e eer EMEN sr deed Eee te eie 3 37 3 26 Lovejoy Coupling 2 2 eoe ep e en tree he d RD A EG RR erdt 3 39 3 27 Hayes Coupling u u nuy Sua sua a kuu IPM ne E RIDE edo 3 40 3 26 Tilt Switch Adjustment 1 5 3 40 3 27 Switch Adjustment Voltmeter 3 41 3 28 Throttle Checks and Adjustments Deutz 3 42 4 1 Boom Mounted Limit Switches and Valves Installation 4 2 4 2 Main Boom Assembly Sheet 1 2 4 4 4 3 Main Boom Assembly Sheet 2
32. The following information is provided to assist you in the use and application of servicing and maintenance proce dures 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 1 2 2 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions 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 discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter Clean and inspect all parts during servicing or main tenance 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 contain ers until they are
33. WHT BLU J 5 RESS rd 2 7 GRY RED 49 GRY BRN JACK SWITCH at AXLE SWITCH 3120679 REAR RED ORN 1 RED ORN 1 FRONT AXLE REAR FRONT AXLE AXLE AXLE GRY ORN JACK SWITCH AXLE SWITCH Figure 6 4 Electrical Schematic Sheet 4 of 5 Lift WHT YEL BROWN 1870233 B 6 25 SECTION 6 SCHEMATICS REF CONTROLLER PIN COLOR FUNCTION i BLACK GROUND 2 ORANGE 5 AUX TOWER TOWER 3 RED V S t MET TELESCOPE 4 WHT ORN E O T AUX H 5 YELZBLK COW 6 YELZRED CW LT ME 7 GRAY CREEP 8 5 5 58 L SEARE lt S288 lt 9 SPARE fata gg gt gt gt gt 21724262 2474262 qae n TE RED IIRIz25 lu BROWN mg ORANGE 104 GRAY g WHITE e WHITE 2 ORN YEL 8 n 5 z zx Ow gt 8 lt i eSess sf 6 l m WHT BRN M A 2 AAAA z BLUE 6 YEL BLK ii S
34. bearing and return to service NOTICE 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 Replacement and Devcon Application Procedures REMOVAL 1 From ground control station operate tower boom lift control and raise tower boom adequately to provide access to rotary coupling A WARNING NEVER WORK BENEATH THE BOOM WITHOUT FIRST PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND OR BLOCKING 2 Attach an adequate support sling to boom and draw all slack from sling Block boom if feasible From under side of machine frame remove bolts lockwashers which attach rotary coupling retaining yoke to coupling housing NOTICE HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMI NANTS INTO THE SYSTEM 4 Lift Tag and disconnect hydraulic lines from fittings on top and sides of rotary coupling Use a suitable con tainer to retain any residual hydraulic fluid Immedi ately cap lines and ports Attach suitable overhead lifting equipment to base of turntable weldment Using a suitable tool scribe a line on inner race of swing bearing and on underside of turntable This line will aid in aligning bearing upon installation Remove bolts nuts and wash
35. der Plug ports in swing motor After installing temporary hoses use auxiliary power and activate swing function to fully retract lower master level cylinder Remove temporary hoses from lower master level cylinder and cap them Plug cylinder ports Remove bolt and lockwasher securing barrel end attach pin to turntable Using a suitable brass drift drive out barrel end attach pin from cylinder Remove cylinder from turntable 3120679 SECTION 5 HYDRAULICS Lower Master Level Cylinder Installation 1 With tower boom partly raised and properly sup ported align level cylinder barrel end bushing with pin attach blocks in turntable and install barrel attach pin using appropriate brass drift Secure pin with bolt and lockwasher Remove caps from temporary hydraulic lines and attach to level cylinder ports Using auxiliary power activate swing function and extend cylinder rod until rod bushing aligns with cylinder rod end attach points on base boom Using an appropriate brass drift drive rod attach pin through aligned bushing of cylinder rod end and boom attach points taking care to align pin attach hole with hole on boom Secure rod end attach pin with bolt and lockwasher Remove temporary hydraulic lines from cylinder ports and turntable swing motor hydraulic supply Reattach hydraulic supply to swing motor Remove caps from cylinder hydraulic lines and cor rectly install lines to cylinder Remove supports fr
36. i E 1 x 5 d MAIN Z 0 y LIFT Sa 9 amp x zx Ow iiir 2 142 1 FEET SEE 1 dotggS ORN RED 174 AA M A 4 RED YEL 1i28l RA BLK YEL w l gt WHT BRN GRAY 1 WHITE BRN BLK gu u YEL ORN 125 BRN ORN 26 5 i WHT BRN YEL RED T BRN RED a PLATFORM ENS o CREEP BLU RED 4 GRY YEL g YEL BLU 129 gt X BLK RED 6 H START GRY YEL sTo BLACK 103 ENABLE ROTATE LEVEL EUN RED BLK 97 GRY YEL t 1 1 if RED ORN 123 L Q BLU BLK BLK BLU ORN BLU 115 RED BLU ma 6 26 Figure 6 5 Electrical Schematic Sheet 5 of 5 JLG Lift 1870233 B 3120679 SECTION 6 SCHEMATICS This page left blank intentionally 3120679 JLG Lift 6 27 SECTION 6 SCHEMATICS 4 SPOOL SOLENOID VALVE Eee eed 43 um gt
37. 131 K 0 15 In Sq In LB IN LB N m IN LB N m IN LB 4 40 0 1120 0 00604 48 0 1120 0 00661 6 32 01380 00009 _ _ 40 01380 0 01015 _ 8 32 0 1640 001400 36 0460 0 01474 150 43 5 10 24 0 1900 001750 180 60 7 32 01900 00200 1800 68 8 5 7 5 5 5 0 0 5 2 2 3 3 5 6 8 9 1 129 1 __ 28 0250 0 0364 3280 164 19 148 1 HERE Sq In 24 0 3125 0050 520 2 3 25 35 20 38 16 03750 0 0775 700 45 60 40 5 3 24 0 3750 0 0878 7900 5 72 45 6 3 20 0437 0 1187 10700 so no 70 9 60 20 0500 0 1599 14400 120 165 10 150 90 18 0565 0 2030 18250 10 20 15 210 130 18 06250 02560 23000 20 35 25 290 180 30100 375 510 340 460 80 895 1160 1300 1635 1810 2145 2435 2845 3200 3 4 10 16 78 9 14 1 8 12 1 0000 0 6630 59700 95 1355 12 1 1250 0 8560 77000 1445 1965 12 12500 1 0730 96600 2015 2740 138 6 13750 1 1550 104000 2385 3245 12 13750 13150 118100 2705 3680 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000053 REV 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER S
38. Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Clean all parts thoroughly before assembly 2 Press new rotary oil seal 23 into housing 21 Note direction of the seal NOTE Earlier models did not use retaining ring 22 3 Install new bearing 19 and retaining ring 22 shaft 10 4 Insert shaft assembly and retaining ring 18 in hous ing 21 NOTE Be sure to use the same number of springs spring pattern as recorded during disassembly Spring retainer 17 was not used in earlier models 5 Insert dowel pins 20 spring retainer 17 and springs 15 amp 16 in housing 21 3120679 SECTION 3 CHASSIS amp TURNTABLE Capscrew Shaft Bearing End Cover Disc Dowel Pin Bleeder Screw Friction Disc Housing Case Seal Separators Retaining Ring O ring Return Plate Rotary Oil Seal Back Up Ring Spring O ring Piston Spring Gasket O ring Spring Guide Pin Backup Ring Retaining Ring 1 2 3 4 5 6 7 8 9 Figure 3 3 Drive Mico March 1992 to S N 33746 3120679 Lift 3 15 SECTION 3 CHASSIS amp TURNTABLE 6 Position new large diameter return plate 14 in housing with tabs guided by dowel pins 20 until disc rests on springs 15 amp 16 NOTICE DISCS 11 14 AND FRICTION DISCS 12 SHOULD REMAIN DRY DURING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CON
39. Cylinders 5 2 Cylinders w Single Counterbalance Valves Main Lift Cylinder Tower Telescope Cylinder 4 5 2 Cylinders w Dual Counterbalance Valve Main Telescope Cylinder Tower Lift Cylinder Platform Slave Level 5 3 Cylinder Removal and Installation 5 3 Tower Telescope Cylinder 5 3 Tower Telescope Cylinder Installation 5 4 Tower Lift Cylinder 1 5 4 Tower Lift Cylinder Installation llis II 5 4 Main Telescope Cylinder 5 5 Main Telescope Cylinder Installation 4 5 5 Main Lift Cylinder 5 6 Main Lift Cylinder Installation isses RII III 5 6 Lower Master Level Cylinder 5 6 Lower Master Level Cylinder Installation 5 7 Upper Master Level Cylinder 5 7 Upper Master Level Cylinder 5 7 G linder Repair DA
40. DAMAGE I E ELECTRONIC MODULES SWING BEARING COLLECTOR RING BOOM WIRE ROPES ETC JLG Lift 2 5 SECTION 2 GENERAL Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Delivery2 4 s a Maintenance Maintenance Inspection Inspection Boom Assembly 9 Boom Weldments 1 2 4 1 2 4 Hose Cable Carrier Installations 1 2 9 12 1 2 9 12 Pivot Pins and Pin Retainers 1 2 1 2 Sheaves Sheave Pins 1 2 1 2 Bearings 1 2 1 2 Wear Pads 1 2 1 2 Covers or Shields 1 2 1 2 Extend Retract Chain Cable Systems 1 2 3 1 2 3 Platform Assembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Gate 5 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 15 Lanyard Anchorage Point 2 1 2 10 1 2 10 Turntable Assembly 9 Swing Bearing oor Worm Gear 1 2 14 1 2 3 13 14 Oil Coupling 9 Swing Drive System 11 11 Turntable Lock 1 2 5 1 2 5 Hood Hood Props Hood Latches 5 1 2 5 Chassis Assembly 9 Tires 1 16 17 16 17 18 16 17 18 Wheel Nuts Bolts 1 15 15 15 WheelBearings 14 24 Oscillating Axle Lockout Cylinder Systems 5 8 Outrigger or Extendable Axle Systems 5 8 5 8 Steer Components Drive Motors Drive Hubs 11 11 24 Functions Controls 9 Platform Controls 5 5 6 6 2 6 JLG Lift 3120679 SECTION 2 GENERAL Table 2 3 Inspection and Preventive Maintenance Schedule
41. Discard bearings if the races and balls or rollers are pitted scored or burned 3 If bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing 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 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If 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 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices See Torque Chart Section 1 3120679 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydr
42. Flat Side of Seal Thrust Plate 14 15 JLG Lift Gently slip the thrust plate through the gear housing and into place on the shaft end cover The channel seal from step 13 should face the shaft end cover The relief groove in the plate should face the outlet side of the pump Slide the driven gear through the housing and into the bushing in the shaft end cover Coat the steel sleeve tool with grease Place the lightly greased drive shaft inside the sleeve and slide both through the shaft end cover with a twisting motion until the integral gear rests against the thrust plate Avoid damaging the double lip seal Remove the steel sleeve Squirt clean oil over the gears 5 27 SECTION 5 HYDRAULICS 16 17 5 28 Slip the thrust plate with seal over gear journals 18 into the housing bore The flat side of the seal should face up with the relief groove facing the out let side Position the bearing carrier over the gear housing so the bushings receive the journals of the drive and driven gears Be sure to line up the dowel holes over the dowel pins When the parts are parallel squeeze them together or alternately tap over each dowel until the parts are together JLG Lift 19 Insert the connecting shaft in the spline of the drive gear Position and place the second gear housing on the bearing carrier as outlined in step 12 Place the thrust plate in the gear
43. Inspection must be performed by a Factory Trained Service Technician on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc rec ognizes 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 appropri ate JLG inspection form for performance of this inspec tion 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 man ual 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 mainte nance 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 train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product mod
44. Level Cylinder Rod End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 17 Level Cylinder Barrel End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 18 Engine Crankcase Lube Point s Fill Cap Drain Plug Capacity 10 quarts 9 5 L w o filter Lube EO Comments Check daily Refer to Engine Manual for Change interval 3120679 SECTION 1 SPECIFICATIONS 24 Main Pivot Pin Lube Point s N A Lube Point s 1 Grease Fitting Lube EO Capacity A R Comments Refer to Engine Manual for Change Lube MPG interval Interval Every 3 months or 150 hrs of operation 20 Main Boom Chains Lube Point s N A Capacity N A Lube Chain Lube Interval Every 2 years or 1200 hours of operation 25 Tower Boom Pivot Pin 21 Main Boom Extend Chain Sheave Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Align access holes in mid and fly boom 22 Main Boom Lift Cylinder Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 26 Level Links Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 23 Main Boom Retract Chain Sheave Lube Point s 1 Greas
45. Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France c 33 0 5 53 88 3170 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 A JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy FF 39 029 359 5210 39 029 359 5845 e Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 465 6591 9030 65 6591 9031 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 El 34 93 771 1762 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 www jlg com
46. 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 Approved for the application by the tire manufacturer including inflation pressure and maximum tire load 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 replace ment 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 The rims installed on each product model have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diam eter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque A WARNING WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSIBLE DANGEROUS SEPARATION OF WH
47. Pd r 3 4 PH REAR EXTENSION CYL ma 7 p 3 Het 5 125 72 FRONT FRAME LIFT CYL 1 amp EX J Lied 4G Pi REAR FRAME LIFT CYL S d DRIVE a BRAKES 1 R ATE 0 H 1 3 ups E I 1 I ES 23 1 2 SPD SELECT VALVE 4 FR x d FRONT EXTENSION CYL RES B d 4 o vi A Lu 1 ini x I TOWER LIFT cYL el i I Yo FRONT STEER CYL REAR CYL DC A 1 DN EE I LEE t 77 z LT IT il Xk BRAKE ERKE dl v 3 SPOOL SOLENOID VALVE MAIN LIFT CYL
48. Place bearing cones 29 into cluster gear While holding planet shaft in position slide cor rect spacer onto planet shaft j Place cluster gear into carrier with large gear up A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION m Place carrier on table with something under planet shaft to hold it in correct position and install retaining ring 25 k Slide planet shaft through carrier and cluster gear from bottom side Slot in planet shaft must line up with roll pin hole in edge of carrier A CAUTION EYE PROTECTION SHOULD BE WORN DURING THIS OPERATION n Drive roll pin 24 into carrier Use a punch to drive roll pin completely into planet shaft 3120679 JLG Lift 3 9 SECTION 3 CHASSIS amp TURNTABLE Repeat steps a through n for remaining two cluster gears 10 Time carrier gears as follows a Place carrier assembly on a flat surface posi tioning two top gears at ten o clock and two o clock and one bottom gear at six o clock as shown in Figure 3 2 Torque Hub Carrier Timing b Find marked punch mark teeth on large gears Rotate gears until punch mark is located in a straight up 12 o clock position Punch marks at ten o clock and two o clock will be located just under edge of carrier and not readily visible 11 Taking care to ensure that timing is maintained install ring gear 13 in mesh with large diameter cluster gear Side
49. Rotary Valve 11 Spline Shaft CheckValve Ball 12 Body Bearing Assembly IGR Assembly 13 Cover Bearing Assembly Snap Ring Figure 3 25 Swing Motor 3120679 JLG Lift 3 37 SECTION 3 CHASSIS amp TURNTABLE 3 12 PQ CONTROLLERS 14 Using all applicable safety precautions start machine and allow hydraulic oil to reach a tempera ture of 100 to 140 degrees 38 to 60 degrees C TRIM Adjustment ii nd 15 Depress footswitch and operate controller until trail 1 Disconnect ORANGE RED dump wire from appli ing edge of slide lock is even with housing lock cable terminal strip in platform console notch Hold control handle in that position 2 Install ammeter capable of measuring from zero to 2 16 Adjust LO trimpot until applicable function just starts amps in series with either valve coil B or D to work Immediately stop adjustment 3 Position IGNITION EMERGENCY STOP switch to 17 Release footswitch and stop machine ON but do not start engine 18 Seal each trimpot with a drop of enamel paint to pre 4 Depress footswitch vent maladjustment due to vibration 5 Operate controller until trailing edge of slide lock is 19 Install controller and secure machine even with housing lock notch Hold control handle in that position RANP Adjustment 6 Using correct size common blade screwdriver Controllers equipped with the RAMP feature actu adjust LO trimpot until am meter indicates 300 ma ally compensate for
50. The Operator and Safety Manual must be read in its entirety and understood prior to per forming 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 recog nized 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 pro cedures are performed in the same manner but at differ ent 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 ser vice 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 3120679 Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection The Annual Machine
51. adhesive once out of contact with air it begins to set Read steps j thru m before performing them as quickly as possible j Apply Loctite 277 to threads of locknut 8 DO NOT put Loctite on shaft threads k Thread locknut onto shaft making sure that chamfered side of locknut is facing toward lock washer and tighten locknut down by hand 3120679 JLG Lift 1 Using torquing tool and locknut wrench torque locknut to 175 ft Ib 237 Nm One tab of lock washer should be aligned with slot in locknut when torquing is done Tighten locknut to align slot if necessary but NEVER LOOSEN THE LOCKNUT m Check final rolling torque Put a torque wrench on bolt in hub and keeping torque wrench tan gent to bolt circle pull torque wrench smoothly toward you Final rolling torque must be 5 10 in Ib 0 6 1 Nm greater than initial reading If final reading is correct proceed to step o If not perform step n n If final rolling torque is less than 5 10 in Ib 0 6 1 Nm higher than initial reading tighten locknut slightly and re measure If final rolling torque is greater than 5 10 in Ib 0 6 1 Nm higher than initial reading remove locknut and lockwasher remove Loctite from all parts and repeat steps g through m to reinstall parts o Remove bolt 31 from bolt circle of hub and bend aligned tang of lockwasher into slot in locknut p Stake locknut in four equally spaced places 1 8 inch 3 2 mm from
52. and lift cover from unit Remove o ring 14 from counter bore of cover Disassemble cover 4 as follows a Remove two bolts 12 securing disconnect cap 11 to cover and remove disconnect cover b Remove two bolts 12 securing cover cap 7 to cover and remove cap c Remove disconnect rod 9 from cover cap and remove o rings 8 and 10 from cover cap Dis card o rings d If necessary remove pipe plugs 5 and 6 from cover Remove two thrust washers 15 and thrust bearing 16 from carrier counterbore One thrust washer may stick to cover Inspect thrust washers and bear ing for wear and replace if necessary Lift carrier assembly 22 from hub and spindle assembly 30 Disassemble carrier as follows A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL a Remove retaining ring 25 from planet shaft 23 10 b Remove spacer 26 from planet shaft then using a suitable drift drive planet shaft from car rier shearing off roll pin Tap remaining roll pin from carrier using a suitable punch c Remove cluster gear 27 from carrier and remove bearing cones 29 from cluster gear If necessary press bearing cups 28 from clus ter gear Lift ring gear 13 from housing 36 Remove o ring 14 from counterbore of ring gear and discard Remove input sun gear 17 input spacer 18 and input shaft 20 from spindle 30 Remove two thrust washers 15 and thrust b
53. as an aid to pin alignment during boom assembly Using a suitable slide hammer remove trunnion pins attaching telescope cylinder to mid section Remove cotter pins and chain attach pins attaching fly retract chains to chain clevis at lower aft end of fly section and remove chains Remove setscrews which attach retract chain sheave pin at lower aft end of mid section Using a suitable brass drift carefully drive sheave pin from mid section and remove sheave If neces sary remove bushings from sheave and replace Ensure that pins grease fittings and corresponding boom and sheave surfaces are not damaged Pull fly section out several feet to allow ample clear ance for telescope cylinder removal Using suitable lifting equipment carefully slide tele scope cylinder out of fly and mid sections along with extension chain Carefully lift telescope cylinder clear of boom assembly and lower to ground or suitably supported work area Note and record number and thickness of any wear pad shims during wear pad removal Remove bolts and lockwashers which attach upper aft mid section wear pads and remove pads and any shims 3120679 SECTION 4 BOOM amp PLATFORM 29 30 31 32 33 Remove bolts lockwashers which bottom wear pads at front of outer mid section and remove pads and any shims Remove bolts and lockwashers which attach side wear pads at front of mid section and remove pads an
54. dle safety deadman switch failed Improper null ofthe handle with the handle safety deadman switch failed Too much rampin controller Microswitch in controller bad Controller improperly adjusted Checkthe safety deadman switch and replace Re adjustthe null ofthe handle Checkthe safety deadman switch and replace Readjustthe null ofthe potentiometer Adjustramp as required Replace microswitch Adjust controller Regardless of which way the handle is moved only one function occurs Improper wiring or loose wiring to the solenoids or potentiometer Printed circuit board failure Potentiometer needs adjusted Spool stuck in valve bank Check all wiring for proper connections Replace printed circuit board or use a handle assembly from the circuit thatis presently work ing to check valve Adjust potentiometer as required Clean replace spool 3120679 JLG Lift 6 19 SECTION 6 SCHEMATICS Table 6 6 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function occurs very rapidly when handle is moved in one direction and very slowly when moved in the opposite direction Improper null ofthe handle Potentiometer off center Defective printed circuit board Checkand re adjust null Center potentiometer Replace printed circuit board Valve will notfunction when handle is moved in either direction No electrical power to handle
55. e RULES 5 8 Disassemble X ee il reete e ese tive ae eee Teo e I GO Ue d DRE 5 8 Cleaning and 5 8 Assembly ss aaa EN EPOD EPA IR PAAR 5 9 Pressure Setting Procedutes E 5 11 Eow Brive System ure bester Eu ED Gate T Ed dete d 5 11 5 Stack Directional Control Valve Internal Relief Adjustment 5 11 5 Stack Directional Control Valve External Relief Adjustment 5 12 Two Stack Directional Control 1 5 16 Three Stack Directional 1 5 16 Four Stack Directional Control 5 17 Hydraulic Gear PUMP so o t pa TA e weg subs rci Ee 5 19 Disassembly eiernes aa eran aa se oe e a den wu A dde Pe d 5 19 Assembly cese cicero x e I Rede ROTE lod hd ar quam au 5 24 Wear Guide for Replacement 2 01 5 29 Recommended Start up Procedure for New or Rebuilt 5 30 Recommended Test Procedure 5 30 Gen ral ze EE REG LEUR REM DUET SM UE 6 1 Troubleshooting luu iqu Re rev de queden OE OR A med 6 1 Hydraulic Circuit
56. filters at the same time Lift 1 5 SECTION 1 SPECIFICATIONS 1 Torque Hubs Lube Point s 1 Fill Plug per hub Capacity Lube EPGL Interval Check oil level at side plug on hub weekly Change after first 3 months 150 hours then every 2 years or 1200 hours of operation Comments Place Fill port at 12 o clock position and pour lubricant into fill port until it just starts to flow out of check port when it s at the 3 o clock position 2 Steer Spindles Lube Point s 4 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 1 6 JLG Lift 3 Tie Rod Center Pivot Links Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 4 Steer Oylinder Barrel Ends e Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 5 Steer Cylinder Rod Ends 2 Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 3120679 SECTION 1 SPECIFICATIONS 6 Extending Axles p Lube Point s N A Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Apply by brush 7 Swing Bearing Gear Lube Point s N A Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Apply by brus
57. head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect thread ring for scoring or other damage Dress threads or applicable surfaces as necessary If applicable inspect rod and barrel bushings for signs of correct lubrication and excessive wear Replace as necessary 3120679 SECTION 5 HYDRAULICS 14 15 16 17 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 7 Push the piston onto the rod until it abuts the spacer end and install the attaching nut A WARNING IF CYLINDER IS EQUIPPED WITH A PISTON NUT APPLY LOC QUIC PRIMER T AND JLG THREADLOCKER P N 0100011 TO PIS TON NUT THREADS THEN TIGHTEN NUT TO TORQUE SHOWN IN Table 5 1 Ta
58. increase pressure on pump in 500 psi incre ments until the desired test pressure has been reached This should take about five minutes Delivery should run close to rated performance figures which are averaged from testing several pumps Some thing like a 5 lower reading may be used as a rated min imum if new or relatively new parts have been used When rebuilding the pump with parts from the original pump which while worn appear satisfactory for reuse a 10 or 15 lower reading may be permitted depending on the performance expected from the equipment One s own experience will prove the best guide here Many repairmen measure the output at normal operating speed and at zero pressure then again at 1000 psi or the operating pressure of the equipment and allow a volume decrease approximating the listing below It is a sug gested reference only which makes allowance for reused parts GPM GPM DROP OFF AT DELIVERY at 1800 rpm 1000 psi 70 2000 psi 140 3000 210 100psi bar bar bar 10 30 1 5 3 2 3 5 2 5 4 30 50 2 3 2 5 4 3 4 5 50 70 2 5 3 5 3 5 3 5 5 5 At test speeds other than 1800 rpm gpm delivery wilt vary almost proportionately but the same drop oft figures should be used Be sure to run the pump in the direction for which it was designed and built Driving pump in the wrong direction will build up pressure behind shaft seal damaging it and necessitating replacement Aft
59. inner edge of locknut q Apply a light coat of Never Seize to three mag netic pipe plugs 12 and install then into side of hub r Turn unit over onto its wide end Using a seal pressing tool press seal 10 seal lip facing up into hub around end of shaft S Apply a light coat of Never Seize to pipe plug 11 and install it into bottom of hub near shaft Assemble carrier assembly 16 as follows a Apply a light coating of petroleum jelly or multi purpose grease to inside of one cluster gear 19 and line inside of large end of cluster with nine teen needle rollers 13 b Place spacer 17 on top of needle rollers inside cluster gear 3 27 SECTION 3 CHASSIS amp TURNTABLE c Apply a light coating of petroleum or multi pur pose grease to inside of small end of cluster and line inside of small end of cluster gear with nine teen needle rollers 13 d Stand carrier housing 16 on its side Insert a planet shaft 14 end with roll pin last into one of the planet shaft holes in carrier housing e Note tab on thrust washer 15 Place thrust washer onto end of planet shaft in carrier hous ing placing tab of washer into slot in side of car rier housing f Following the thrust washer place assembled cluster gear large end toward roll pin holes onto planet shaft g Following the cluster gear place one more thrust washer 15 onto planet shaft placing tab of thrust washer into slot in side
60. of carrier housing Now insert planet shaft into opposite planet shaft hole in carrier housing h Using an alignment punch align roll pin holes in carrier housing and planet shaft then drive roll pin 18 into the aligned holes i Repeat steps a through h to assemble and install remaining two cluster gears Place hub assembly 9 on work surface with open end facing up Oil all exposed surfaces inside hub then lower inter nal gear 20 small end down into hub A CAUTION BEWARE OF SHARP EDGES AND BURRS IN THE COUNTERBORE WHEN INSTALLING O RING 5 Grease and place o ring 23 into counterbore of 3 28 hub O ring can be made to fit counterbore exactly by stretching it if it is too small or by squeezing it together bit by bit as it is placed around the counter bore if it is too large Place carrier assembly on work surface so one planet shaft hole faces you and other two planet shaft holes are opposite you Line up punch marks on gear teeth of carrier assembly to the 12 o clock position as shown in Figure 3 2 Place ring gear 21 onto carrier to keep punch marks in position Lower carrier assembly into hub meshing gears of carrier with internal gear splines Place input gear 25 down into hub into middle of carrier Lift ring off of carrier carefully so carrier gears do not move and replace ring gear 21 onto hub ensuring bolt holes in hub and ring gear are aligned A CAUTION BEWARE OF S
61. replace valve as necessary FUEL SYSTEM Strong fuel odor during machine operation Fuel tank overfilled Fuel tank damaged Fuel line from tank damaged Check fuel tank and immediately wipe up spilled fuel Drain all fuel from tank and remove tank for replacement or repair Replace fuel line 3120679 JLG Lift 6 9 SECTION 6 SCHEMATICS Table 6 4 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY FRONT AXLE AREA Oneor both front wheels will not steer Steering link ortie rod broken or attaching hardware missing Replace steering link tie rod or hardware as necessary Oneor both front wheels will not rotate or rotate erratically Wheel hub or bearings damaged or not lubri cated Hub attachment nut loose or missing Replace hub or bearings as necessary and repack bearings with approved grease Secure or replace hub attachment nut cotter pin as necessary Difficulty encountered when moving machine Load capacity exceeded Machine being moved up too steep a grade Gradetoo steep Drive wheel tire treads worn smooth System pressure too low Reduce load Apply loads only in accordance with load capacity indicator Remove machine from grade and check that drive system operates correctly See Caution Placard on platform for specified grades and sideslopes Replace tires as necessary and inflate to s
62. retained on shaft by snap ring 7 Do not remove this snap ring Remove two check valve balls 5 Check balls fre quently fall into body tapped holes or into body valve ports during disassembly Ensure check balls are removed and accounted for Remove shaft 11 IGR element and rotary valve as one assembly With shaft assembly removed from body inspect IGR inner component rotary valve and shaft for wear or other damage Shaft should have a smooth polished surface in bearing and seal areas If any of these components are damaged snap ring must be removed and appropriate component replaced If snap ring is removed discard it and install new snap ring Quad ring seal 3 and back up ring 2 can be removed using a dull pointed object such as a pen cil point or the end of a paper clip DO NOT use a sharp object such as a knife because the sealing surface in the body can be damaged Assembly NOTE Prior to motor assembly lightly oil all seals rollers 10 11 12 Lift and threaded bolt ends Install new back up ring 2 first pushing it sealing surface toward outside of motor Back up be seated with a dull object Install new quad ring 3 by pushing it against inboard side of back up ring Lubricate inside diameter of quad ring and back up ring with oil or Vaseline Check output shaft 11 end for burrs and scratches Deburr if necessary Shaft must be free of burrs to avoid cutting
63. to the extend port Open the bleeder port plug TP venting all trapped air to atmosphere Retighten the bleeder port plug Disconnect the hydraulic power source and remove plug from retract port An alternative to steps 18 through 20 is to posi tion the barrel horizontally in a suitable holding device attach a hydraulic power source to both extend and retract ports while supporting the cylin der rod cycle the cylinder a minimum of 5 times with the bleeder port unplugged venting all trapped air to atmosphere A suitable hose may be attached to the bleeder port with the end in a container suitable to contain the hydraulic fluid After all air is vented remove all attached hoses and install the bleeder port plug Also plug the extend and retract ports until cylinder is installed in boom 3120679 SECTION 5 HYDRAULICS 5 6 PRESSURE SETTING PROCEDURES Cold temperatures have a significant impact on pressure readings JLG Industries Inc recommends operating the machine until hydraulic system has warmed to normal operating temperatures prior to checking pressures It is also recommended that a calibrated gauge is used Pres sure readings are acceptable if within 5 of specified pressures Low Drive System NOTE Make all drive pressure adjustments with pressure gauge plugged into quick connect on the propor tional relief and dump valve 1 Sequence Pressure a Using a suitable hot wire activate dump
64. tower boom 7 Usingaslide hammer or similar tool and taking care not to damage pin remove pin from tower boom 8 Carefully remove main lift cylinder from tower boom and place in a suitable work area 9 Remove bolts and lockwashers securing tower lift cylinder rod end attach pin to tower boom 10 Using a slide hammer or similar tool and taking care not to damage pin remove pin from tower boom 11 Using all applicable safety precautions and only if necessary operate tower lift down and fully retract tower lift cylinder 3120679 12 13 14 15 16 17 18 Shut down machine systems Tag and disconnect all wiring to ground control box Remove the bolts and lockwashers securing the lower master cylinder rod end to the tower boom Using a slide hammer or similar tool and taking care not to damage pin remove pin from tower boom Remove cylinder rod end from tower boom Remove bolts and lockwashers securing tower boom pivot pin to turntable Ensuring that boom is adequately supported and using a suitable slide hammer carefully remove pivot pin from tower boom and turntable Ensure that main boom and turntable are not damaged Carefully lift tower boom assembly clear of turntable and lower to ground or suitably supported work sur face Main Boom Disassembly NOTE Left or right is determined facing the machine from the platform Loosen the right side powertrack bracket and pow ertrack and lay on t
65. 0 quarts 9 5 liters w o filter Cooling System System Engine Radiator 21 4 quarts 20 2 liters 7 4 quarts 7 0 liters 14 0 quarts 13 2 liters Torque hubs should be one half full of lubricant 1 2 ENGINE DATA Table 1 2 Engine Datas Model Cummins 4B3 9C Low RPM 1800 High RPM 2500 Alternator 60 Amp belt driven Battery 85 Amphour 550 CCA 12 volts Horsepower 76 2500 RPM no load 1 3 DRIVE STEER SYSTEM Table 1 3 Drive Steer System Drive Hub Gear Ratio 93 7 1 Drive Brake Automatic spring applied hydrau lically released Release pressure 150 psi 10 3 Bar initial 170 psi 11 7 Bar full Tires Size 445 65R22 5 foam filled 3120679 Table 1 4 Performance Data Maximum Drive Speed 2 7 mph 4 3 kph Max RPM Maximum Travel Grade Grade 3196 ability Turning Radius Outside 24ft 2 in 7 4 meters w axles retracted 27 ft 2 in 8 3 meters w axles extended Gross Machine Weight 57 000 Ibs 25 855 kg Length Stowed 39ft 5 in 12 0 meters w main boomfully retracted and platform in normal position 41 ft 7 in 12 7 meters w main boom telescoped out and plat formtilted to stow at minimum height Machine Width 11 ft 3 5 meters w axles retracted 18 ft 0 in 5 5 meters w axles extended Wheelbase 18 ft 0 in 5 5 meters Platform Capacity 500 Ib 230 kg unrestricte
66. 12500 1030 96600 2015 2740 1810 240 1510 2055 13 8 6 1375 1 1550 10400 2385 3245 2145 2915 1785 2430 oo 112 6 1 5000 1 4050 126500 3165 4305 2845 3870 2370 3225 12 T 15000 1 5800 142200 3555 4835 3200 4350 2665 3625 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 5 Torque Chart SAE Fasteners Sheet 4 of 7 1 14 JLG Lift 3120679 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque 10918 dne ion n Size PITCH Stress OR Vibra OR Vibra Area TM TM TITE 131 TITE 7111 or 140 ee 8 14 35 06 628 295 23 34 5 os 1420 618 6 8 6 1 2040 874 12 19 125 3660 159 28 55 97 14 2 154 16 2 241 18 2 5 331 20 2 5 469 22 2 5 639 24 811 27 459 1080 810 970 1130 30 33 561 1320 1530 694 2090 4 2690 45 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO
67. 330 49 28 363 523 1 8 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 12 1 0000 0 6630 42200 70 99 50 79 735 100 69 858 11 8 7 1 1250 0 7630 42300 800 1085 600 813 840 1142 714 968 1 1250 0 8560 47500 880 1193 660 895 925 1258 802 1087 12 1368 13 8 6 1 3750 1 1550 64100 1460 1979 1100 1491 1525 2074 1322 1792 12 13750 13150 7300 1680 2278 120 1708 1750 2380 1506 2042 11 2 6 1 5000 1 4050 78000 1940 2630 1460 1979 2025 2754 1755 2379 12 1 5000 1 5800 87700 2200 2983 1640 2224 2300 3128 1974 2676 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100019 27 Vibra TITE 140 High Strength Red 0100071 i Vibra TITE 131 Medium High Strength Red 0100011 220 Vvibra TITE 121 Medium Strength Blue Figure 1 2 Torque Chart SAE Fasteners Sheet 1 of 7 3120679 JLG Lift 1 11 SECTION 1 SPECIFICATIONS Tensile EOD Stress Area Torque Dry or Loctite amp 263 Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Loctite 242 or 271 OR Vibra TITE 111 or 140 K 18 Torque Loctite 262 or Vibra TITE
68. 39 3LIHM f 18 Nu8 N3o n18 N30 n18 18 Nu8 9 OPTIONAL PLATFORM WORK LIGHTS ee 1 84 511405 Figure 6 1 Electrical Schematic Sheet 1 of 5 3120679 JLG Lift 6 22 SECTION 6 SCHEMATICS S qnaids 69 8 s e s eee 9 N3349 21 311HM 311HM 55585955 E E ele E 9 ana 1 034 n 8 itn 5 ows rei lt l ERU o u 856656 zo 8 19 5 9 Ci asa 5 ania i 21 ama 4 S 3LIHM NHUB NNO 9 9 31 N38 134 8 az i lt lt ts 5 9 ov18 x H j 038 134 lt lt menu X04 lt gt xm 18 134
69. 50 126500 2690 3660 2530 3440 2370 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 3120679 NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 4 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift SECTION 1 SPECIFICATIONS SOCKET HEAD SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque TM TM T 22 S Tensile Clamp Load Loctite 242 or 271 Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 ST Hoa 85 K 0 15 In Sq In LB H 5 a ona T 0064 L 1 0061 S 6 32 015 0099 1 101 010 001005 L 1 8 32 0160 00140 J 71 61 9449 001474 SSS 39 24 0190 001750 J 0 02000 0 7500 0 3730 33600 420 i 2 1 1 1250 0 7630 68700 1290 1755 1160 1580 965 12
70. 6 355 a e 310434 OL E 8 O ABE 29 14 03 a S 2 EI a S 2 u z WHT BLK YEL 343 B43 WHITE 8 WHITE 8 B gt WHT BLK YEL Figure 6 3 Electrical Schematic Sheet 3 of 5 3120679 JLG Lift 6 24 SECTION 6 SCHEMATICS 7 INTERCOM MAIN BOOM LIFT gt BLACK PROX SWITCH BOOM BLU ORN 1 FAULT 8 el pr BE BROWN BLACK 912 BLUE RED H RED 10 BLUE 10 n lal BLACK BLACK 10 TOWER LIFT UP E sls WHT BLU 532 28 RED YEL REEL depen TELE IN MAIN TELE OUT ORANGE BROWN TOWER LIFT DOWN BRN ORN RED GREEN 5 TOWER TELE PROX SWITCH TOWER LIFT PROX SWITCH o z amp g o RED 238
71. 679 SECTION 5 HYDRAULICS 3120679 COUNTERBALANCE VALVE FLOW DIVIDER SOLENOID VALVE FOUR STACK DIRECTIONAL CONTROL VALVE THREE STACK DIRECTIONAL CONTROL VALVE Figure 5 3 Valve Locations Frame Mounted Valves Lift 5 15 SECTION 5 HYDRAULICS out Tower Lift Down function d Adjust pressure to 3000 psi 207 bar TOWER LIFT DOWN 6 Swing Relief a Lock turntable b Bottom out Swing Right function c Adjust pressure to 1700 psi 117 bar d Bottom out Swing Left function e Adjust pressure to 1700 psi 117 bar f Unlock turntable Two Stack Directional Control Valve 1 5 16 Attach pressure gauge to quick disconnect at two stack directional control valve located inside control valve compartment on right side of machine adja cent to engine compartment Loosen locknut on adjusting screw on rotate right valve section and turn adjusting screw clockwise to increase pressure Bottom out Rotate Right function Remove cap plug on main relief and adjust main relief to 2750 psi 190 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Replace cap plug After main relief has been set bottom out Rotate Right again and turn adjusting screw on rotate right valve section to 2500 psi 172 bar Turn adjusting 10 11 screw clockwise to increase pressure counterclock wise to d
72. EEL 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 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 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten nuts in the following sequence Lift 3 1 SECTION 3 CHASSIS amp TURNTABLE 3 tightening of the nuts should be done in stages Following the recommended sequence tighten nuts per wheel torque chart Table 3 1 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 70 ft Ibs 170 ft Ibs 300 ft Ibs 95 Nm 225 Nm 405 Nm Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of operation 3 2 DRIVE TORQUE HUB Disassembly 1 Position hub over suitable container and remove drain plug 37 from unit Allow oil to completely drain Remove sixteen bolts 1 four shoulder bolts 2 and twenty lockwashers 3 from cover 4
73. G A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS INTRODUCTION Original Issue Revised Revised Revised A 2 REVISON LOG May 15 1992 January 2 2001 February 4 2010 February 15 2012 JLG Lift 3120679 TABLE CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION INTRODUCTION SAFETY PRECAUTIONS A En E ean vedi dul Les 1 Hydraulic System 2 22 2 A 1 C Mainternarice a a CR iem AQ uso Va ee ek arse A 1 SECTION 1 SPECIFICATIONS 1 1 C apacitl8S Lec ep eem NER uu Re eee s 1 1 1 2 Engine Dateien iets abe REIP ru eae reif 1 1 1 3 DriVe Steer SYStem us La She ns ee eet e e pee n 1 1 1 4 Performance re
74. H IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE i Following the Torque Sequence diagram shown in Figure 2 8 tighten bolts to an initial torque of 410 ft Ib 555 Nm Then following the same sequence tighten bolts to a final torque of 545 ft Ib 740 Nm j Remove lifting equipment from bearing 3120679 SECTION 3 CHASSIS amp TURNTABLE k Use suitable lifting equipment to carefully posi tion turntable assembly above machine frame Carefully lower turntable onto swing bearing ensuring that turntable and bearing align as noted in step i above A CAUTION 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 m Apply a light coating of Loctite 277 to the new bearing bolts and install bolts washers and nuts through turntable and inner race of bearing n Following the Torque Sequence diagram shown 3120679 in Figure 2 9 tighten bolts to an initial torque of Fh lt MEASURING POINT 410 ft Ib 555 Nm Then following the same sequence tighten bolts to a final torque of 545 ft Ib 740 Nm o Remove lifting equipment p Install rotary coupling retaining yoke apply a light coating of Loctite Sealant Number TL277 41 to attaching bolts and secure yoke to rot
75. HARP EDGES AND BURRS IN THE COUNTERBORE WHEN INSTALLING O RING 10 11 12 13 14 Set cover 28 on work surface interior side up Grease and place o ring 23 into counterbore around rim of cover Make o ring fit counterbore exactly by stretching it or by pinching it together bit by bit Grease and place thrust washer 27 halfway down in counterbore in center of cover until it rests on a ledge in counterbore Grease and place thrust washer 22 around edge of raised circular center of cover Lower cover interior side down onto ring gear Align bolt holes in cover and ring gear Grease and place thrust washer 29 into counter bore inside center of cover on top of retaining ring 30 A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL 15 Lift Place retaining ring into groove inside counterbore in center of cover 3120679 SECTION 3 CHASSIS amp TURNTABLE 16 17 18 19 20 21 22 3 8 Place twenty lockwashers 24 over bolt holes in cover Place twenty bolts 31 into bolt holes in cover and tighten Torque bolts to 35 45 ft Ib 47 61 Nm Apply a light coat of Never Seize to three pipe plugs 32 and tighten pipe plugs into holes in cover Place roll tester in coupling in end of unit and roll it in both clockwise and counterclockwise directions Perform the same number of turns in each direction as the ratio of the
76. IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC SEMPERATUNE OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 F 43 AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES OF 100 F 38 OR ABOVE 100 F 38 C 90 F 32 C 8 E sro 8 70 F 21 C 5 9 60 F 16 C 9 HYDRAULIC 50 F 10 e gt z SPECIFICATIONS E 40 F 4 C 30 F 1 i 20 F 7 C 9 10 F 12 C 0 18 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE dien DO NOT START UP HYDRAULIC SYSTEM 30 F 34 C WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE 40 F 40 NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEALEVEL 4150548 D Figure 2 1 Engine Operating Temperature Specifications Cummins 3120679 Lift 2 9 SECTION 2 GENERAL LS NOTES 2 10 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE 3120679 SECTION 3 CHASS
77. IS amp TURNTABLE 3 1 TIRES amp WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG prod uct or rim decal for safe and proper operational character istics Tire Damage For pneumatic tires JLG Industries Inc recommends that when any cut rip or tear is discovered that exposes side wall or tread area cords in the tire measures must be taken to remove the JLG product from service immedi ately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires JLG Industries Inc rec ommends that when any of the following are discovered measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly a smooth even cut through the cord plies which exceeds 3 inches 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable crite ria 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
78. LAST 5 DIGITS OF SERIAL NUMBER STAMPED x g xL SERIAL NUMBER PLATE SERIAL NUMBER STAMPED JLG Lift 3120679 SECTION 1 SPECIFICATIONS Figure 1 1 Operator Maintenance Lubrication Diagram 1 12 OPERATOR MAINTENANCE NOTE The following numbers correspond to those in Fig ure 1 1 Operator Maintenance amp Lubrication Dia gram NOTE The lubrication intervals in Figure 1 1 Operator Maintenance amp Lubrication Diagram are equivalent to the following 150 hours 3 months 300 hours 6 months 600 hours 1 year 1200 hours 2 years 3120679 Table 1 15 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F 177 C Excellent water resistance and adhesive qualities andbeing of extreme pressure type Timken 0K 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classifi cation GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 EO Engine crankcase Oil Gas API SF SH SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C NOTICE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRON MENTS OR CONDITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY NOTE Itis recommended as a good practice to replace all
79. LET An Oshkosh Corporation Company Service and Maintenance Manual Model 150HAX P N 3120679 February 15 2012 An Oshkosh Corporation Company INTRODUCTION A SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that maintenance per sonnel pay strict attention to these warnings and precau tions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER SI 3120679 The specific precautions to be observed during mainte nance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided A WARNING NCE THE MACHINE MANUFACTURER HAS NO DIRECT C
80. NEXT BOOM OVERHAUL AND WHEN DEEMED NECESSARY BY MACHINE OWNER INSPECTION INTERVAL SHOULD NOT EXCEED 500 HOURS OF MACHINE OPERATION Inspect boom chains for the following conditions 1 Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the extend retract sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elongated 396 they must be removed and replaced Refer to Table 4 1 Chain Stretch Tolerance for proper chain specifications and allowable stretch tolerances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replacement of the chain and correction of the cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalign ment of the sheave chain anchors and must be cor rected promptly Do not repair chains if a section of chain is damaged replace the entire chain set d 5 of H H for a 1 chain 0 950 Maximum wear 5 of 0 950 0 047 Minimum plate depth 0 950 0 047 0 903 2 Lubrication One of the most important but often overlooked factors is adequate lubrication In addi tion to reducing internal friction maintaining a film of oil on all chain surfaces will inhibit rusting and corr
81. NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED wo 42 Figure 1 6 Torque Chart METRIC Fasteners Sheet 5 of 7 3120679 JLG Lift 1 15 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M3 M5 Torque Eu Torque Lub OR Loctite amp Torque ensie Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress TM i Area Load 263 Vibra TITE 111 or Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 Beep 3 5 0 6 6 78 4 22 4 oz ez sa 5 os 1420 e ai oo as O T 5 125 3660 228 365 8 24 24 3 353 2220 14065 90 33 3 5 694 432 5 2855 2570 2140 36 4 817 509 0 3665 3300 2750 42 4 5 5865 5275 4395 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10
82. No electrical signal to valve Failed printed circuit handle Failed open control handle safety deadman switch Improper ground Failed microswitch No pilotoil at valve No sequence pressure at valve No oil volume at valve bank Failed or stuck port relief Check electrical input to handle 12V Check electrical valve output of printed circuit board and electrical signal at the valve Replace square wave generator or use a handle assembly thatis presently workingin the system Check and replace safety deadman switch Check for proper grounding of handle Replace microswitch Check pressure reducing valve and adjustif needed Check pressure reducing valve and adjust as needed Check pump for failure Check hydraulic oil level Clean or replace port relief Functions occur in the opposite direction than required in regard to handle movement Valve coils are reversed Coil wires are reversed Hydraulic hoses reversed Reverse control valve coils Reverse coil wires Refer to hydraulic diagram for proper hosing Abrupt start up of any functions both directions Card Low potentiometer setting too high High and Low pots set too close together Adjust Low potentiometer to Just Start func tion Adjust per PQ Publication 3120304 Slow function speed engine lugs down at full throw handle position Card High potentiometer set too low Ad
83. ON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY THIS AREA RESPONSIBILITY OF THE OWNER OPERATOR HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pres sures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be discon nected with minimal fluid loss A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON NEL INJURY OR DEATH AND 15 A SAFETY VIOLATION JLG Lift ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE e DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT e OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICEMANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKIN
84. OXIMATELY 681 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS 2 Remove case seal 11 from housing 7 then remove bleeder screw 14 from end cover 13 3 Remove piston 24 from end cover 13 Remove o ring 19 back up ring 18 o ring 21 and back up ring 20 from piston 24 3120679 SECTION 3 CHASSIS amp TURNTABLE 3120679 5 Remove separators 10 from housing 7 6 Remove stack assembly consisting of discs 23 return plate 8 and friction discs 22 from housing 7 7 Remove dowel pins 17 springs 5 amp 6 from hous ing 7 8 Remove retaining ring 3 from housing 7 Remove shaft by pressing or using a soft mallet on male end of shaft 4 10 Remove retaining ring 15 bearing 2 from shaft 4 11 Press rotary seal 1 from housing 7 Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are inspection they are found to be in good condition Assembly NOTE NOTE NOTE 10 11 12 JLG Lift Lubricate all seals and o rings with clean hyaraulic
85. Schedule 2 6 3 1 Wheel Torque Chart eas GE laku de Sane FORMER OE C 3 2 4 1 Chain Stretch 1 14 4 16 5 1 Cylinder Piston Nut Torque 5 9 5 2 Holding Valve Torque Specifications 1 5 10 6 1 Platform Assembly 4 0 6 2 6 2 Boom Assembly Troubleshooting 1 4 6 4 6 3 Turntable Troubleshooting RH etna 6 8 6 4 Chassis Troubleshooting 6 10 6 5 Hydraulic System Troubleshooting 6 16 6 6 Electrical System 0 6 18 vi JLG Lift 3120679 SECTION 1 SPECIFICATIONS 1 4 5 SECTION 1 SPECIFICATIONS 1 4 PERFORMANCE DATA Table 1 1 Capacities Fuel Tank 68 gallons 257 liters Hydraulic Oil Tank Approx 124 gallons 469 liters Hydraulic System Approx 150 gallons 568 liters Drive 90 ounces 2 7 liters Drive 90 ounces 2 7 liters Swing 60 ounces 1 8 liters Swing 60 ounces 1 8 liters Engine Crankcase 10
86. TAMINATE DISC SURFACES 7 Place a new friction disc 12 on shaft 10 until it contacts return plate 14 8 Add additional new discs 11 and new friction discs 12 as required to complete assembly 9 Insert separators 13 in holes of return plate 10 Install new o ring 5 new backup ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings 11 Install new case seal 4 in housing 21 then install bleeder screw 3 in end cover 2 12 Position end cover 2 on housing 21 aligning dowel pins 20 with holes in end cover NOTE If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening capscrews 13 Press on inner ring of bearing 37 until it shoulders on shaft 45 to eliminate binding on bearings Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing 54 NOTICE IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING 3 16 JLG Lift 3 4 DRIVE BRAKE MICO MACHINES BUILT S N 33476 TO PRESENT Disassembly 1 With the shaft protrusion downward remove end cover 13 by removing capscrews 12 NOTICE END COVER IS UNDER SPRING TENSION OF APPR
87. TANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER EN A NOTES Figure 1 3 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift 3120679 SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 Torque Torque Tensile Clamp Load Torque esie 204 e ae Loctite 2627 Sike zaba ise fitim Dry K 17 Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 859 4 40 0520 006000 48 00661 6 32 01380 00909 40 01380 0 01015 8 32 060 0 01400 141 36 0 1640 0 01474 10 24 0 1900 0 01750 32 0 1900 0 02000 14 20 0250 00318 280 122 14 m Bn T 28 0 2500 0 0364 3280 139 16 131 15 Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 25 25 20 25 24 0 3125 20 25 3 8 16 35 50 24 _ 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 916 5 8 3 4 78 9 08750 0 4620 41600 515 70 485 660 455 620 1 8 10000 06060 51500 730 995 65 930 645 875 11 8 11 4 138 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 40
88. able containers to retain any residual hydraulic fluid Cap hydraulic lines and ports Remove two snap rings securing telescope cylinder pin to base boom Using a suitable brass drift carefully drive telescope cylinder pin from base boom Remove telescope cylinder trunnion pin covers from each side of boom Remove capscrews securing trunnion pins from each side of boom Using a suitable slide hammer remove trunnion pins attaching telescope cylinder to mid boom Attach a suitable sling to telescope cylinder rod Support with an overhead crane or other suitable lift ing device Remove two extension chain adjusting nuts from eye bolt through chain adjust block Remove four bolts and lockwashers attaching chain attach block to base boom section and remove block Using the lifting equipment raise cylinder to obtain sufficient clearance for removal of rod support bracket Remove cylinder rod support bracket Attach a suitable lifting device to extension chain adjusting eye bolt above cylinder rod The extension chain will come out of the boom twice as far as the telescope cylinder Using both lifting devices carefully pull cylinder from boom assembly As cylinder is removed from boom lay extension chain on top of base boom 18 19 Using another lifting device support sheave wheel end of cylinder and remove cylinder from boom assembly Carefully lift cylinder clear of boom assembly and lower to ground
89. abrupt control handle operation Clockwise rotation of trimpot adjust screw increases by slowing the response time of the output signal ammeter counterclockwise rotation decreases regardless of the speed with which the handle is ammeter reading moved 7 Operate controller in the same direction as in step NOTE It should be remembered that the ramp feature oper 5 to the full extent of its travel and hold handle in ates in both directions of the particular proportional that position function therefore adjusting the ramp potentiometer 8 Adjust HI trimpot until ammeter indicates 500 ma fo provide delay in starting provide a corresponding delay in stopping that function 9 Move controller handle back to the position given in step 5 and check ammeter reading This reading 1 Drive Controller will have changed due to HI trimpot adjustment and Usi licabl fet ti tart must be readjusted back to 300 ma machine ensure that adequate space is 10 Move handle to the position given in step 7 and available to maneuver machine check ammeter reading This reading too will have b Position ENGINE SPEED switch to HIGH and changed due to LO trimpot readjustment and must DRIVE SPEED switch to HIGH be adjusted back to 500 ma NOTE Clockwise rotation of the ramp potentiometer adjust 11 p steps 9 and 10 until LO and HI readings screw increases ramp delay time counterclockwise 300 500
90. aft end of base boom section and install attach pin and bushing If necessary tap pin and bushing into place using a soft headed mallet Secure pin and bushing with set screws Torque extend and retract chains to 50 ft Ib 68 Nm and tighten locknuts Install base boom end cover and secure in place with locknuts and washers Attach platform to boom assembly Connect wiring to platform control box Connect hydraulic lines to slave level cylinder and rotator motor Attach the right side bracket and powertrack to boom assembly Tower Boom Assembly 1 NOTE JLG Lift If removed align barrel end of upper master cylinder with mounting holes on end of tower boom fly sec tion and install attach pin Secure pin in place with a bolt and lockwasher If removed align horizontal level link with mounting holes in end of fly section and install attach pin Secure pin in place with a bolt and lockwasher When installing mid section wear pads install same number and thickness of shims as were removed during disassembly Install top aft fly section wear pads and shims as required using bolts and lockwashers Install side aft fly section wear pads and shims as required using bolts and lockwashers Using suitable lifting equipment carefully slide fly section into mid section just far enough that tele scope cylinder fly end attach pin mounting hole is still exposed Using suitable lifting equipment maneuver te
91. and lockwashers Install telescope cylinder mounting plate on aft end end of base boom and secure with bolts and lock washers When installing base section wear pads install same number and thickness of shims as were removed during disassembly Install base section top front wear pads and shims as required using bolts and lockwashers Install base section lower front wear pads mounting blocks and shims as required using bolts wash ers and lockwashers Install base section side front wear pads and shims as required using bolts and lockwashers Attach the right side bracket and powertrack to boom assembly Tower Boom Installation 1 10 11 JLG Lift Using suitable lifting equipment position assembled tower boom on turntable so that boom pivot holes in tower boom and turntable are aligned Insert boom pivot pin gently tapping pin into posi tion with a soft headed mallet if necessary Secure pin with bolts and lockwashers Align rod end attach hole of lower master cylinder with mounting hole in tower boom Install attach pin If necessary gently tap pin into position with a soft headed mallet and secure with a bolt and lock washer Connect all wiring to ground control box Activate hydraulic system and operate tower lift up to extend tower lift cylinder until rod end attach hole is aligned with mounting hole in tower boom Install attach pin If necessary gently tap pin into position wi
92. and pressure can then be increased to normal operating settings Reset the main relief valve to its proper setting while the pump is running at maximum operating engine motor speed for the vehicle Recommended Test Procedure Be sure there is an adequate supply of oil for the pump at least one gallon of oil for each gpm of pump capacity If one section of a tandem pump is being tested make sure that all other sections not being tested are ade quately supplied with oil If any of the other sections run dry or if plugs are left in ports serious and permanent damage will result The oil should be a good quality hydraulic oil rated at 150SSU at 100 F with the oil temperature held at 120 F plus or minus 5 F Test procedures are described in detail in SAE handbooks see Hydraulic Power Pump Test Procedure SAE J745c The feed line must be of adequate size with no more than 5 mercury vacuum adjacent to the pump inlet As a rule the feed line must provide a feed flow velocity not in excess of 8 feet per second Feeding hot oil into a cold pump may cause the pump to seize Jog the pump by momentarily starting the driving engine or motor to gradually equalize pump and oil tem peratures 3120679 SECTION 5 HYDRAULICS 3120679 Run the pump at least two minutes at load and moder ate speed not over 1500 rpm if the pump becomes excessively hot shut down immediately and locate the problem source Gradually
93. and retorquing bolt or bolts recheck all existing bolts for looseness NOTE This machine is not equipped with a tow package Check the frame to bearing Attach bolts as follows Refer to Section 6 of the Operating and Safety Man ual for emergency towing procedures 3120679 JLG Lift 1 Elevate the fully retracted boom to 70 degrees full elevation At the positions indicated on Figure 3 18 Swing Bearing Bolt Feeler Gauge Check try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position Assure that the 0 0015 feeler gauge will not pene trate under the bolt head to the bolt shank Swing the turntable 90 degrees and check some selected bolts at the new position Continue rotating the turntable at 90 degrees inter vals until a sampling of bolts have been checked in all quadrants 3 19 SECTION 3 CHASSIS amp TURNTABLE MEASURING a Boom at horizontal and fully retracted MEASURING POINT b Tower boom fully elevated and fully retracted Main boom fully extended at horizontal over the front of the machine Figure 3 19 Swing Bearing Tolerance Boom Placement 3 20 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE Check the turntable to bearing attach bolts as follows 1 Elevate the fully retracted boom to 70 degrees full elevation At the positions indicated on Figure 3 18 Swing Bearing Bolt Feeler Gauge Check
94. ary coupling with bolts and lockwashers Connect hydraulic lines to rotary coupling as tagged prior to removal At ground control station use tower boom lift control to lower boom to stowed position Using all applicable safety precautions activate hydraulic system and functionally check swing system for proper and safe operation TURNTABLE REF SWING BEARING FRAME REF Figure 3 19 Swing Bearing Tolerance Measuring Point Lift 3 23 SECTION 3 CHASSIS amp TURNTABLE Figure 3 20 Swing Bearing Torquing Sequence Swing Bearing Torque Values 3 7 SWING TORQUE HUB 1 Outer Race 545 ft Ib 740 Nm JLG Threadlocker 2 Inner Race 545 ft Ib 740 Nm JLG Threadlocker 3 Swing Bearing Torquing Sequence see Figure 2 9 A WARNING CHECK INNER AND OUTER SWING BEARING BOLTS FOR MISSING BOLTS OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION 3 AND EVERY 600 HOURS THEREAFTER Disassembly 1 Set unit on its shaft 1 Remove pipe plug 11 from bottom of hub near shaft and drain oil from unit into a suitable container Remove the three pipe plugs 32 from cover 28 Remove the twenty bolts 31 and lockwashers 24 from cover Remove thrust washer 29 from inside center coun terbore of cover on top of retaining ring 21 A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL 5 3 24 JLG Lift Remove retaining ring 30 from
95. aulic 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 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 primary enemy of a hydraulic system is contam ination 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 permi
96. back up rings 14 and 16 from piston OD and ID grooves Back up rings will be damaged and should not be removed if replacement is not planned Pressure relief valve 23 can be removed and inspected to assure spring loaded ball moves freely and is contamination free Cleaning and Inspection Clean all parts thoroughly Closely inspect all parts for damage excessive wear cracks and chips Replace parts as necessary Discard seals and o rings Closely inspect bearings and bearing contact sur faces NOTE Bearings may be re used if after thorough inspec tion they are found to be in good condition Assembly NOTE Lubricate all seals o rings cylinder of the power plate and piston with clean hydraulic oil prior to assembly Assemble piston 13 into power plate 21 using a shop press being careful not to damage the o rings or back up rings Visually align the center of the cut outs in piston with torque pin 8 holes in power plate Avoid pushing the piston all the way to the bottom of the cylinder in the power plate Try to keep the top surface of the piston flush to 1 8 in 3 2 mm below the machined surface of the power plate When pressing the bearing onto the shaft press on the inner race of the bearing and support the shaft properly Rotating discs must be clean and dry Worn or heavily scored discs must be replaced Press bearing 3 into housing 1 Bearing must be seated against shoulder in housing
97. bar Turn adjusting screw clockwise 3120679 SECTION 5 HYDRAULICS 3120679 to increase pressure counterclockwise to decrease pressure Tighten locknut FRONT STEER LEFT 6 Bottom out Rear Steer Right function 7 Loosen locknut on rear steer valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut REAR STEER RIGHT Bottom out Rear Steer Left function Loosen lock nut on opposite side of valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut REAR STEER LEFT Four Stack Directional Control Valve 1 Lift Plug pressure gauge into quick connect at three stack directional control valve located inside left rear of machine frame Bottom out Front Axle Extend function Loosen locknut on applicable valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut FRONT AXLE EXTEND Bottom out Front Axle Retract function Loosen lock nut on opposite side of valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise
98. 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 lubri cated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and opera tion 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 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 NOTICE FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COMPONENT
99. ble if a new swing bearing is used ensure that filler plug fitting is at 90 degrees from fore and aft centerline of turntable c Ensure that all turntable and bearing attachment holes are aligned and install four 4 diametri cally opposed clamps or bolts and nuts to secure bearing to turntable Tighten nuts and bolts or clamp evenly in a diametrical pattern to a torque of 20 ft Ib 27 Nm d Allow Devcon filler to cure at room temperature approximately 21 degrees C for 10 to 16 hours e After the appropriate interval place a suitable hydraulic jack under bearing and release clamps or remove nuts and bolts use hydraulic jack to carefully remove bearing from turntable f Careful remove excess filler from turntable mounting area from bearing attachment holes and from between gear teeth g Position bearing on machine frame in same position as noted in step c above A CAUTION JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE IT IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED h Apply a light coating of Loctite 277 to the new bearing bolts and loosely install bolts and wash ers through frame and outer race of bearing A CAUTION IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENC
100. ble 5 1 Cylinder Piston Nut Torque Specifications WHEN INSTALLING NEW POLY PAK TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 1 FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTAL LATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 1 Place a new wiper seal and rod seal into the applica ble cylinder head gland grooves Carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dis lodged Push the head along the rod to the rod end as applicable PISTON REF 3120679 Figure 5 1 Poly Pak Seal Installation Carefully slide the piston spacer on the rod If appli cable align the oil holes in the rod and the spacer Secure the spacer if applicable If applicable correctly place a new o ring and back up rings in the inner piston diameter groove Carefully place the piston on the cylinder rod ensur ing that the o ring and back up rings are not dam aged or dislodged Piston Nut Setscrew Torque Value Torque Value fai w JLG w o JLG Description Threadlocker Threadlocker n 600 ft Ib 200 in Ib Main Lift Cylinder Nm 23Nm 600 ft Ib 200 in Ib Tower Lift Cylinder 813 Nm 23Nm Main Telescope 600 ft Ib 100 Ib Cylinder 813 Nm 11 Nm Tower Telescope 600 ft Ib 200 Ib Cyl 1stSection 813 Nm 23 Nm 400 ft Ib 100 in Ib 2nd Section
101. ce bushings Repair or replace oil coupling 3120679 JLG Lift 6 15 SECTION 6 SCHEMATICS Table 6 5 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEM GENERAL Hydraulic pump noisy Air entering system through broken line or fitting Suction Side Air bubbles in oil Reservoir oil too low Oil filter s dirty Repairor replace line or fitting Replenish oil as required Clean and or replace filter s as necessary Pump cavitating Vacuum in pump due to oil starvation Restricted suction line Restricted reservoir air vent Oil viscosity too high Clean repair or replace line Clean vent Drain system and replace with recommended oil Refer to Hydraulic Oils System overheating Pump not delivering Oil viscosity too high Bypass valve not operating properly Main relief valve settoo high Hydraulic system oil low Restricted suction line Air entering system through broken line or fitting Broken pump drive shaft pump coupling Drain system and replace with recommended oil Refer to Hydraulic Oils Repair or replace valve Reset valve as required Replenish oil as necessary Clean repair or replace line Repair or replace line or fitting Repair or replace pump pump coupling Function sluggish during operation System pressure too low Main relie
102. ch controller not functioning prop erly Restricted or broken hydraulic line on valve bank hydraulic pump or rotary coupling If equipped swivel coupling leaking internally Seals defective Control valve not functioning properly Steer cylinder not functioning properly Determine and correct cause reset circuit breaker Replenish oil as necessary Adjust pressure See proper wiring diagram Replace switch controller Clean repair or replace line Repair or replace coupling Repair or replace valve Repair or replace cylinder 3120679 JLG Lift 6 13 SECTION 6 SCHEMATICS Table 6 4 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine hard to steer or steering is erratic Hydraulic system oil low Restricted hydraulic line or fitting Lack of lubrication Restricted crossover relief valve Steer system pressure low Bent linkage tie rod s or steering hitch Hydraulic pump not functioning properly Steer cylinder not functioning properly King pins and bushings worn Replenish oil as necessary Clean repair or replace line or fitting Lubricate as required Refer to Lubrication Chart Clean or replace valve Adjust pressure Repair or replace linkage as required Repair or replace pump Repair or replace cylinder Replace king pins and bushings Steering inoperative Circuit breaker open Damaged wiring on con
103. coupling from end of input gear 25 Lift ring gear off of hub 9 Lift input gear 25 out of hub Lift carrier assembly 16 out of hub Disassemble carrier assembly as follows a Set cluster planet gear 19 on its side Using a hammer and alignment punch drive roll pin 18 completely into hole in planet shaft 14 If roll pin is not completely driven into hole in planet shaft carrier housing could be damaged when planet shaft is removed b Using a punch and hammer drive planet shaft down out of carrier housing 16 When planet shaft is removed from carrier housing two thrust washers 15 and assembled cluster gear will slide off planet shaft into carrier housing Remove these parts from carrier housing c Remove nineteen needle rollers 13 from inside large end of cluster gear d Remove spacer 17 from inside of cluster gear e Remove nineteen needle rollers 19 from inside of small end of cluster gear f Repeat steps a through e for remaining two cluster gears Remove o ring 23 from counterbore of hub Dis card o ring Remove thrust washer 22 from around shaft 1 in hub Lift internal gear 20 out of hub Disassemble hub shaft assembly 9 as follows a Remove three pipe plugs 12 from side of hub b Bend the aligned tang of lockwasher 6 out of slot in locknut 8 c Remove locknut from shaft It may be necessary to cut locknut from shaft If this is necessary take care n
104. d 1000 Ib 450 kg restricted 1 5 FUNCTION SPEEDS Table 1 5 Function Speeds Function Speed In Seconds Lift Up 115 190 LiftDown 140 160 Tower Lift Up 89 103 Tower Telescope Out 125 160 Tower Telescope In 65 90 Tower Lift Down 61 83 Swing Right amp Left 72 84 Telescope Out 46 50 Telescope In 46 50 Platform Rotate Left amp Right 24 26 Jib Up 25 27 Jib Down 21 23 High Drive 200 ft 42 46 3 0 mph Drive above Horizontal 50 ft 65 71 0 5 mph JLG Lift SECTION 1 SPECIFICATIONS 1 6 LUBRICATION Table 1 8 Mobil EAL 224 H Specs Table 1 6 Hydraulic Oil Type Biodegradable Vegetable Oil Hydraulic System Operating SAE Viscosity ISO Viscosity Grade 32 46 Temperature Range Grade Specific Gravity 922 910 23 F 18 to 5 10W 0 to 23 F 18 to 5 0 Pour Point Max 25 F 32 C 0 to 210 F 18 to 100 C 10W 20 10W 30 50 to 210 F 10 to 99 C 20W 20 Flesh ro Weight 7 64 lb per gal NOTE Hydraulic oils must have anti wear qualities at least 0 9 kg per liter to Service Classification GL 3 and sufficient Viscosity chemical stability for mobile hydraulic system ser o o 7cSt vice JLG Industries recommends Mobilfluid 424 ik T anes hydraulic oil which has an SAE viscosity index of at 212 F 100 C 8 4 cSt 152 Viscosity Index 213 Operating Te
105. d any shims Remove bolts and lockwashers which attach top wear pads to front of mid section and remove pads and any shims Using suitable lifting equipment carefully slide fly section clear of outer mid section and lower to ground or suitably supported work area Remove bolts and lockwashers which secure top and side aft wear pads to fly section Tower Boom Disassembly NOTE Left or right is determined facing the machine from the platform Loosen the left side powertrack bracket and power track and lay on top of boom assembly A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON TAMINANTS INTO SYSTEM 2 3120679 Remove bolts and lockwashers securing telescope cylinder attach plate to aft end of base boom NOTE 10 11 12 JLG Lift Remove bolts and lockwashers securing telescope cylinder mounting plate to telescope cylinder Note and record the number and thickness of any wear pad shims during wear pad removal Remove bolts and lockwashers attaching side wear pads to front of base section Remove pads and any shims Remove bolts washers and lockwashers attaching lower front wear pads and mounting blocks to base section While supporting assembled fly and mid sections remove wear pads mounting blocks and shims Remove bolts and lockwashers attaching top front wear pads to base section Remove pads and shims Using su
106. d be no gap at the OD when power plate is properly seated against housing If a shop press is not avail able use assembly bolts 22 Tighten sequentially one at a time until power plate is properly seated Torque bolts to 50 to 60 ft Ib 68 to 81 Nm 9 If replacement of pressure relief valve is necessary install 1 2 to 3 4 turns beyond finger tight 10 Bleed air from brake via bleeder screw 3 9 SWING BRAKE MICO MACHINES BUILT TO 1992 Disassembly 1 Separate end cover 34 from housing 56 by removing capscrews 31 and lockwashers 32 A CAUTION END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 1 500 LB 680 KG THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3 000 LB 1 360 KG MINIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS 2 Tap cover with a soft mallet in order to dislodge bearing from cover 3 Remove o ring 36 square ring 35 pipe plug 33 bleeder 43 from end cover 3120679 4 Remove piston 40 from end cover by inserting two 1 4 20 UNC bolts into threaded holes in piston By turning and pulling piston can be removed from bore 5 Remove o ring 38 back up ring 39 o ring 41 and back up ring 42 from piston 6 Remove separators 49 from housing 56 7 Remove shaft assembly consisting of shaft 45 discs 46 50 friction plates 48 springs 47 snap ring 44 a
107. der barrel end bushing with pin attach holes in turntable and install barrel attach pin using appropriate brass drift Secure pin with bolt and lockwasher Remove caps from temporary hydraulic lines and attach to level cylinder ports Using auxiliary power activate swing function and extend cylinder rod until rod bushing aligns with cylinder rod end attach points on level links Using an appropriate brass drift drive rod attach pin through aligned bushing of cylinder rod end and level link attach points Secure rod end attach pin with setscrews Remove temporary hydraulic lines from cylinder ports and turntable swing motor hydraulic supply Reattach hydraulic supply to swing motor Remove caps from cylinder hydraulic lines and cor rectly install lines to cylinder Check hydraulic fluid level and adjust accordingly 5 7 SECTION 5 HYDRAULICS 5 5 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ONA CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3 If applicable remove the car
108. ding pins Keep chains lubricated Lift 7 Stress Corrosion Cracking The outside link plates which are heavily press fitted to the pins are particularly susceptible to stress corrosion cracking Like fatigue cracks these initiate at the point of high est stress aperture but tend to extend in an arc like path often parallel to the rolling grain of the material ABNORMAL PROTRUSION OR TURNED PINS e Also more then one crack can often appear on a link plate In addition to rusting this condition can be caused by exposure to an acidic or caustic medium or atmosphere Stress corrosion is an envi ronmentally assisted failure Two conditions must be present corrosive agent and static stress ARC LIKE CRACKED PLATES STRESS CORROSION In the chain static stress is present at the aperture due to the press fit pin No cycle motion is required and the plates can crack during idle periods The reactions of many chemical agents such as battery acid fumes with hardened metals liberate hydrogen which attacks and weakens the metal grain struc ture 4 15 SECTION 4 BOOM amp PLATFORM 8 Chain Anchors Sheaves and Pins An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They should also be adjusted to eliminate twisting the chain for an e
109. ds Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Start up of hydraulic system with oil temperatures below 15 degrees F 26 degrees C is not recom mended 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 mini mum temperature of 15 degrees F 26 degrees C The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent This will allow start up at temperatures down to 20 degrees F 29 degrees C However use of this oil will give poor performance at temperatures above 120 degrees F 49 degrees C Systems using DTE 13 oil should not be operated at temperatures above 200 degrees F 94 degrees C under any condition JLG Lift Changing Hydraulic Oil 1 Filter elements must be changed after the first 50 hours of operation and every 300 hours unless specified otherwise thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil annually 2 Use every precaution to keep the hydraulic oil clean If the oil must be poured fro
110. e E Rie Ua 1 1 1 3 Drive Steer Systemin 4 2 shit o dips er Qt od au pav 1 1 1 4 Performance Data uuu a er keen ee usa oe ce e dors 1 1 1 5 FUNCHION LEE dens E E pad Ee e 1 1 1 6 Fiydraulie Oil 2 2 PPAR eee se TN 1 2 1 7 Mobilfluid 424 Specs ER E REID Pues wanes 1 2 1 8 M bILEAL 224 A SPECS ee eR Rte dus td TUR aay 1 2 1 9 MOBI DTE Specs i ta nda a 1 2 1 10 Exxon Univis MVI 26 Specs on he Y Paw YU RR de ed 1 2 1 11 Torque 5 1 3 1 12 Pressure Settings 5 Spool Proportional 1 1 3 1 13 Major Component 4 1 4 1 14 Critical Stability 1 4 1 15 Lubrication 1 5 2 1 Inspection and 2 2 2 2 2 5 2 3 Inspection and Preventive Maintenance
111. e Fitting Capacity A R Lube MPG Lube Point s 3 Grease Fitting Capacity A R Lube MPG 3120679 Interval Every 3 months or 150 hrs of operation Comments Align with access hole in base boom JLG Lift Interval Every 3 months or 150 hrs of operation Comments SECTION 1 SPECIFICATIONS 27 Upper Master Cylinder Rod End 31 Hydraulic Filter Interval Replace filter after first 50 hours of opera tion then every 6 months or 300 hours thereaf ter 32 AirFilter Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 28 Upper Master Cylinder Barrel End uL 32 Lube Point s Replaceable Element Interval Every 6 months 300 hours of operation Lube Point s 1 Grease Fitting or as indicated by the condition indicator Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 29 Tower Boom Lift Cylinder Rod End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 30 Hydraulic Oil Lube Point s Fill Cap Drain Plug Capacity A R Lube HO Interval Check daily Change every 2 years or 1200 hours Comments On new machines those recently over hauled or after changing hydraulic oil operate all systems a minimum of two complete cycles and recheck oil level in reservoir
112. e p e e Fa ee etd SEK 1 1 1 5 Furiction Speeds ssepe ttu EO em ue CARE Soon A CRI A eund 1 1 1 6 E briCatiori A Renoir ue 1 2 1 7 Torque Requirements 22 22 10 4 bes 1 3 1 8 Pressure Settings PSI 1 3 1 9 Major Component 4 1 4 1 10 Critical Stability weights Messi eae ble de 1 4 1 11 Serial Number 1 4 1 12 Operator Maintenance 1 5 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 Generak 2 1 Preparation Inspection 2 1 AC REED Mo eae ger ee sq Us 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 2 2 1 Preventative 4 1 2 1 2 2 Service and
113. eads of the barrel If applicable secure the cylinder head retainer using a suitable spanner type wrench in the holes pro vided 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 If applicable install the cartridge type holding valve and fittings in the rod port block using new o rings as applicable A CAUTION IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER A TRAVELING OVERHEAD HOIST FORKLIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD Table 5 2 Holding Valve Torque Specifications Description Torque Value Sun 7 8 Hex M20 x 1 5 Thds 30 35 Ibs 41 48 Nm Sun 1 1 8 Hex 1 14 UND Thds 45 508 Ibs 61 68 Nm Sun 1 1 4 Hex M36 x 2 Thds 150 160 ft Ibs 204 217 Nm Racine 1 1 8 Hex 1 1 16 12 Thds 50 55 ft Ibs 68 75 Nm Racine 1 3 8 Hex 1 3 16 12 Thds 75 80 ft Ibs 102 109 Nm Racine 1 7 8 Hex 1 5 8 12 Thds 100 1104 Ibs 136 149 Nm 5 10 NOTE Steps 17 through 20 apply to the telescope cylin 17 18 19 20 JLG Lift der Elevate the barrel end of the cylinder to a work bench or other suitable device Plug the retract port and supply hydraulic power
114. earing 16 from end of spindle One thrust washer may stick in carrier counterbore Inspect thrust washers and thrust bearing for wear and replace if necessary Lift internal gear 21 out of hub A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL 11 12 Remove keeper ring 40 retaining ring 35 and bearing shim 34 from end of spindle Remove hub from spindle Remove bearing cone 32 and seal 31 from spin dle 30 Seal will possibly hold bearing cone into hub If so remove both from hub If bearing cups 33 require replacing they can be driven out of hub counterbores Discard seal and replace with new seal CAUTION SHOULD WORN DURING RETAINING RING REMOVAL 13 14 15 To remove cluster gear 27 from carrier remove retaining ring 25 from planet shaft 23 and drive planet shaft out of carrier Cluster gear and bearings 27 29 can now be slid out of carrier and spacer 18 removed from carrier bore If bearing cups 28 require replacing they can be driven out of cluster gear counterbores Repeat steps 12 and 13 for remaining cluster gears NOTICE WHEN REBUILDING THE UNIT O RINGS AND RETAINING RINGS SHOULD ALWAYS BE REPLACED JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE Bolt Bolt Lockwasher Cover Pipe Plug Pipe Plug Cover Cap O ring Disconnect Rod 10 O ring 11 Disconnect Cap 12 B
115. ecrease pressure Tighten locknut Bottom out Rotate Left function Loosen locknut and turn adjusting screw on oppo site side of valve section to 2500 psi 172 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut Bottom out Level Up function Loosen locknut and adjust level up relief valve located adjacent to single spool proportional relief valve to 2500 psi 172 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut Bottom out Level Down function Loosen locknut and adjust level down relief valve located adjacent to single spool proportional relief valve to 2500 psi 172 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut Three Stack Directional Control Valve 1 JLG Lift Plug pressure gauge into quick connect at three stack directional control valve located inside left rear of machine frame Bottom out Front Steer Right function Loosen locknut on front steer valve section and turn adjusting screw to adjust valve section to 2000 psi 138 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut FRONT STEER Bottom out Front Steer Left function Loosen lock nut on opposite side of valve section and turn adjusting screw to adjust valve section to 2000 psi 138
116. ed that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more that one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 6 3 HYDRAULIC CIRCUIT CHECKS The reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic check of the circuit componen
117. eds when descending a grade Counterbalance valve improperly adjusted or defective Adjust or replace valve Motor turns slowly in the direction of the last comm and Failed controller resulting in a command at neutral position Failed pilot valve Sticking spool due to contamination Replace controller Replace pilot valve Remove end cap and check spool freedom Repair as necessary Motor turns slowly at maximum command Valve spool is not traveling far enough due to Low pressure gain of pilot valve Low control pressure supply Plugged pilot valve Check filter in the inlet section for restriction Replace pressure regulator if necessary Change pilot valve 6 12 JLG Lift 3120679 SECTION 6 SCHEMATICS Table 6 4 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Poor response function shuts off slowly when command is removed Low spool spring preload Restricted tank return line Sticking spool due to contamination Ramp potentiometer adjustment improper Check for correct spring and shims in end caps Check for restrictions in tank return line Remove end cap and check spool freedom Re adjust ramping time on controller STEERING SYSTEM No response to control Circuit breaker open Hydraulic system oil low Hydraulic system pressure too low Damaged wiring on control switch or solenoid valve Control swit
118. el Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires JLG Lift 24 SECTION 2 GENERAL Table 2 1 Inspection Maintenance Type Frequenc sales Reference 4 y Responsibility Qualification Pre Start Inspection Prior to use each day or User or Operator User or Operator Operator and Safety Manual Ateach Operator change Pre Delivery Priorto each sale lease or Owner Dealer or User Qualified JLG Service and Maintenance Inspection rental delivery Mechanic Manual and applicable JLG inspection form Frequent Inspection Inservicefor3 months 150 hours which Owner Dealer User Qualified JLG Service and Maintenance ever comes first or Mechanic Manualand applicable JLG Out of service for a period of more than 3 inspection form months or Purchased used Annual Machine Annually no later than 13 months from the Owner Dealer or User Factory Trained Service and Maintenance Inspection date of the prior inspection Service Technician Manual and applicable JLG inspection form Preventative Atintervals as specified in the Service and Owner Dealer or User Qualified JLG Service and Maintenance Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES General
119. er completing testing procedures pump is ready for installation and immediate duty operationonequip ment Againf itmustberememberedthattopreventsei zure hotoilmustnot be fed into a cold pump JLG Lift 5 31 SECTION 5 HYDRAULICS 2 NOTES 5 32 JLG Lift 3120679 SECTION 6 SCHEMATICS 3120679 SECTION 6 SCHEMATICS 6 1 GENERAL This section contains troubleshooting information 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 qual ified guidance should be obtained before proceeding with any maintenance 6 2 TROUBLESHOOTING The troubleshooting procedures applicable to the aerial platform are listed and defined in Tables 3 1 through 3 6 As an aid to table use the aerial platform is divided into four major groups each covered separately within this section These groups are as follows elevation system chassis assembly hydraulic system and electrical system Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the remedial action should where possi ble be checked in the order listed in the tables It should be not
120. er operating SWING function as described in step d the platform stops moving to the left and the spring action of the boom tends to ini tiate the swing right motion before the control valve starts to operate the ramp pot adjust screw should be rotated counterclockwise to decrease ramp time g Repeatthe test in both swing directions h Release footswitch and stop machine i Seal ramp pot adjustment screw with a drop of enamel paint to prevent maladjustment due to vibration j Install controller and secure machine 3 13 PUMP COUPLING CONVERSION PROCEDURES The following procedures are provided to assist in the con version from a solid pump coupling to a Lovejoy or Hayes pump coupling Lovejoy Coupling Coupling Bolt Lockwasher Pump Adapter Bolt Lockwasher Figure 3 26 Lovejoy Coupling 3 Separate coupling disc and hub and align plastic disc on flywheel with webbing facing flywheel Install attaching bolts and lockwashers and torque bolts to 30 ft Ib 41 Nm 4 Attach pump mounting plate adaptor to bell housing of engine and secure with bolts and lockwashers 5 Slide coupling hub onto pump shaft bottoms out on roll pin located inside hub Secure hub onto shaft by torquing torque screws to 22 ft Ib 30 Nm 6 Insert coupling hub now affixed to pump shaft through pilot bore in pump mounting plate Align coupling hub and disc push pump into position and secure with bolts and lockwashers JLG L
121. ers which attach turn table to bearing inner race Discard nuts and bolts Use lifting equipment to carefully lift complete turnta ble assembly from bearing Ensure that no damage occurs to turntable bearing or frame mounted com ponents Carefully place turntable on a suitably supported trestle 3 21 SECTION 3 CHASSIS amp TURNTABLE 9 Using a suitable tool scribe a line on outer race of swing bearing and frame This line will aid in aligning bearing upon installation Remove bolts and wash ers which attach outer race of bearing to frame Dis card bolts Use suitable lifting equipment to remove bearing from frame move bearing to a clean suit ably supported work area INSTALLATION NOTE Manufacturing tolerances of frames and turntables are inspected prior to the factory installation of swing bearings to determine the need for use of Devcon filler When servicing machine swing bearing apply Devcon filler only to those machines having Devcon previously applied at the factory If new turntable or frame is being installed contact manufacturer for pro cedures to determine the need for Devcon applica tion 1 Use suitable standard tools and equipment to care fully remove any hardened epoxy residue from bear ing mounting area of frame and turntable 2 Apply a layer of Devcon or equivalent filler approxi mately 0 125 in 3 18 mm thick on bearing mount ing plate on frame 3 Use suitable lifting equipment t
122. f valve set too low Pump section not delivering sufficient oil Main relief valve stuck in open position Oil viscosity too low Leakin component line or fitting Scored valve spool scored cylinder Reset valve as required Repair or replace pump section or pump Clean repair or replace valve Check system oil for contamination Drain system and replace with recommended oil Refer to Hydraulic Oils Repair or replace component line or fitting Replace valve replace cylinder 6 16 Lift 3120679 SECTION 6 SCHEMATICS Table 6 5 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY System s operate erratically Sticking or binding valve spools pistons rods etc Clean repair or replace components as required AUXILIARY HYDRAULIC SYSTEM Auxiliary hydraulic pump inoperable Circuit breaker open Battery requires charging or will not hold a charge Damaged wiring on control switch or auxiliary pump Control switch not functioning properly Restricted or broken hydraulic line or fitting Pump motor solenoid not functioning properly Pump motor not functioning properly Low pilot pressure Determine and correct cause reset circuit breaker Charge or replace battery as required See proper wiring diagram Replace switch Clean repair or replace line or fitting Replace solenoid Repair or replace moto
123. from piston 7 JLG Lift 3 33 SECTION 3 CHASSIS amp TURNTABLE 1 Capscrew 10 Shaft 19 Bearing 2 End Cover 11 Disc 20 Dowel Pin 3 Bleeder Screw 12 Friction Disc 21 Housing 4 Case Seal 13 Separators 22 Retaining Ring 5 O ring 14 Return Plate 23 Rotary Oil Seal 6 Back Up Ring 15 Spring 24 O ring 7 Piston 16 Spring 25 Gasket 8 O ring 17 Spring Retainer 26 Pin 9 Backup Ring 18 Retaining Ring Figure 3 24 Swing Brake Machines Built 1992 to Present 3 34 Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE 5 Remove separators 13 from housing 21 6 Remove stack assembly consisting of discs 11 return plate 14 and friction discs 12 from housing 21 NOTE Not all models use the same number of springs or spring pattern Record this information for assembly purposes Spring retainer 17 was not used in ear lier models 7 Remove dowel pins 20 springs 15 amp 16 and spring retainer 17 from housing 21 8 Remove retaining ring 18 from housing 21 9 Remove shaft by pressing or using a soft mallet on male end of shaft 10 NOTE Earlier models did not use retaining ring 22 10 Remove retaining ring 22 and bearing 19 from shaft 10 11 Press Rotary oil seal 23 from housing 21 Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as
124. front wear pads and remove pads and any shims Remove bolts and lockwashers which attach side wear pads to front of mid section and remove pads and any shims Remove bolts and lockwashers which attach top wear pads to front of mid section and remove pads and any shims Using suitable lifting equipment carefully slide fly section clear of mid section and lower to ground or suitably supported work area Remove bolts and lockwashers which attach top aft wear pads to fly section and remove pads and any shims Remove bolts and lockwashers which attach side aft wear pads to fly section and remove pads and any shims If necessary remove bolt and lockwasher securing horizontal level link attach pin to fly section Using a slide hammer or other suitable tool remove pin from fly section and remove level link and bushings If necessary remove bolt and lockwasher securing barrel end of upper master cylinder to fly section Using a slide hammer or other suitable tool remove pin from fly section and remove cylinder Inspection 1 10 11 12 13 14 JLG Lift Inspect all sheaves extend chains retract chains and telescope cylinder for excessive groove wear burrs or other damage Replace sheaves as neces sary Inspect extend chain and retract chain sheave bush ings for wear scoring or other damage and for ovality Replace bushings as necessary ensuring they are installed flush with sheave surface
125. g continuity See proper wiring dia gram INSTRUMENTS AND INDICATORS Ammeter inoperative Damaged wiring in circuit Ammeter not functioning properly Defective charging circuit components Repair or replace wiring Replace ammeter Check charging system for correct output Repair or replace as necessary Voltmeter inoperative 6 18 Broken wire faulty voltmeter JLG Lift Repair or replace as necessary 3120679 SECTION 6 SCHEMATICS Table 6 6 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Travel warning horn inoperative Damaged wiring in horn circuit Repair or replace wiring Damaged horn Replace horn Hourmeter inoperative Damaged wiring in hourmeter circuit Repair or replace wiring Defective vacuum switch Replace vacuum switch Inoperative hourmeter Replace hourmeter Tiltalarm circuit Damaged wiring in tilt alarm circuit Tiltalarm inoperative Tiltalarm not adjusted properly Repair or replace wiring See proper wiring dia gram Replace tilt alarm Adjusttiltalarm as described in Section 2 Wheel motor speed circuit Switch damaged or inoperative Damaged or disconnected wiring in circuit Replace switch Repair or replace wiring P Q CONTROLLER Actuation ofa function of the valve continues when the handle is in the center position Improper null ofthe handle with the control han
126. g properly Distorted boom section s Chain sheaves worn damaged Main boom only Boom chains loose Main boom only Counterbalance valve not functioning properly Replenish oil as necessary Adjustor replace pads as required Clean repair or replace line or fitting Replace lever Replace seals Replace cylinder Replace distorted section s Replace worn damaged components Main boom only Tighten chains Torque to 50 ft Ib 68 Nm dry Main boom only Replace counterbalance valve Midor fly section inoperative Broken drive chain Main boom only Repairor replace chain Mid and fly sections extend and retract erratically Drive chain out of adjustment Wear pads out of adjustment or worn Damaged worn sheave or chain links Main boom only Mid or fly section distorted Adjust chain as required Main boom only Adjust or replace pads as required Repair or replace chain or sheave as required Main boom only Replace mid or fly section as necessary Lift 3120679 SECTION 6 SCHEMATICS Table 6 2 Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM SWING SYSTEM Noresponse to swing control Hydraulic system oillow Swing controllever notfunctioning Restricted or broken supply line on valve bank or hydraulic pump Control valve not functioning properly Swing motor
127. groove inside coun terbore in center of cover Lift cover off of ring gear 21 and set it aside interior side facing up 3120679 SECTION 3 CHASSIS amp TURNTABLE m gt 2 3 12 20 16 14 19 17 13 15 24 d N En 2 f 777 P cum XN 2 3 NN H SS DN lt ETT ESSA Z Zt rS A E Z 4 rT 222 Output Shield 8 Bearing Nut 15 ThrustWasher 21 Ring Gear 27 ThrustWasher Outer Bearing Cup 9 Housing 16 Carrier 22 Thrust Washer 28 Input Cover Outer Bearing Cone 10 Lip Seal 17 ThrustSpacer 23 O ring 29 Thrust Washer Inner Bearing Cup 11 Pipe Plug 18 Roll Pin 24 Lockwasher 30 Retaining Bolt Inner Bearing Cone 12 Pipe Plug 19 Cluster Gear 25 Sun Gear 31 Bolt Lockwasher 13 NeedleBearing 20 Internal Gear 26 Adapter Coupling 32 PipePlug Flatwasher 14 Planet Shaft Figure 3 21 Swing Torque Hub JLG Lift d5 SECTION 3 CHASSIS amp TURNTABLE 10 11 12 13 14 15 16 17 NOTE 3 26 Remove o ring 6 from counterbore around rim of cover Discard o ring Remove thrust washer 27 from ledge halfway down in counterbore in center of cover Thrust washer may be on top of coupling 26 Remove washer and set it aside Remove thrust washer 22 from around edge of raised circular center of cover Thrust washer may be around coupling 26 Remove thrust washer and set it aside Remove
128. gure 1 8 Torque Chart METRIC Fasteners Sheet 7 of 7 JLG Lift SECTION 1 SPECIFICATIONS 25 NOTES JLG Lift 3120679 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive 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 fur ther 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 per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection
129. h Lube Point s 1 Grease Fitting Capacity A R Lube MPG 3120679 Lift 10 Swing Bearing 11 Interval Every 3 months or 150 hrs of operation Comments Remote Fitting on Left Rear of Turnta ble 9 Tower Boom Lift Cylinder Barrel End mE Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Fitting on Left Rear of Turnta ble Lube Point s 2 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Fitting on Left Rear of Turnta ble Lower Master Cylinder Rod End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 1 7 SECTION 1 SPECIFICATIONS 12 Platform Hinges EM f Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 13 Platform Door Latch Lube Point s N A Capacity A R Lube EO Interval Every 3 months or 150 hrs of operation 14 Platform Rotate Pivot Rotator Worm Gear Lube Point s 2 Grease Fittings on pivot 1 Grease Fitting on worm gear Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 1 8 15 Platform Level Links Lube Point s 3 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 16
130. h a screwdriver 3120679 SECTION 5 HYDRAULICS 3120679 New plugs should screwed tightly Stake plug with a prick punch at both ends of screwdriver slot and around edges Peen edge of hole 0 031 to 0 062 inches with a 1 5 inch diameter steel ball If new plugs are being installed coat threads with JLG Threadlocker Steps 5 thru 8 apply to shaft end cover bearing car riers and port end cover Any bushings removed from the shaft end cover port end cover or bearing carrier should be assem bled in drive bores with groove to the top of unit 12 o clock Assemble bushings in driven bores with the groove to the bottom of the unit 6 o clock Model P315 pumps do not have grooved bushings so the bushing seams should be placed at the 12 and 6 o clock positions JLG Lift 7 Bushings should be pressed into the bores one time using the special installation tool and an arbor press Be sure the grooves or seams are posi tioned as stated in step 5 Bushings must be pressed into the bores flush with the casting face Be sure to support the castings so they are square and level gt Repeat steps 1 2 stone parts 5 25 SECTION 5 HYDRAULICS 5 26 See that dowel pins place in new cast ings Examine all dowels Before inserting make sure the hole is clean and free from burrs Gently start pin straight into hole and
131. housing per step 14 Insert the drive and driven gears of the second section in their respective bearings Make sure the gears are in contact with the thrust plate face Place the port end cover plate in the housing per step 16 3120679 SECTION 5 HYDRAULICS 20 Check the plug plugs the port end cover to be sure they are tight Follow the procedure outlined in step 4 for new plugs 21 Place the port end cover over the gear journals Align the dowels with the holes in the mating cast ing Being careful not to pinch the gasket seal tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in the final seating 22 Thread the studs washers and nuts into the shaft end cover and tighten alternately or cross corner Rotate the drive shaft with a wrench to make sure there is no binding in the pump After the fasteners are tight and there is no internal binding torque the fasteners in a diagonally opposed pattern to 200 ft lbs 280 Nm or for P315 models to 140 ft Ibs 196 Nm Wear Guide for Replacement GEAR HOUSINGS Wear in excess of 0 007 in 0 18 mm cut out necessitates replacement of the gear housing Place a straight edge across the bore If a 0 007 feeler gauge can be slipped under the straight edge in the cut out area replace the gear housing Pressure pushes the gears against the housing on the low pressure side As the hubs a
132. ift 3 39 SECTION 3 CHASSIS amp TURNTABLE Hayes Coupling Coupling Bolt Lockwasher Pump Adapter Bolt Lockwasher Figure 3 27 Hayes Coupling 1 Install pump coupling on flywheel and secure with bolts and lockwashers Torque bolts to 30 ft Ib 41 Nm NOTICE BEFORE ASSEMBLING PUMP COUPLING AND PUMP BE SURE TO COAT INTERNAL SPLINES OF COUPLING AND EXTERNAL SPLINES OF PUMP SHAFT WITH TEXACO CODE 1912 GREASE 2 Attach pump mounting plate adaptor to bell housing of engine and secure with bolts and lockwashers 3 Align pump shaft with coupling push pump into position and secure with bolts and lockwashers 3 14 TILT ALARM SWITCH NOTE Each machine is equipped with a tilt alarm switch factory set to activate at 5 degrees which will illumi nate a warning light sound a warning horn and cut out 2 speed drive Consult factory for tilt sensor adjustment The only field adjustment necessary is leveling the switch on the spring loaded studs There are two methods of adjustment a manual adjust ment and an adjustment using a voltmeter 3 40 JLG Lift A CAUTION PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 Park the machine on flat level surface Ensure machine is level NOTE Ensure switch mounting bracket is level and securely attached 2 Level the base of the indica
133. ift cylinder not functioning properly Repair or replace cylinder Contaminated port relief Repair or replace valve Boom will not lower See Boom will not raise 6 4 JLG Lift 3120679 SECTION 6 SCHEMATICS Table 6 2 Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boomraises and lowers erratically Hydraulic system oillow Restricted or broken hydraulic line or fitting Lackoflubricanton cylinder shafts and orboom pivot Counterbalance valve on lift cylinder improperly adjusted or not functioning properly Control valve not functioning properly Worn seals in lift cylinder Cylinder not functioning properly Replenish oil as required Clean or replace line Lubricate as required Refer to Lubrication Chart Replace valve Repair or replace valve Replace seals Repair or replace cylinder Boom drifts down Manual lowering valve not functioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Holding valve on cylinder not Repair or replace valve functioning properly High engine does not operate below horizontal Damaged wiring on boom limit switch Repair or replace wiring Damaged boom limit switch Replace switch MAIN TELESCOPE SYSTEM No response to telescope control Circuit breaker open Determine and correct cause Reset circuit Hydraulic system oil low Damaged wi
134. inside mid boom section and secure with two trunnion blocks four bolts and lockwashers Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports Install cylinder mounting plate on cylinder base end port block and secure with four bolts and lockwash ers Secure cylinder mounting plate to base boom with four bolts and lockwashers Using auxiliary power extend telescope cylinder until fly end rod attach bushing is aligned with fly attach holes in fly boom Using a suitable brass drift drive fly attach pin into fly boom and fly end rod attach bushing Secure attach pin with end cap bolt and lockwasher on each end of pin Fully retract boom and shut down engine Check hydraulic fluid level and adjust accordingly Tower Lift Cylinder Removal 1 Place machine on a flat and level surface Start engine and raise tower boom Shut down engine and attach a suitable support device to boom Remove four bolts and lockwashers securing lift cyl inder rod attach pin to tower boom Using a suitable brass drift drive out lift cylinder rod attach pin Using auxiliary power retract tower lift cylinder rod completely Tag disconnect and cap tower lift cylinder hydraulic lines and ports Remove the four bolts and lockwashers securing barrel end attach pin to turntable Using a suitable brass drift drive out barrel end attach pin from turn table Remove cylinder from boom and place in a s
135. itable lifting equipment slide assembled mid and fly sections out of base section Carefully lift mid and fly sections clear of base sec tion and lower to a suitably supported work area Remove bolts and lockwashers securing trunnion blocks to sides of mid section Carefully pull fly section from mid section far enough to expose telescope cylinder fly attach pin cover caps Remove bolts and lockwashers securing cover caps to each end of telescope cylinder fly attach pin Remove cover caps Using a slide hammer or brass drift remove attach pin from fly section 4 7 SECTION 4 BOOM amp PLATFORM Base Boom Mid Boom Fly Boom Telescope Cylinder Upper Rear Wear Pads Cylinder Mounting Plate 1 2 3 4 5 6 Figure 4 4 Tower Boom 3120679 JLG Lift 4 8 SECTION 4 BOOM PLATFORM 13 14 15 16 17 18 19 20 21 22 23 3120679 Using suitable lifting equipment carefully slide tele scope cylinder out of fly and mid sections and lower to ground or suitably supported work area Note and record number and thickness of any wear pad shims during wear pad removal Remove bolts and lockwashers which attach mid section top aft wear pads and remove pads and any shims Remove bolts and lockwashers which attach mid section side aft wear pads and remove pads and any shims Remove bolts and lockwashers which attach mid section bottom
136. itch not functioning properly or improperly adjusted Control handle micro switch not functioning properly Replenish fuel as necessary Clean or replace fuel line Replace or charge battery as required Replace fuel pump Repair or replace wiring Replace switch Repair or replace governor Adjust repair or replace switch Repair or replace control handle 6 8 Lift 3120679 SECTION 6 SCHEMATICS Table 6 3 Turntable Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve Spool Sticking Dirtinoil causing excessive temperature build Up Incorrect valve mounting causing warping ofthe unit Valve spool scored Return spring weakor broken Relief valve malfunctioning causing excessive pressure within valve Change oil using recommended viscosity and flush system Loosen valve and check mounting Repair as necessary Remove valve and repair or replace as neces sary Remove valve and repair or replace as neces sary Check pressure delivery to and from valve and repair or replace as necessary Valve Leaking Dirtor other foreign material under seal Valve spool scored Excessive back pressure caused by restricted return line to reservoir Damaged valve seals Remove and repair valve as necessary Repair or replace valve Remove line and clear obstruction or replace line as necessary Repair or
137. just High potentiometer until function speed does notlug down 6 20 Lift 3120679 SECTION 6 SCHEMATICS Table 6 6 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Speed not proportional High and Low pots not adjusted properly Adjust pots to factory specifications or refer to PQ Publication 3120304 for proper adjustment Cylinder drifts or drive motor slowly rotates when controller is returned to neutral high null bias tral position Microswitch remained open controller Ramp too high in controller Brakes not applying in swing or drive Controller failed resulting ina command at neu Adjust or replace microswitch Replace microswitch Setramp as needed Check brakes Repair or replace if needed 3120679 JLG Lift 6 21 SECTION 6 SCHEMATICS RED BLK lt 038 134 lt 0 avas 1
138. lace fly section retract chain around chain sheave at aft end of mid section and through bottom of base section Install fly section retract chain clevis into attach block at lower front end of base section Install adjust nut and locknut on clevis Install clevis cover on bottom of base section and secure in place with bolts and lockwashers Using suitable lifting equipment carefully align holes in telescope cylinder trunnion and holes in aft end of mid section 3120679 SECTION 4 BOOM amp PLATFORM 24 25 26 27 28 29 30 31 32 33 34 35 3120679 Install trunnion pins tapping pins into place with a soft headed mallet if necessary Install cover plate over trunnion pins and secure to mid section with bolts washers and lockwashers Install outer mid section retract chain clevis into attach block at lower front end of base boom sec tion Install adjust nut and locknut on clevis When installing base section wear pads install same number and thickness of shims as were removed during disassembly Install base section top front wear pads and shims as required using bolts and lockwashers Install base section lower front wear pads mounting blocks and shims as required using bolts wash ers and lockwashers Install base section side front wear pads and shims as required using bolts and lockwashers Carefully align telescope cylinder rod end with holes in
139. le scope oylinder into position at aft end of assembled boom sections Align fly attach end of telescope cylinder with mounting holes in fly section and install attach pin Secure pin in place with cover caps bolts and lock washers Carefully slide fly section the rest of the way into the mid section Carefully align ears on base end of cylinder barrel with notches in base end of mid section Secure inder barrel in place with trunnion blocks bolts and lockwashers 4 11 SECTION 4 BOOM amp PLATFORM 10 11 12 13 14 15 16 17 18 19 20 21 4 12 When installing mid section wear pads install same number and thickness of shims as were removed during disassembly Install mid section top front wear pads and shims as required using bolts and lockwashers Install mid section side front wear pads and shims as required using bolts and lockwashers Install mid section bottom front wear pads and shims as required using bolts and lockwashers Install mid section top aft wear pads and shims as required using bolts and lockwashers Install mid section side aft wear pads and shims as required using bolts and lockwashers Using suitable lifting equipment carefully slide assembled mid and fly sections into base section Install telescope cylinder mounting plate on base attach end of telescope cylinder Secure mounting plate with bolts
140. le voltage reading 12 Check voltage at trip point in all four directions If voltage reading is not symmetrical repeat step 4 above 3 15 THROTTLE CHECKS AND ADJUSTMENTS NOTE Never run fuel tank dry Diesel engines cannot be 3120679 restarted after running out of fuel until fuel system has been air vented or bled of air See Cummins instruction manual for procedure a Disconnect actuator cable from throttle lever With the aid of an assistant start the engine and allow it to come up to operating temperature Adjust throttle lever stop until engine runs at BLACK YELLOW 1800 RPM Shut down engine Reattach actuator cable to throttle lever making sure that low mid engine setting remains the same If necessary adjust slide pin to contact low mid engine limit switch at 1800 RPM Shut down engine b Disconnect power red wire from high drive dump valve at rear of valve compartment With the aid of an assistant start engine from basket and allow to come up to operating temperature Activate footswitch Turn on HIGH ENGINE switch Hold drive controller in full drive position Adjust slide pin to contact high engine limit switch at 2500 RPM Shut off all switches and controllers Re connect power red wire to high drive dump valve NOTE Actuator cable travel must stop slightly before lever makes contact with throttle lever stop Failure to do so Will burn o
141. lve Slave cylinder not functioning properly Repair or replace cylinder Platform will not adjust up to level Damaged wiring on control switch or solenoid Repair or replace wiring valve Restricted or broken hydraulic line or Clean repair or replace line or fitting fitting Slave cylinder not functioning properly Repair or replace cylinder Platform will not adjust down to level See Platform will not adjust up to level 6 2 Lift 3120679 SECTION 6 SCHEMATICS Table 6 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking Dirtin oil causing excessive temperature build Up Moisture in oil Incorrect valve mounting causing warping of the unit Valve spool scored Tie bolts in valve over torqued Return spring weak or broken Relief valve malfunctioning causing excessive pressure within valve Flush system and change oil using recom mended viscosity Flush system and change oil using recom mended viscosity Loosen valve and check mounting Repair as necessary Remove valve and repair or replace as neces sary Correctly torque bolts Remove valve and repair or replace as neces sary Check pressure delivery to and from valve and repair or replace as necessary Valve leaking Dirt or other foreign material under seal Valve spool scored Excessive back pressure caused b
142. m the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance 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 evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods 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 3120679 SECTION 2 GENERAL Gylinder Drift Table 2 2 Cylinder Drift
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144. move four bolts and lockwashers securing tele scope cylinder attach plate to base end of tower boom Remove four bolts and lockwashers securing tele scope cylinder attach plate to port block of tele scope cylinder Remove attach plate A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM 5 Tag and disconnect hydraulic lines to telescope cyl Lift inder Use suitable containers to retain any residual hydraulic fluid Cap hydraulic lines and ports 5 3 SECTION 5 HYDRAULICS 1 0 Remove two bolts and lockwashers securing each of two trunnion blocks to base end of mid boom sec tion Remove trunnion blocks Remove bolt lockwasher and end cap from each end of fly attach pin Using a suitable brass drift carefully drive fly attach pin from fly section Attach a suitable sling to the telescope cylinder rod Support with an overhead crane or other suitable lift ing device Using the lifting equipment carefully pull cylinder from boom assembly Using another lifting device support telescope cylin der fly end rod and remove cylinder from boom assembly Lower cylinder to the ground or suitably supported work area Tower Telescope Cylinder Installation 5 4 1 Using suitable lifting equipment carefully insert fly end cylinder rod into boom assembly Slide cylinder trunnion into appropriate slots
145. mp 0 180 F 17 162 C NOTE When temperatures remain consistently below 20 degrees F 7 degrees C Industries recom mends the use of Mobil DTE11 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 If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations Table 1 7 Mobilfluid 424 Specs Note Must be stored above 32 F 14 C SAE Grade 10W30 Gravity API 29 0 Density Lb Gal 60 F 7 35 Pour Point 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cP 18 2700 at 40 C 55 cSt at 100 C 9 3 cSt Viscosity Index 152 Table 1 9 Mobil DTE 13M Specs ISO Viscosity Grade 32 Specific Gravity 0 877 Pour Point Max 40 F 40 C Flash Point Min 330 F 166 C Viscosity at 40 C 33cSt at 100 C 6 6 cSt at 100 F 169 SUS at 210 F 48 SUS cp at 20 F 6 200 Viscosity Index 140 Table 1 10 Exxon Univis 26 Specs Specific Gravity 32 1 Pour Point 76 F 60 C Flash Point 217 F 103 C Viscosity at 40 C 25 8 cSt at 100 C 9 3cSt Viscosity Index 376 JLG Lift NOTE Mobil Exxon recommends that this be checked on a yearly basis for vi
146. n g Place bearing cone 32 over end of spindle and around retaining ring and on bearing shim into bearing cup h Place bearing shim 34 over end of spindle and against bearing cone k With large open end of hub spindle assembly facing up place one spacer washer 42 into spindle counterbore A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION 3120679 JLG Lift 3 5 SECTION 3 CHASSIS amp TURNTABLE l Place spring 43 into spindle counterbore atr m Set second spacer washer 42 on top of spring A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION n Compress spacer washer and spring into spin dle counterbore and install retaining ring 41 into spindle groove 3 6 Lift 2 Position hub spindle assembly 36 and 30 with large open end up W are 3 Lower internal gear 21 onto spindle Ree Sh 4 Place one thrust bearing 16 between two thrust washers 15 and place them onto spindle pilot A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION 3120679 SECTION 3 CHASSIS amp TURNTABLE 5 Install retaining ring 19 in groove of input shaft 8 Place o ring 14 into counterbore of hub spindle 20 assembly Use grease or petroleum jelly to hold o asss 6 Place input shaft into spindle counterb
147. n boom structure Install pin attaching bolts and lockwashers Shut down machine systems Connect hydraulic lines running along side of boom Using all applicable safety precautions operate machine systems and raise and extend boom fully noting the performance of the extension cycle If chattering is apparent extend chain system requires adjustment Retract and lower boom noting performance of retraction cycle If chattering is apparent retract chain system requires adjustment Shut down machine systems If necessary adjust extend and retract chain sys tems and secure adjustment locknuts As necessary lubricate all points requiring lubrica tion 4 2 BOOM CHAINS Adjusting Procedures Main Boom JLG Lift D p we gro A WARNING ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE Position main boom fully retracted at 5 degrees horizontal no load in platform Extend main boom 3 feet 1 meter Torque retract chain adjuster to 50 ft Ib 68 Nm then torque extend chain adjuster to 50 ft Ib 68 Nm Retract main boom 1 foot 30 5 cm Check torque on extend chain adjuster Again retract main boom 1 foot 30 5 cm Recheck torque on extend chain adjuster Extend main boom 1 foot 30 5 cm Recheck retract chain adjuster torque Check for proper operation of main boom 4 13 SECTION 4 BOOM amp PLATFORM Inspection Procedure A WARNING BOOM CHAINS ARE TO BE INSPECTED AT TIME OF
148. nd bearings 3 54 from housing by pressing or using a soft mallet on male end of shaft 8 Remove springs 47 from between tabs of discs 46 50 9 Remove bearings 37 54 from shaft 45 with appropriate bearing puller The discs and friction discs will then slide off male end of shaft Remove snap ring and shaft 10 Remove dowel pins 53 springs 51 52 and o ring 55 from housing Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are found to be in good condition JLG Lift 3 31 SECTION 3 CHASSIS amp TURNTABLE Capscrew O ring Spring Lockwasher Back Up Ring Spring Plug Bleeder Dowel Pin Cover Retaining Ring Bearing Square Ring Shaft O ring O ring Disc Housing Bearing Spring Spiral Pin O ring Friction Disc Gasket Back up Ring Separator Piston Disc Figure 3 23 Swing Brake Mico Machines Built to 1992 3 32 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Insert new o ring 55 dowel pins 53 and springs 51 52 in housing 56 2
149. nd bushings wear the cut out becomes pronounced Excessive cut out in a short period of time indicates excessive pressure or oil contamination If the relief valve settings are within prescribed limits check for shock pressures or tampering Withdraw oil sample and check it and tank for dirt GEARS Any scoring on gear hubs necessitates replacement Scoring grooving or burring of outside diameter of teeth requires replacement Nicking grooving or fretting of teeth surfaces also necessitates replacement 3120679 JLG Lift 5 29 SECTION 5 HYDRAULICS DRIVE SHAFTS Replace if there is any wear detectable by touch in the seal area or at the drive coupling 0 002 inches 0 05 mm wear is the maximum allowable Wear in the shaft seal area indicates oil contamination Wear or damage to splines keys or keyways necessitates replacement THRUST PLATES The thrust plates seal the gear section at the sides of the gears Wear here will allow internal slippage meaning oil will bypass the pump A maximum of 0 002 inches 0 05 mm wear is allowable Replace thrust plates if they are scored eroded or pitted Check center of thrust plates where the gears mesh Ero sion here indicates oil contamination Pitted thrust plates indicate cavitation or oil aeration Discolored thrust plates indicate overheating probably insufficient oil DOWEL PINS If either the dowel or dowel pin hole is damaged the dowel or machined ca
150. necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are found to be in good condition Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Clean all parts thoroughly before assembly 2 Press new rotary oil seal 23 into housing 21 Note direction of the seal NOTE Earlier models did not use retaining ring 22 3 Install new bearing 19 and retaining ring 22 on shaft 10 4 Insert shaft assembly and retaining ring 18 in hous ing 21 NOTE Be sure to use the same number of springs and spring pattern as recorded during disassembly Spring retainer 17 was not used in earlier models 3120679 5 Insert dowel pins 20 spring retainer 17 and springs 15 amp 16 in housing 21 6 Position new large diameter return plate 14 in housing with tabs guided by dowel pins 20 until disc rests on springs 15 amp 16 DISCS 11 14 AND FRICTION DISCS 12 SHOULD REMAIN DRY DURING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES 7 Place a new friction disc 12 on shaft 10 until it contacts return plate 14 8 Add additional new discs 11 and new friction discs 12 as required to complete assembly Insert separators 13 in holes of return plate 10 Install new o ring 5 new backup
151. nel Seal Drive Gear Set Square Seal Gear Housing Bearing Carrier Connector Shaft Gear Set Gear Housing Piggyback Housing Nut Flatwasher Stud Connector Shaft Thrust Plate Channel Seal Gear Set Square Seal Gear Housing Dowel Pin End Cover Bolt Thrustwasher Figure 5 5 Main Gear Pump Assembly 3120679 JLG Lift 5 21 SECTION 5 HYDRAULICS Carefully remove the drive and driven gears Avoid tapping the gear teeth together or against other hardened surfaces Keep these gears together because they are a matched set Examine and replace if necessary Remove the thrust plate from the bearing carrier Examine and replace if neces sary Lift the gear housing from the bearing carrier If pry ing is necessary take care not to damage machined surfaces Examine and replace if necessary e JLG Lift Carefully lift of pry off the bearing carrier to prevent damage to contact face and edges Dowel pins will remain in either the bearing carrier or the gear hous ing Do not remove them Remove the connecting shaft Remove the thrust plate Examine and replace if necessary Remove the driven gear and the integral gear and drive shaft Keep these together as they are a matched set Examine and replace if necessary Be careful not to damage the machined surfaces of the gears E 3120679 SECTION 5 HYDRAULICS 9
152. ng all applicable safety precautions operate boom functions Check for correct operation and hydraulic leaks Secure as necessary Cycle boom several times and torque boom chains to 50 ft Ib 68 Nm Check fluid level of hydraulic tank and adjust as nec essary SECTION 5 HYDRAULICS Main Lift Cylinder Removal 1 NOTE With tower boom at horizontal depress plunger on limit switch in main lift circuit located inside turnta ble Keep plunger depressed with a c clamp Raise main boom above horizontal just enough to be able to access main lift cylinder Attach a suitable support device or devices to main boom When raising main boom with tower boom at hori zontal do not completely raise main boom as tip ping may occur Remove four bolts and lockwashers securing main lift cylinder rod end attach pin to boom Using a suit able brass drift drive attach pin from main boom Using auxiliary power retract main lift cylinder com pletely Remove four bolts and lockwashers securing main lift cylinder barrel end attach pin to tower boom Using a suitable brass drift drive out attach pin from tower boom Remove cylinder from boom and place in a suitable work area Main Lift Cylinder Installation 1 5 6 Install main lift cylinder in place using suitable lifting slings or supports aligning barrel end attach pins with holes in base boom Using a suitable brass drift drive barrel end attach pin through m
153. not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counterbalance valve is defective and must be replaced To check piston seals carefully remove the counter balance valve from the retract port After initial dis charge there should not be any further leakage from the ports If leakage occurs at a rate of 6 8 drops per minute or more the piston seals are defective and must be replaced If no repairs are necessary or when repairs have been made replace counterbalance valve and care fully reconnect hydraulic hoses to cylinder port block Activate hydraulic system and run cylinder through one complete cycle to check for leaks 5 4 CYLINDER REMOVAL AND INSTALLATION Tower Telescope Cylinder Removal NOTE The tower boom can be telescoped without elevating the tower by overriding the plunger valves Refer to Figure 4 1 Boom Mounted Limit Switches and Valves Installation A CAUTION MAKE SURE THE TOWER BOOM IS NOT EXTENDED BEYOND WHAT IS NEEDED TO GAIN ACCESS TO THE ATTACH PINS NOTICE MAKE SURE THE TOOLS USED TO OVERRIDE THE PLUNGER VALVE IS REMOVED BEFORE RETURNING THE MACHINE TO SER VICE 1 Place machine on a flat and level surface with boom in the horizontal position and extended just enough so that the fly section cylinder attach pins are exposed Shut down engine Support main boom and tower boom with props or overhead lifting devices Re
154. not functioning properly Swing brake not releasing Torque hub not functioning properly Foreign objects s wedged between torque hub pinion and swing gear Sheared shaft on swing motor brake Replenish oil as necessary Repair or replace swing lever Clean or replace line Repair or replace valve Repair or replace motor Repair or replace brake Repair or replace torque hub Remove objects check for damage and repair or replace component s as required Repair or replace motor brake will not swing outside of drive steer wheels Boom will swing in only one direction Axles not extended and locked Extend and lock axles Restricted or broken hydraulic line or fitting Control valve not functioning properly Foreign object s wedged between torque hub pinion and swing gear Swing control lever not functioning properly Brake shuttle valve defective Clean repair or replace line or fitting Repair or replace valve Remove object s check for damage and repair orreplace component s as required Repair or replace swing control lever Replace shuttle valve Boom swings erratically in either direction Hydraulic system oil low Lack of lubricant on swing gear or torque hub pin ion Swing motor not functioning properly Worn or broken teeth on swing gear or torque hub pinion Swing brake not functioning properly Swing brake shuttle valve defective
155. nstall a new relief cartridge and springs and install the main relief cap h Remove the vacuum from the hydraulic tank and retest the main pressure reading Main Telescope Relief a Bottom out Main Telescope Out function b Adjust pressure to 3000 psi 207 bar MAIN TELESCOPE OUT c Bottom out Main Telescope In function d Adjust pressure to 3300 psi 228 bar Main Lift Relief a Tower boom section must be fully raised to oper ate Main Lift Up and Main Lift Down functions b Bottom out Main Lift Up function 3120679 SECTION 5 HYDRAULICS Adjust pressure to 3000 207 bar Adjust pressure to 2600 179 bar out Main Lift Down function 5 Tower Lift Relief e Adjust pressure to 1850 psi 128 bar a Bottom out Tower Lift Up function b Adjust pressure to 3700 psi 255 bar 4 Tower Telescope Relief a Bottom out Tower Telescope Out function b Adjust pressure to 3000 psi 207 bar TOWER TELESCOPE OUT c Bottom out Tower Telescope In function 3120679 JLG Lift 5 13 SECTION 5 HYDRAULICS PROPORTIONAL PLATFORM DIRECTIONAL RELIEF AND LEVEL DUMP VALVE RELIEF CONTROL VALVE SEQUENCE OR SOLENOID VALVE FIVE STACK DIRECTIONAL CONTROL VALVE ONE STACK DIRECTIONAL CONTROL VALVE 0 Figure 5 2 Valve Locations Turntable Mounted Valves 5 14 JLG Lift 3120
156. o sion This is important as corrosion of highly stressed hardened steel chain components can cause a major reduction in the load capacity of leaf chain and result in link plate cracking NOTE The need for lubrication can be determined by the presence of rust on the exposed portions of chain 4 14 _ JLG Lift Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate cracking The initial lubrication at the factory is applied in a hot dip tank to assure penetration into the joint Do not steam clean or degrease chains At time of chain installation factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times If chains are corroded they must be inspected espe cially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dip ping in heated oil and reinstall on the machine Keep chains lubricated Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line position Inspect chains carefully after long time use and heavy loading for this type of crack If any cracks are discovered replace all chains as seemingly sound plates are
157. o carefully lower swing bearing into position on frame Ensure that scribed line of outer race of bearing aligns with scribed mark on frame if a new swing bearing is used ensure that filler plug fitting is at 90 degrees from fore and aft centerline of frame 4 Ensure that all frame and bearing attachment holes are aligned and install four diametrically opposed bolts or clamps to secure bearing to frame Tighten bolts or clamps evenly in a diametrical pattern to a torque of 20 ft Ib 27 Nm 5 Allow Devcon filler to cure at room temperature approximately 21 degrees C for 10 to 16 hours 6 After the appropriate interval release clamps or remove bolts Use a suitable lifting device to care fully remove bearing from frame 7 Carefully remove any excess filler from frame mount ing area from bearing attachment holes and from between gear teeth A WARNING ENSURE THAT TURNTABLE 15 ADEQUATELY SUPPORTED WHILE APPLYING DEVCON AND WHILE INSTALLING THE BEARING EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL a Apply a layer of Devcon or equivalent filler approximately 0 125 in 3 18 mm thick to 3 22 JLG Lift underside of bearing mounting area of turntable base plate b Use suitable hydraulic jacks to carefully raise swing bearing to underside of turntable mount ing plate Ensure that scribed line of inner race of bearing aligns with scribed mark on turnta
158. o tower boom Ensuring that boom is adequately supported and using a suitable slide hammer carefully remove pivot pin from main boom and tower boom Ensure that main boom and tower boom are not damaged Carefully lift main boom assembly clear of tower boom and lower to ground or suitably supported work surface 4 1 SECTION 4 BOOM amp PLATFORM SIDE VIEW MAIN BOOM AND TOWER BOOM ATTACH TOP VIEW BOOM ATTACH TO TURNTABLE Figure 4 1 Boom Mounted Limit Switches and Valves Installation 4 2 JLG Lift 3120679 SECTION 4 BOOM amp PLATFORM Tower Boom Removal 1 NOTE Remove main boom as outlined in Main Boom Removal Shut down machine systems Tower Boom Assembly weighs approximately 14 700 Ib 6 668 kg Using suitable lifting equipment adequately support boom weight along entire length of retracted boom CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON TAMINANTS INTO SYSTEM 4 Tag and disconnect hydraulic lines that run along the side of the boom and also lines to main lift cylin der upper master level cylinder and tower tele scope oylinder 5 Using suitable lifting equipment adequately support main lift cylinder 6 Remove bolts and lockwashers securing main boom lift cylinder barrel end to
159. oe I oc NS T 21 anna 01 3n18 i L v18 lt N38 1HM 8 1 3A 1HM L 13AZ1HM Mans NM8 1HN je 5 311HM 9 21 311HM 1 aan geo 01 3LIHM 01 39NVNO P M i 8 8 8 r EM 01 SLIHM a zs Bu Aveo i a ana 1 manna B ma na d aasma m 18 n38 p lt i af 033 134 o lt HOTA MO113A 9 8 58 318713 lt 0 lt aay NHO 1HM lt 1 i i lt lt lt lt lt lt 2 13AZ71HM ie 18 N30 mag q3a 018 034 T3A 1HM i 3187039 19 TaA LHM x a 5 8 Oi 3 21 g uu z 5 3 2 5 as 50 18 SE 35 5 i lt 1 1870233 B Figure 6 2 Electrical Schematic Sheet 2 of 5 6 23 Lift 3120679 SECTION 6 SCHEMATICS
160. of ring gear with long shoulder is installed down 3 10 JLG Lift 12 While holding ring gear in mesh with carrier assem bly lower into internal gear 21 Small diameter cluster gear will mesh with internal gear Slight rota tion of ring gear may be necessary 13 Locate the one hole on underside of ring gear that has an X stamped beside it This hole should be positioned in line with one of four counterbored holes in face of hub These holes have been coun terbored to accept four shoulder bolts upon installa tion of cover 1 14 Thrust spacer 18 input gear 17 are installed onto input shaft 20 Counterbore in input gear should be facing thrust spacer 3120679 SECTION 3 CHASSIS amp TURNTABLE 15 Place one thrust bearing 16 between two thrust Install o ring 10 into bore of cover 7 Dis washers 15 and place into carrier counterbore connect rod 9 may be used to push o ring down to groove in cover cap bore 16 Assemble cover assembly as follows d Push disconnect rod into bore of cover cap gt Screw pipe plugs 5 6 into cover 4 e Locate large clearance hole in cover cap over pipe plug in cover and install cover cap in cover Use two bolts 12 torqued to 70 to 80 in lbs 81 92 kgcm 3120679 JLG Lift 3 11 SECTION 3 CHASSIS amp TURNTABLE f Install disconnect cap 11 to cover cap wi
161. oid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Proportional Control Valves Vickers The Vickers proportional valves provide a power output matching that required by the load A small line connected to a load sensing port feeds load pressure back to a sequence valve The sequence valve senses the differ ence between the load and pump outlet pressure and varies the pump displacement to keep the difference con stant This differential pressure is applied across the valve s meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load p
162. oil prior to assembly Press new rotary seal 1 into housing 7 Note the direction of seal Install new bearing 2 on shaft 4 Install shaft assembly and retaining ring 3 into housing 7 Install dowel pins 17 spring retainer 16 and springs b amp 6 into housing 7 Be sure to use the same number of springs and spring pattern as recorded during disassembly Position new large diameter return plate 8 in hous ing with tabs guided by dowel pins 17 until disc rests on springs 5 amp 6 Discs 8 amp 23 and friction discs 22 should remain dry during installation No oil contaminate disc sur faces Place new disc 22 on shaft 4 until it contacts return plate 8 Add additional discs 23 as required to complete assembly Insert separators 10 in holes of return plate 8 Install new o ring 19 new back up ring 18 new o ring 20 and new back up ring 21 on piston 24 Insert piston 24 into end cover 13 being careful not to shear o rings or back up rings Install new case seal 11 in housing 7 then install bleeder screw 14 in end cover Position end cover 13 on housing 7 aligning dowel pins 17 with holes in end cover Insert capscrews 12 and tighten evenly to draw end cover 13 to housing 7 Torque capscrews to 55 ft Ibs 75 Nm SECTION 3 CHASSIS amp TURNTABLE 3 56 IP 52 2270 Po 33 d 7 NE f
163. olt 13 Ring Gear 14 O ring 15 Thrustwasher 16 Thrust Bearing 17 Input Gear 18 Thrust Spacer 19 Retaining Ring 20 Input Shaft 21 Internal Gear 22 Carrier 23 Planet Shaft 24 Roll Pin 25 Retaining Ring 26 Spacer 27 Cluster Gear 28 Bearing Cup 29 Bearing Cone 30 Spindle 31 Seal 32 Bearing Cup 33 Bearing Cone 34 Bearing Shim 35 Retaining Ring 36 Hub 37 Pipe Plug 38 Magnetic Plug 39 Stud 40 Keeper Ring 41 Retaining Ring 42 Washer 43 Spring 44 Not Used 45 Input Coupling COON Oy ON Figure 3 1 Drive Torque Hub 3120679 Lift 3 3 SECTION 3 CHASSIS amp TURNTABLE Cleaning and Inspection 1 Thoroughly clean all parts in an approved cleaning solvent Inspect geared or splined components in primary and secondary planet carriers input and output sun gears ring gear coupling and input shaft for chipped or broken teeth and excessive or uneven wear patterns Replace components as necessary Inspect all thrust washers for scoring pitting ero sion discoloration or excessive wear Replace thrust washers as necessary Inspect all bearing cones and cups for scoring pit ting or excessive wear If necessary using a suitable press remove bearing cups from hub and replace bearings as a set Inspect all needle rollers for scoring pitting or excessive wear Replace all rollers as necessary Inspect planet gear pins for grooves sco
164. om boom Lower tower boom to stowed position Check hydraulic fluid level and adjust accordingly Upper Master Level Cylinder Removal 1 NOTE 3120679 With main boom positioned to horizontal and prop erly supported prepare to remove upper master level cylinder Loosen and remove setscrews securing upper mas ter level cylinder rod attach pin to level links Using an appropriate brass drift drive out level cylinder rod attach pin Tag disconnect and cap hydraulic lines to level cyl inder and disconnect supply lines from turntable swing motor When disconnecting hydraulic lines any residual hydraulic fluid should be drained into a suitable con trainer Make up two temporary hydraulic hoses to carry power from swing motor supply lines to upper mas ter level cylinder Couple temporary hoses to swing motor supply hoses and to upper master level cylin der Plug ports in swing motor After installing temporary hoses use auxiliary power and activate swing function to fully retract upper master level cylinder Remove temporary hoses from lower master level cylinder and cap them Plug cylinder ports 7 Remove bolt and lockwasher securing level cylinder barrel attach pin to lower boom Using an appropri ate brass drift drive out level cylinder barrel attach pin and remove cylinder from lower boom Upper Master Level Cylinder Installation 1 JLG Lift With tower boom at horizontal align level cylin
165. on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains 3120679 SECTION 4 BOOM amp PLATFORM 3120679 5 Tight Joints All joints the roller chain should flex freely On roller chain tight joints are usually caused by rust corrosion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrication Tight joints on leaf chain are generally caused by 1 Bent pins or plates 2 Rusty joints 3 Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated TIGHT JOINTS e S 9s Protruding or Turned Pins Chains operating with inadequate lube generate tremendous friction between the pin and plates pin and bushing on roller chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protru
166. ons 2 4 3120679 JLG Lift TABLE OF CONTENTS Continued 24 Cylinder Drift RR Rude A Pusa skye PRU E RE ume 2 4 Platform Drift u apas 2 4 Cylinder ewan uberem vr MR Re pp Page Uu 2 5 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Welding on JLG 2 5 Do the Following When Welding on JLG 2 5 Do NOT Do the Following When Welding on JLG 2 5 SECTION 3 CHASSIS amp TURNTABLE 3 1 Tires amp Wheels L us T L u E Ue ame S uA ia Eae urs 3 1 Tire Inflati ryi 3 1 hire Damage zc y upp uu Mere ade aati ee eit Meu Iu EA 3 1 Tire Replacement ob s t ue he eke ua US 3 1 Wheel Replacement 2 22 2 1 4 2 ed 3 1 Wheel Installation nete n Ee ete Re esr ve RR E eme Rec 3 1 3 2 Drive Torque Hub o uru RR ET EN PR HR E e dude Rod po 3 2 Disassembly EGRE ELI Ree eee ee 3 2 Cleaning and 21 3 4 Assemblyz ul
167. op of boom assembly A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON TAMINANTS INTO SYSTEM 2 JLG Lift Tag and disconnect hydraulic lines to slave level cyl inder and rotator motor Tag and disconnect wiring to platform control box Remove platform from end of main boom assembly Remove setscrews and bushing retaining telescope cylinder rod attach pin to base section 4 8 SECTION 4 BOOM amp PLATFORM Figure 4 2 Main Boom Assembly Sheet 1 of 2 4 4 JLG Lift 3120679 SECTION 4 BOOM PLATFORM Base Boom Mid Boom Fly Boom Telescope Cylinder Extend Sheave Fly Extend Chain Fly Retract Chain Chain Adjustment Assembly Chain Adjustment Assembly 0 Retract Sheave 1 Upper Rear Wear Pads So mg ox mem Figure 4 3 Main Boom Assembly Sheet 2 of 2 3120679 Lift 4 5 SECTION 4 BOOM amp PLATFORM 10 11 12 13 14 15 16 17 18 4 6 Using suitable brass drift carefully drive telescope cylinder pin from base section Remove three locknuts and flatwashers from studs on top of aft end of base section Remove fly section extend chain adjust nut locknut and washer from chain attach plate at upper aft end of base section Remove bolts washers and lockwashers attaching fly section extend chain attach plate to uppe
168. oper system operation is suspected Cylinders w o Counterbalance Valves Front and Rear Steer Cylinders Front and Rear Frame Lift Cylinders Upper Master Cylinder Lower Master Cylinder Front and Rear Axle Extension Cylinders OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate engine and fully extend cylinder to be checked Shut down engine Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port Activate engine and activate cylinder extend func tion Check retract port for leakage If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder With cylinder fully retracted shut down engine and carefully disconnect hydraulic hose from cylinder extend port Activate engine and activate cylinder retract func tion Check extend port for leakage If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks
169. or suitably supported work area Main Telescope Cylinder Installation 1 10 11 12 13 14 15 16 17 18 19 JLG Lift Using suitable lifting equipment carefully lower cyl inder to boom assembly Using another lifting device support sheave wheel end of cylinder and install cylinder into boom assembly Slide cylinder into boom sliding extension chain in place as cylinder is moving in Attach a suitable lifting device to extension chain adjusting eye bolt Attach cylinder rod support bracket to rod support block on telescope cylinder Install chain adjust block to base boom section with four lockwashers and bolts Install two extension chain adjusting nuts that attach eye bolt to chain adjust block Remove sling attached to telescope cylinder rod Using a suitable brass drift install trunnion pins attaching telescope cylinder to mid boom section Install capscrews securing trunnion pins to each side of boom Note that JLG Threadlocker P N 0100011 is required on capscrew threads Install trunnion pin covers on each side of boom Carefully install telescope cylinder rod attach pin into base boom Install snap rings that retain telescope rod attach pin to base boom Remove applicable hydraulic line and port caps and correctly connect hydraulic lines to telescope cylin der Ensure all hoses are correctly routed Install boom end cover Activate hydraulic system Usi
170. ore of spindle assembly The action of the disengaged 9 Assemble carrier assembly 22 as follows spring should be checked at this time a Press bearing cups 28 into both ends of cluster gear 27 with large inside diameter facing out Use an arbor type press with an adapter tool b Place planet shaft 23 on a flat surface with large diameter down Place one bearing cone 29 over shaft and against shoulder This should be a slip fit A CAUTION BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O RING 3120679 JLG Lift 3 7 SECTION 3 CHASSIS amp TURNTABLE c Place cluster gear over planet shaft and onto f Bearings in cluster gear must be seated by bearing cone with large gear on top applying 25 50 Ibs 11 23 kg against them and a s rotating cluster gear at the same time This a 22 pes be done by sliding a second spacer 26 over planet shaft and pushing downward while rotat 5 ing the gear d Place another bearing cone 29 over planet shaft and into cluster gear This is a slip fit g See if retaining ring 25 will fit onto planet shaft groove If not try smaller spacer 26 until retain ing ring fits This will set bearings at 0 000 0 152 mm h Place carrier on edge of a table with one set of holes hanging over the edge Side with roll pin hole should be down 3 8 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE i
171. ot to damage shaft and be sure to discard locknut d Remove lockwasher from around shaft e Remove tanged washer 7 from around shaft f Set hub on something wide enough to allow shaft to fall out of hub and hammer or press shaft down out of hub g Bearing cone 3 should be lying loose in hub Remove bearing cone and set it aside h Remove seal 10 and discard it Seal may be loose around shaft or it may still be in small end of hub i Using a punch and hammer remove bearing cone 5 from around shaft j Using a punch and hammer carefully drive bear ing cup 4 out of counterbore in small end of hub k Turn hub over Using a punch and hammer carefully drive bearing cup 2 out of counter bore in tall end of hub Cleaning and Inspection 1 JLG Lift Clean all parts thoroughly in an approved cleaning solvent Inspect bearing components 2 3 4 5 for damage pitting corrosion or excessive wear Replace bear ings as a complete set if necessary Inspect all thrust washers for scoring or excessive wear Inspect all geared or splined components for chipped or broken teeth and for excessive or uneven wear patterns Inspect o ring grooves in hub 9 and cover 28 for burrs or sharp edges Dress applicable surfaces as necessary Inspect all thrust washer and bearing surfaces for damage Repair or replace as necessary Inspect all threaded components for damage includ ing stretching
172. ounting holes in base boom and cylin der barrel end Secure in place with four bolts and lockwashers Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports Using auxiliary power extend cylinder rod until rod end aligns with attach pin holes in main boom Using a suitable brass drift drive rod end attach pin through aligned holes taking care to align pin retaining plate holes with holes in main boom Secure pin in place with four bolts and lockwashers Remove supports and lower boom to stowed posi tion Remove c clamp from limit switch to release plunger Shut down engine check hydraulic fluid level and adjust accordingly Lower Master Level Cylinder Removal 1 NOTE JLG Lift With tower boom partly raised and properly sup ported prepare to remove lower master level cylin der Remove bolt and lockwasher securing level cylinder rod attach pin to base end of tower boom Using an appropriate brass drift drive out level cylinder rod attach pin Tag disconnect and cap hydraulic lines to level cyl inder and disconnect supply lines from turntable swing motor When disconnecting hydraulic lines any residual hyaraulic fluid should be drained into a suitable con trainer Make up two temporary hydraulic hoses to carry power from swing motor supply lines to lower mas ter level cylinder Couple temporary hoses to swing motor supply hoses and to lower master level cylin
173. peci fied pressure Re adjust pressure REAR FRAME AXLE AREA One or both front wheels will not steer Steering link or tie rod broken or attaching hardware missing Replace steering link tie rod or hardware as necessary One or both front wheels will not rotate or rotate erratically Wheel hub or bearings damaged or not lubri cated Hub attachment nut loose or missing Replace hub or bearings as necessary and repack bearings with approved grease Secure or replace hub attachment nut cotter pin as necessary 6 10 JLG Lift 3120679 SECTION 6 SCHEMATICS Table 6 4 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Difficulty encountered when moving machine Load capacity exceeded Machine being moved up too steep a grade Gradetoo steep Drive wheel tire treads worn smooth System pressure too low Reduce load Apply loads only in accordance with load capacity indicator Remove machine from grade and check that drive system operates correctly See Caution Placard on platform for specified grades and sideslopes Replace tires as necessary and inflate to speci fied pressure Re adjust pressure DRIVE SYSTEM No response to control Machine drives erratically Hydraulic system oil low Hydraulic pump not functioning properly Restricted or broken pump supply line Restricted or broken line on valve bank o
174. quad ring and back up ring during shaft installation Install shaft assembly into body bearing assembly 12 Place contour member of IGR 6 over inner member and insert seven rollers into inner pockets The seven rollers are larger in diameter than the eight rollers Lightly oil square ring seal 8 and place in body groove Place check balls 5 over two 1 8 inch 3 2 mm diameter holes in body Ensure check balls do not fall into tapped holes in body Place locating ring section 4 5 inch 11 4 cm diam eter of IGR onto body with check ball holes facing downward over balls Align eight bolt holes in locat ing ring with eight holes in body Holes will align in only one position Be sure not to dislodge square ring seal while moving locating ring Install eight locating ring rollers into their pockets and oil lightly Place lightly oiled square ring seal 8 into groove in cover and place cover shaft and align bolt holes Install eight bolts 10 with lightly oiled thread ends into bolt holes Tighten diagonally to 15 ft Ib 20 Nm Turn shaft by hand through several rotations Increase torque of each bolt by 5 ft Ib 7 Nm ina diagonal pattern Turn shaft by hand through several rotations Repeat this procedure until torque of each bolt has reached 27 ft Ib 37 Nm 3120679 SECTION 3 CHASSIS amp TURNTABLE DustSeal 8 RingSeal BackupRing 9 VentPlug Includes O ring Quad Ring Seal 10 Bolt
175. r Adjust pilot pressure to 250 400 psi 17 28 bar 3120679 JLG Lift 6 17 SECTION 6 SCHEMATICS Table 6 6 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS No power to platform controls 20 Amp self reset circuit breaker open Contact blockin footswitch malfunctioning Faulty power circuit wiring Check footswitch to ensure that both switches are making contact when pedalis depressed Repair or replace footswitch as necessary Repair replace or adjust contact block as required Check wiring continuity Refer to proper wiring diagram ENGINE STARTER SYSTEM Starter will not crank Discharged battery or loose battery terminals Starter relay faulty or faulty relay connections Malfunctioning starter solenoid or motor Malfunctioning ignition switch Faulty ignition and or starter circuit wiring Check and charge battery or replace battery as necessary Clean and secure battery terminals Using a test meter check relay coil terminals for presence of electrical power and for energization of relay coil Also check relay terminals for cor rect switching of contacts Replace relay as nec essary Replace solenoid or motor in accordance with applicable manufacturer s manual Using a test meter check ignition switch for cor rect switching of contacts Replace switch as necessary Check wirin
176. r aft end of base section Remove plate Remove six bolts and lockwashers securing retract chain clevis cover to lower front bottom of base sec tion Remove fly section retract chain adjust nut locknut and washer at lower front end of base section Note and record the number and thickness of any wear pad shims during wear pad removal Remove bolts and lockwashers attaching side wear pads to front of base section Remove pads and any shims Remove bolts washers and lockwashers attaching lower front wear pads and mounting blocks to base section While supporting assembled fly and mid sections remove wear pads mounting blocks and shims Remove bolts and lockwashers attaching top front wear pads to base section Remove pads and shims Using suitable lifting equipment partially slide assembled mid and fly sections out of base section Using suitable straps tie off fly section retract chains to underside of mid section as mid and fly sections are exiting base section Carefully lift mid and fly sections clear of base sec tion and lower to a suitably supported work area Using suitable lifting equipment support telescope cylinder rod 19 20 21 22 23 24 25 26 27 28 JLG Lift Remove two bolts washers and lockwashers secur ing each trunnion pin cover to mid section Using a suitable tool scribe a line on the outer end of each trunnion pin and boom structure
177. r rotary coupling Rotary coupling leaking internally Seals worn Drive motor s not functioning properly Air in wheel brake circuit Damaged wiring on control switch Control lever not functioning properly Brake s not releasing Microswitch on controller improperly adjusted Replenish oil as necessary Repair or replace pump Clean repair or replace line Clean repair or replace line Repair or replace coupling Repair or replace motor s Bleed circuit determine and correct cause Repair or replace wiring Replace lever Determine cause and repair or replace Adjust microswitch on controller for proper oper ation 3120679 JLG Lift 6 11 SECTION 6 SCHEMATICS Table 6 4 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine will not travel in forward Machine will nottravelin reverse Hydraulic system oil low Restricted or broken hydraulic line or fitting Control valve not functioning properly Drive motor s not functioning properly Circuit breaker open Counterbalance valve sticking on return side See Machine will nottravel in forward Replenish oil as necessary Clean repair or replace line or fitting Repair or replace valve Repair or replace motor s Determine and correct cause reset circuit breaker Adjust return counterbalance out 3 turns cycle drive return to original position Machine overspe
178. re at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral reliefs are provided for each side of the circuit 5 2 CYLINDERS THEORY OF OPERATION Cylinders are of the double acting type Systems incorpo rating double acting cylinders are as follows Tower Lift Tower Telescope Main Lift Main Telescope Front and Rear Steer Lower Master Upper Master Platform Slave Level Front and Rear Frame Lift and Front and Rear Axle Extend A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Direct ing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the oppo site direction and the cylinder rod will retract Holding valves are used in the Tower Lift Tower Tele scope Main Lift Main Telescope and Platform Slave Level circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylin der and its related control valve JLG Lift 5 1 SECTION 5 HYDRAULICS 5 3 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when impr
179. ready to be used Components Removal and Installation 1 JLG Lift 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 eye bolt 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 3120679 SECTION 2 GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component com plete 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 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2
180. ressure Return lines are connected together simplifying routing of return flow and to help reduce cavi tation Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve Inte gral actuator port relief valves anti cavitation check valves and load check valves are standard Relief Valves Main relief valves are installed at various points with the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressu
181. ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings 11 Install new case seal 4 in housing 21 then install bleeder screw 3 in end cover 2 12 Position end cover 2 on housing 21 aligning dowel pins 20 with holes in end cover NOTE If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening capscrews 13 Press on inner ring of bearing 37 until it shoulders on shaft 45 to eliminate binding on bearings Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing 54 NOTICE IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING JLG Lift 3 35 SECTION 3 CHASSIS amp TURNTABLE 3 11 SWING MOTOR Disassembly NOTE NOTE 3 36 Prior to any motor disassembly plug open ports and clean all dirt from outside of motor Mount motor in a vise or other holding device with shaft facing down Remove eight bolts 10 from cover bearing assem bly 13 Remove cover bearing assembly and o ring 8 Dis card o ring Remove IGR assembly 6 starting with outer locat ing ring and rollers The innermost IGR component and rotary valve 4 are
182. ring on control switch solenoid valve or proportional valve Control switch or valve not functioning properly Restricted or broken supply line on valve bank or hydraulic pump Telescope cylinder not functioning properly Hydraulic pump not functioning properly breaker Replenish oil as necessary Repair or replace wiring Replace switch or valve Clean or replace line Repairor replace cylinder Repair or replace pump 3120679 JLG Lift SECTION 6 SCHEMATICS Table 6 2 Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom will not extend Damaged wiring on control switch solenoid Repair or replace wiring valve or proportional valve Solenoid valve or proportional valve notfunction Repair or replace valve ing properly Control lever not functioning properly Restricted or broken hydraulic line or fitting Telescope cylinder not functioning properly Pressure setting not correct Repair or replace lever Clean repair or replace line or fitting Repair or replace cylinder Check pressure re adjust as necessary Broken telescope chain Main boom only Replace chain Main boom only Boom extends and retracts erratically Hydraulic system oil low Wear pads not adjusted or worn Restricted or broken hydraulic line or fitting Control lever not functioning properly Worn seals in telescope cylinder Cylinder not functionin
183. ring or excessive wear Replace pins as necessary Inspect all threaded components for damage includ ing stretching thread deformation or twisting Replace as necessary Inspect oil seal surfaces in hub and spindle for burrs or sharp edges Dress applicable surfaces or replace components as necessary Inspect mating surfaces of hub ring gear and cover for burrs and sharp edges Dress applicable sur faces or replace components as necessary Assembly 1 3 4 If necessary assemble the hub spindle assembly 36 and 30 as follows a With large open end of hub 36 up press bear ing cup 33 into hub If no press is available bearing cup may be frozen and tapped into place with a non metallic faced hammer JLG Lift b Turn hub over small diameter up Install two pipe plugs 37 into hub C Press bearing cup 33 into small diameter end of hub If no press is available bearing cup may be frozen and tapped into place with a non metallic faced hammer e Press seal 31 into hub counterbore with flat metal side facing out Use a flat object to ensure that seal is pressed evenly and is flush with hub face 3120679 SECTION 3 CHASSIS amp TURNTABLE Secure retaining ring 35 completely into spin dle groove and against bearing shim Ensure retaining ring is entirely in groove f Lower hub onto spindle 30 with large open end Install retaining ring keeper ring 40 in locatio
184. roperly Returns to neutral or off position when released Clean and free of debris Interlocks function properly Check for signs of leakage Decals installed and legible Check for proper fluid level Check for chafing and proper routing Check for proper tolerances Properly lubricated Torqued to proper specification No gouges excessive wear or cords showing Properly inflated and seated around rim Proper and authorized components Fully charged No loose connections corrosion or abrasions Verify Perform Sealed Properly Drain Clean Refill Lift 3120679 SECTION 2 GENERAL AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS 1207 FSG AMBIENT TEMPERATURE 110 F 43 C 100 F 38 C 90 F 32 C SUMMER GRADE 70 F 21 C ENGINE FUEL E NR SPECIFICATIONS z 50 10 40 F 4 C 92 30 F 1 C 20 F 7 C ENGINE WILL START AND OPERATE UNAIDED AT THIS z TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 15 10 F 12 C FULLY CHARGED BATTERY WINTER 5 0 F 18 C GRADE FUEL 10 F 23 C SN 20 F 29 C 30 F 34 C 2 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE 180 F 82 C HYD OIL TANK TEMP
185. rt to determine proper torque value Steer Reliefs 2000 138 4 Spool Solenoid Valve Extension Cylinder Reliefs 2000 138 Low Drive System Sequence Valve 450 31 Main Relief on External Relief Valve 3200 221 Proportional Drive Valve Section Relief 3200 221 Factory set does not normally need to be adjusted 3120679 JLG Lift 1 8 SECTION 1 SPECIFICATIONS 1 9 MAJOR COMPONENT WEIGHTS Table 1 13 Major Component Weights 1 10 CRITICAL STABILITY WEIGHTS Table 1 14 Critical Stability Weights LB KG LB KG 36x96 Platform 420 191 Counterweight 3285 1490 Platform Level Cylinder 80 36 Tire amp Wheel Assembly 1020 494 Main Boom 6350 2880 Engine 680 308 Main Lift Cylinder 830 377 8ft Platform 295 134 Master Level Cylinder each 60 27 1 11 SERIAL NUMBER LOCATIONS Tower Boom 14700 6668 For machine identification a serial number plate is affixed Tower Lift Cylinder 1100 499 to the machine The plate is located on the left side of the turntable just behind the fuel tank If the serial number Turntable Complete includes swing 14200 6441 plate is missing the machine serial number is stamped on bearing the left side of the frame below the turntable bearing In Frame Complete 19200 8709 addition the last five digits of the serial number are stamped on the top of the fly end of each of the tower Complete Machine 57000 25855 boom and main boom sections
186. scosity 3120679 SECTION 1 SPECIFICATIONS 1 7 TORQUE REQUIREMENTS 1 8 PRESSURE SETTINGS PSI BAR Table 1 11 Torque Requirements Table 1 12 Pressure Settings 5 Spool Proportional Valve Description Torque Value Interval Dry Hours PSI BAR Bearing To Chassis 545 ft Ibs 50 600 5 Spool Proportional Valve 740 Nm 2 Main Relief 3800 262 Bearing To Turntable 545 ft Ibs 50 600 740 Nm Main Tele Out Relief 2000 138 Wheel Lugs 300 ft Ibs 150 Main Tele In Relief 3300 228 407 Nm Main Lift Up Relief 3000 207 Drive Torque Hub to Spin 260 ft Ibs 200 dle 353 Nm Main Lift Down Relief 1850 128 Main Boom Chains Ibs 200 Tower Tele Out Relief 3000 207 68 Nm Tower Tele In Relief 2600 179 Swing Motor to Swing 110 ft Ibs 500 B ake 149 Nm Tower Lift Up Relief 3700 255 Torque Hub to Turntable 340 ft Ibs 500 ene Jd 207 Mounting Plate 461 Nm Swing Relief 1700 117 Platform Rotator Brake 140 ft Ibs 500 2 Spool Solenoid Valve Bolt 190 Nm Main Relief 2750 190 Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter See Swing Bearing in Rotate Relief 2500 172 Section 2 Level Reliefs 2500 172 NOTE When maintenance becomes necessary or a fastener loosened refer to the Torque 3 Spool Solenoid Valve Cha
187. screw if applicable piston spacer and wear ring if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer if applicable Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 10 11 12 13 5 8 JLG Lift Clean all parts thoroughly in an approved cleaning solvent Inspect the 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 dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing 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 and scoring and for distortion Dress piston surface or replace piston as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary If applicable inspect cylinder head retainer or end cap for surface or thread damage Repair or replace as necessary Inspect cylinder
188. sembly for bend ing cracking separation of welds or other damage Replace boom sections as necessary SECTION 4 BOOM amp PLATFORM Main Boom Assembly NOTE NOTE 10 11 4 10 When installing fly section wear pads install same number and thickness of shims as were removed during disassembly Install top and side aft fly section wear pads and shims as required using bolts and lockwashers Using suitable lifting equipment carefully slide fly section into mid section When installing mid section wear pads install same number and thickness of shims as were removed during disassembly Install mid section top front wear pads and shims as required using bolts and lockwashers Install mid section side front wear pads and shims as required using bolts and lockwashers Install mid section bottom front wear pads and shims as required using bolts and lockwashers Install mid section top aft wear pads and shims as required using bolts and lockwashers Install mid section side aft wear pads and shims as required using bolts and lockwashers Using suitable lifting equipment carefully slide assembled mid and fly sections into base section Place fly section extend chain assembly along tele scope oylinder chain rest with front end of chain hanging just below cylinder sheave Using lightweight motor oil SAE 20W adequately lubricate portion of chain occupying cylinder chain rest Using sui
189. sting or both must be replaced If more than reasonable force is required to seat dowels the cause may be poorly deburred or dirty parts cocking of dowel in the hole or improper pin to hole fit BUSHINGS If gears are replaced bushings must be replaced Bush ings should fit into bore with a heavy press fit SEALS AND GASKETS Replace all rubber and polymer seals including all o rings thrust plate channel seals shaft seal and gasket seal PLUGS Examine the plugs in the shaft end and port end cover to make sure they are in the proper position and tight 5 30 JLG Lift Recommended Start up Procedure for New or Rebuilt Pump Before installing a new or rebuilt pump back off the main relief valve until the spring tension on the adjusting screw is relieved This will avoid the possibility of immediate damage to the replacement unit in the event that the relief valve setting had been increased beyond the recom mended operating pressure prior to removing the old unit Before connecting any lines to the pump fill all ports with clean oil to provide initial lubrication This is particularly important if the unit is located above the oil reservoir After connecting the lines and mounting the replacement unit operate the pump at least two minutes at no load and at low rpm 400 min During this break in period the unit should run free and not develop an excessive amount of heat If the unit operates properly speed
190. t xr RD REPRE RUE eR RE d band 3 38 RAMP Adjustment 2m as tu e She teehee 3 38 3 13 Pump Coupling Conversion Procedures 3 39 Lovejoy Coupling rere kt dee e ex E RHET 3 39 Hayes Gouplitig s s usa sie dos ta Ree eso CA ha Rude dn 3 40 3 14 Tilt Alarm SWIICh ERR wae lu EIER IDEE PNE Nr DES 3 40 Manual Adjustment ic csiis dinot opnari ng Rx ERR m Gu REG eee LEER 3 40 Voltmeter Adjustment 3 41 3 15 Throttle Checks and 2 3 41 SECTION 4 BOOM amp PLATFORM 4 1 Boom Maintenance cessus lel ye yg aQ dux ACE d ee e e y End y 4 1 Boom Mounted Limit Switches and 4 1 Main Boom 2 4 1 Tower Boom 4 3 Main Boom 0 4 3 Tower Boom 4 7 Inspection as ee ee MINE CRI kis ats sas 4 9 Main Boom Assembly i2 lii nag e kp p RR ERE RR REESE 4 10 Tower Boom Assembly u coco sepe REIR Xp pA rer EAE dedans 4 11 Tower Boom Installation
191. table lifting equipment maneuver tele scope cylinder and fly section extend chain assem bly into position at aft end of assembled boom sections 12 13 14 15 16 17 18 19 20 21 22 23 JLG Lift Attach loose end of extend chain to chain clevis at lower aft end of fly section Install chain attach pins and flatwashers and secure with cotter pins Secure chain clevis to bottom aft of fly section with clevis pins and cotter pins If removed install chain attach plate to aft end of base section Secure with bolts washers and lock washers With a slight downward angle on the cylinder insert sheave and chain into boom sections until it is possi ble to insert chain adjust clevis into chain attach plate at aft end of base section Install chain adjust clevis and locknuts Carefully feed telescope cylinder approximately half way into boom sections lubricating chain with light weight motor oil as it passes along chain rest Continue inserting into boom sections Install fly section retract chain sheave at aft end of mid section Install sheave pin and if necessary tap pin into place using a soft headed mallet Secure pin with set screws Install lubrication fitting on end of pin and lubricate sheave with MPG Attach fly section retract chain to chain clevis at lower aft end of fly section Install chain attach pins and flatwashers and secure with cotter pins Carefully p
192. tap lightly with a soft hammer Before inserting a new lip seal in the shaft end cover coat the outer edge of the lip seal and its recess with Permatex Aviation Form A Gasket No 3 non harden ing sealant or equivalent With the metal side of the lip seal up press it into the mounting flange side of the shaft end cover with an arbor press and bar Be careful not do damage the lip of the seal Press in until flush with the recess Wipe off excess sealant 10 11 JLG Lift If the unit is equipped with an outboard bearing guide the bearing into it s recess in the shaft end cover This is a light press fit It may be necessary to lightly tap the bearing into the bore If the pump is equipped with an outboard bearing place the shaft end cover in the vise with the mount ing face up Install the snap ring in the groove to retain the outboard bearing 3120679 SECTION 5 HYDRAULICS 12 Grease the new gasket seals and insert them into the grooves in both sides of all gear housings Posi tion the first gear housing over the shaft end cover and dowels Tap it with a soft hammer until it rests tightly against the shaft end cover Be careful not to pinch the gasket seal Also be sure the large rounded core is on the inlet side 13 Assemble the channel seals into the grooves in the 3120679 thrust plates with the flat side of the seal facing away from the thrust plate as shown below
193. th a soft headed mallet and secure with bolts and lockwash ers Connect hydraulic lines that run along the side of the boom Using all applicable safety precautions operate machine systems and raise and extend boom fully then lower and retract boom fully If problems are present re check procedures and make adjust ments as necessary Shut down machine systems As necessary lubricate all points requiring lubrica tion 3120679 SECTION 4 BOOM PLATFORM Main Boom Installation 1 11 12 13 14 3120679 Using suitable lifting equipment position assembled main boom on tower boom so that boom pivot holes in main boom and tower boom are aligned Insert boom pivot pin gently tapping pin into posi tion with a soft headed mallet if necessary Secure pin with bolts and lockwashers Align rod end of upper master cylinder with attach ing holes in level links Install attach pin and secure with setscrews Align horizontal level link with mounting hole in tower boom and insert attach pin Secure pin with bolt and lockwasher Connect all wiring to ground control box Using all applicable safety precautions operate lift ing equipment in order to position main boom lift cylinder so that holes in cylinder rod end and boom structure are aligned Insert lift cylinder pin If necessary gently tap pin into position with a soft headed mallet ensuring that pin plate holes are aligned with attach holes i
194. th two 18 Secure cover assembly and ring gear to hub with remaining bolts 12 torqued to 70 to 80 in Ibs four shoulder bolts 2 and lockwashers 3 Shoulder 81 92 kgcm bolts fit into four counterbored holes in hub It may be necessary to start bolts into hub by tapping lightly on bolts with a hammer A CAUTION BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING 19 Install sixteen Grade 8 bolts 1 and lockwashers 3 THIS O RING in remaining holes g Place o ring 5 into cover counterbore Use petroleum jelly to hold o ring into place 20 Tighten bolts and shoulder bolts evenly and torque to 100 110 ft lbs 14 15 kgm 17 Place cover assembly 4 onto ring gear 13 Rotate cover assembly until pipe plug 6 is located 90 degrees and 180 degrees from pipe plugs 38 in opposite end of hub 21 Install coupling 45 into spindle onto input shaft 3 12 JLG Lift 3120679 SECTION 3 CHASSIS amp TURNTABLE POSITION PUNCH MARKS AT 12 O CLOCK FOR CORRECT TIMING Figure 3 2 Torque Hub Carrier Timing 3120679 JLG Lift 3 13 SECTION 3 CHASSIS amp TURNTABLE 3 3 DRIVE BRAKE MICO MACHINES BUILT MARCH 1992 TO S N 33476 Disassembly 1 Separate end cover 2 from housing 21 by remov ing capscrews 1 A CAUTION END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE
195. these marks when reassembling 4 Remove the thrust plate Examine and replace if necessary 2 Use a socket wrench to remove the four hex nuts studs and washers 3120679 JLG Lift 5 19 SECTION 5 HYDRAULICS 5 20 Tool List Arbor press Awl 1 1 2 Dia steel ball Bushing Installation Tool 1 5 1 8620 Bearing Quality Steel Heat Treated Bearing puller Owatonna Tool Co MD 956 or equivalent Bushing remover tool See sketch Clean lintless cloths Deburring tool an old file with cutting teeth ground off Machinist s hammer Soft hammer Permatex Aviation Form A Gasket No 3 non hardening sealant or equivalent Medium grit carborundum stone Seal removal tool see sketch Oil and grease Snap ring pliers Prick punch Bushing installation tool see sketch Scale 1 32 or 1 64 graduations Small screw driver Torque wrench Vise with 6 minimum opening Bar for lip seal installation Note For 315 use 1 5 8 dia x 2 bar For 330 use 1 3 4 dia x 2 bar For 350 use 2 1 2 dia x 2 bar C Dia 002 4 000 002 The bushings in P315 P330 P350 Seal Removal Tool Easily made from old Screw driver Heat tip and bend as shown Grind tip to fit notch behind the shaft seal Bushing Puller Grind Relief Allowable D Dia and P365 pumps may be removed from their bores using blind hole collet type
196. thread deformation or twisting Replace as necessary Inspect planet shafts 14 for scoring or other dam age Replace as necessary 3120679 SECTION 3 CHASSIS amp TURNTABLE Assembly 1 Assemble hub shaft assembly as follows a Set hub 9 on work surface wide end up Using a suitable press press bearing cup 2 into counterbore in tall end of hub b Set hub on work surface wide end down Using the press install bearing cup 4 into counter bore in small end of hub c Using the press press bearing cone 5 onto smaller end of shaft 1 d Slowly lower hub small end down onto shaft Check initial torque Install one bolt 31 into bolt circle of hub and keeping torque wrench tan gent to bolt circle pull torque wrench smoothly toward you Rolling torque must fall in the range of 30 40 in Ib 3 5 Nm If it does proceed to step f If not perform step e e If rolling torque is below 30 40 in Ib 3 5 Nm apply more pressure to bearings If rolling torque is above 30 40 in Ib 3 5 Nm tap top of shaft to release bearings and repeat step d f Using the bearing press press bearing cone 3 around shaft in hub g Clean threads on shaft and apply Primer T a de greasing agent to shaft Apply a light coat of Primer T to locknut 8 Allow 2 3 minutes dry ing time h Place tanged washer 7 over end of shaft i Place lockwasher 6 over shaft NOTE Loctite 277 is an anaerobic
197. tion and remove the 6 shims Reinstall the cap and remove the vacuum 2 Adjust the hydraulic pressures Shut off the engine and apply a vacuum to the hydraulic tank If the main relief pressure is incorrect replace the main relief cartridge in the inlet section MAIN RELIEF To adjust the functions identify the correct plug Remove the plug and add shims to increase pressure or remove shims to decrease pressure Each shim added or removed will change the pressure setting approximately 150 psi 10 Bar SECTION 5 HYDRAULICS 5 Stack Directional Control Valve External Relief Adjustment Screws __ EXTERNAL RELIEF St j ADJUSTMENT SCREWS NOTE Make all pressure adjustments with pressure gauge plugged into quick connect adjacent to high drive dump valve at rear of valve compartment 1 Main Relief a Locate the Tower Lift Down Relief Valve Screw the adjustment screw in all the way TOWER LIFT DOWN b Activate Tower Lift Down function The gauge should read 3800 psi 262 bar If the pressure gauge reads 3800 psi 262 bar reset the tower lift down relief to 3000 psi 207 bar c If the pressure gauge does not read 3800 psi 262 bar the main relief cartridge will have to be replaced as follows MAIN RELIEF 5 12 e d Turn off the engine and apply a vacuum to the hydraulic tank e Remove the main relief cap f Remove the springs and relief cartridge g I
198. tor by tightening the three flange nuts Tighten each nut through approxi mately half of it s spring s travel DO ADJUST THE NUT DURING THE REMAINDER OF THE PROCEDURE 3 With the electrical connections complete slowly tighten one of the Y nuts until the circuit is closed and the light on the Platform Control Console illumi nates Figure 3 26 Tilt Switch Adjustment Manual 4 Slowly back off the nut counting the number of turns until the circuit is again closed and the light again illuminates 5 Divide the number of turns determined in step 4 in half Tighten the nut this many turns The line deter mined by this nut and the X nut is now parallel to the ground 6 Repeat steps 3 through 5 for the remaining Y nut The switch is now level 7 Individually push down on one corner at a time there should be enough travel to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the X nut and repeat steps 3 through 7 3120679 SECTION 3 CHASSIS amp TURNTABLE Voltmeter Adjustment 8 Park machine on a flat level surface Ensure machine is level and tires are filled to rated pressure 9 If engine is not running turn ignition switch to ON 10 Connect black lead of voltmeter to ground and red lead to yellow wire protruding from pot on bottom of sensor 11 Adjust leveling nuts to obtain the highest possib
199. tridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture 5 Using a suitable spanner wrench loosen the cylin der head retainer if applicable and or cylinder head gland and remove from cylinder barrel 6 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 7 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel A CAUTION ONCE THE HEAD GLAND HAS CLEARED THE CYLINDER CASE MOUTH THE ROD MUST BE SUPPORTED CLOSE TO THE CYLIN DER CASE PRIOR TO THE PISTON BEING PULLED PAST THE CYL INDER CASE THREADS THIS IS DONE TO AVOID DAMAGE TO THE CYLINDER CASE THREADS AND OR THE PISTON AND PISTON SEALS 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 9 Remove the set screw s if applicable and nut which attach the piston to the rod and remove the piston Discard nylon point set screws 10 11 12 13 Remove the piston rings Remove and discard the piston o rings seal rings and backup rings Remove the set
200. trol switch controller or solenoid valve Solenoid valve not functioning properly Control switch controller not functioning prop erly Relief valve improperly set or not functioning properly Steer cylinder not functioning properly Determine and correct cause reset circuit breaker See proper wiring diagram Repair or replace valve Replace switch controller Reset repair or replace valves as required Repair or replace cylinder Machine will not steer left or to the right Wiring on control switch controller is damaged Wiring on solenoid valve damaged Coil in solenoid damaged No oil flow or pressure to steer circuit Bent cylinder rod Damaged tie rod Crossover relief valve sticking Repair or replace wiring Repair or replace wiring Replace coil Take pressure reading at steer valve and adjust as necessary Repair or replace cylinder Replace tie rod Repair crossover relief valve 6 14 Lift 3120679 SECTION 6 SCHEMATICS Table 6 4 5 Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine wanders steering notfirm Crossover relief valve settoo low or notfunction ing properly Steer linkages loose Steer wheel toe in not set properly Spindle bushings badly worn Leaking rotary oil coupling Reset repair or replace valve as required Tighten linkage Adjusttoe in for 1 4 inch overall Repla
201. try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position Lower the boom to horizontal and fully extend the boom At the position indicated on Figure 3 18 Swing Bearing Bolt Feeler Gauge Check try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position 0015 Feeler Gauge Figure 3 18 Swing Bearing Bolt Feeler Gauge Check Wear Tolerance 1 3120679 From underside of machine at rear center with tower boom fully elevated and fully retracted and main fully elevated and fully retracted See Figure 3 19 using a magnetic base dial indicator measure and record the distance between the swing bearing and the frame At the same point with tower boom at horizontal and fully retracted and main boom at horizontal and fully extended See Figure 3 19 using a magnetic base dial indicator measure and record the distance between the swing bearing and frame See Figure 3 19 If a difference greater than 0 076 in 1 93 mm is determined the swing bearing should be replaced If a difference less than 0 076 in 1 93 mm is deter mined and any of the following conditions exist the bearing should be removed disassembled and inspected for the following a Metal particles in the grease b Increased drive power required 5 c Noise d Rough rotation If bearing inspection shows no defects reassemble
202. ts beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits JLG Lift 6 1 SECTION 6 SCHEMATICS Table 6 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORMLEVELING SYSTEMS Platform will not maintain level attitude Hydraulic system oil low Replenish oil as necessary Dual pilot check valves dirty inoperative Cleanor replace as necessary Restricted or broken hydraulic line or fitting on Clean repair or replace line or fitting slave cylinder or master leveling cylinder Spitvalve s leaking Clean repair or replace spit valve s Worn seal s in slave level or master leveling cyl Replace seal s inder Slave level or master leveling cylinder not func Repair or replace cylinder tioning properly Counterbalance valve on slave Adjust or replace valve leveling cylinder improperly adjusted or not func tioning properly No response to platform leveling controls Circuit breaker open Determine and correct cause Reset circuit breaker Hydraulic system oil low Replenish oil as necessary Damaged wiring on control switch or solenoid Repair or replace wiring valve Control switch not functioning properly Replace switch Restricted or broken hydraulic line or Clean repair or replace line or fitting fitting Control valve not functioning properly Repair or replace va
203. tting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion 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 speci JLG Lift 2 3 SECTION 2 GENERAL fied intervals required the Lubrication Chart 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 cor rosion 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 be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating are recommended for use Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 NOTE 2 4 Refer to Section 1 for recommendations for viscosity ranges JLG recommen
204. uitable work area Tower Lift Cylinder Installation 1 JLG Lift Install lift cylinder in place using suitable slings or supports aligning attach pin mounting holes on turntable Using a suitable brass drift drive the barrel end attach pin through mounting holes in lift cylinder and turntable Secure pin in place with four bolts and lockwashers Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports Using auxiliary power extend cylinder rod until attach pin hole aligns with those in boom Using a suitable drift drive cylinder rod attach pin through aligned holes taking care to align pin retaining plate holes with holes in boom Secure pin in place with four bolts and lockwashers Place boom in stowed position and shut down engine Check hydraulic fluid level and adjust accordingly 3120679 SECTION 5 HYDRAULICS Main Telescope Cylinder Removal 1 Place machine on a flat and level surface with main boom fully retracted and in the horizontal position Shut down engine Support boom platform end with a prop or overhead lifting device Remove boom end cover A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM 4 10 11 12 13 14 15 16 17 3120679 Tag and disconnect hydraulic lines to telescope inder Use suit
205. unit This number is the same as the last two digits in the model number found on the ID tag of the unit Leak test unit at 5 psi 2 bar Remove pipe plugs 12 from hub and fill drive hub half full with EP 90 extreme pressure lubricant then install pipe plugs in hub Torque hub is half full when lubricant runs out of side hole on hub SWING BRAKE AUSCO MACHINES BUILT TO 1992 Disassembly 1 3120679 With shaft protruding downward remove bolts 22 alternately and evenly to reduce spring tension Remove power plate 21 and gasket 2 Bearing 18 is pressed onto shaft 7 and must be removed before removal of rotating discs 11 and stationary discs 12 Further disassembly is not recommended unless necessary for the replacement of specific parts If further disassembly is required remove shaft 7 and stack sub assembly from housing 1 by lightly tapping or pressing on the small external spline end of the shaft and removing the shaft bearings and stack from housing Remove bearing 18 stationary disc 12 rotating disc 11 springs 10 and primary disc 9 Remove bearing 3 from shaft taking care not to damage seal 4 Remove seal 10 11 JLG Lift Remove springs 6 and spring retainer 5 from housing Remove piston 13 from power plate by introducing low pressure air 15 psi 10 bar into the hydraulic inlet Direct piston away from operator Remove o rings 15 and 17 and
206. ust be replaced If the extend port is leaking the counterbalance valve is defective and must be replaced If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports If used remove boom prop or lifting device from boom activate hydraulic system and run cylinder through one complete cycle to check for leaks 3120679 SECTION 5 HYDRAULICS Cylinders w Dual Counterbalance Valve Main Telescope Cylinder Tower Lift Cylinder Platform Slave Level Cylinder NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 3120679 Using all applicable safety precautions activate hydraulic system If working on the main telescope cylinder raise the tower boom and then raise the main boom above horizontal Extend the main fly boom approximately 1 foot 30 5 cm If working on the platform slave level cylinder stroke platform level cylinder forward until platform sits at a 45 degree angle Shut down hydraulic system and allow machine to sit for 10 15 minutes Turn ignition switch to ON move control switch or lever for applicable cylinder in each direction then turn ignition switch to OFF This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appro priate cylinder port block There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should
207. ut actuator Figure 3 27 Tilt Switch Adjustment Voltmeter Lift 8 41 SECTION 3 CHASSIS amp TURNTABLE THROTTLE LEVER ACTUATOR CABLE INJECTION PUMP THROTTLE LEVER STOP ADECO ACTUATOR ADECO ACTUATOR ACTUATOR CABLE HIGH ENGINE LIMIT SWITCH LOW ENGINE SLIDE PIN 2 Figure 3 28 Throttle Checks and Adjustments Deutz Engine 3 42 JLG Lift 3120679 SECTION 4 BOOM amp PLATFORM 3120679 SECTION 4 BOOM 8 PLATFORM 4 1 BOOM MAINTENANCE Boom Mounted Limit Switches and Valves NOTE The numbers on the following descriptions corre spond with the numbers in Figure 4 1 Boom Mounted Limit Switches and Valves Installation Located inside of turntable at the main boom pivot pin on the left side Controls speed of main boom lift and lower at fully stowed and fully elevated posi tions Outside of Fly Boom Prevents operating tower boom lift or lower until the tower telescope is fully retracted If tower telescope drifts out when stowed tower lift will not operate Base end of Tower Boom on the bottom side Pre vents Hi speeds of the engine drive and 2 speed of the drive motors when tower boom is raised Hi engine will operate when operating tower telescope and tower lift On top of Fly Boom Prevents tower lift do
208. valve b Loosen locknut on sequence valve and adjust to 450 psi 31 bar Turn adjusting screw clockwise to increase pressure counterclockwise to decrease pressure Tighten locknut and remove hot wire from dump valve 2 Single Stack Proportional Valve NOTE Prior to adjusting drive pressure plug brake port S on drive counterbalance valve located inside frame beneath swing bearing a Bottom out Drive function b Loosen locknut on adjusting screw on propor tional relief and dump valve and adjust to 3200 psi 221 bar Turn screw clockwise to increase pressure counterclockwise to decrease pres sure Tighten locknut 5 Stack Directional Control Valve Internal Relief Adjustment NOTE Make all pressure adjustments with pressure gauge plugged into quick connect adjacent to high drive dump valve at rear of valve compartment 3120679 Lift 1 Testthe hydraulic pressures a b a b Start the engine and stall each function Record the pressures Shut off the engine and apply a vacuum to the hydraulic tank Remove the plug cap from the Tower Lift Down valve section and add 6 shims Reinstall the cap and remove the vacuum from the hydraulic tank TOWER LIFT DOWN Start the engine and stall the Tower Lift Down function Record the main relief pressure Shut off the engine and apply a vacuum to the hydraulic tank Remove the plug cap from the Tower Lift Down valve sec
209. ven load distribution Sheaves should be inspected for worn flanges which would indicate misalignment and wear on the outside diameter of the sheave A worn sheave can mean several problems as follows 1 Chains too tight 2 Sheave bearings pin bad 3 Bent misaligned chains Table 4 1 Chain Stretch Tolerance CHAIN PIN TO PIN presi SIZE MEASUREMENT 14 IN 36 CM SPAN 0 50in pitch 14in 36 0 42 in 1 27 cm or 28 pitches 1 07 cm 1 00 in pitch 14in 36 cm 0 42 in 2 54 cm or 14 pitches 1 07 cm 1 75in pitch 14in 36 cm 0 42in 4 45 cm or8pitches 1 07 cm 2 00 in pitch 14in 36 cm 0 42in 5 08 cm or 7 pitches 1 07 cm 4 3 WEAR PADS Shim up wear pads to within 5 16 in 0 8 mm tolerance between wear pad and adjacent surface Replace wear pads when worn within 1 8 in 3 2 mm of threaded insert 4 4 PLATFORM ROTATOR BRAKE The platform rotator is equipped with a brake which uses a stack of belleville washers to apply friction to the plat form pivot point To ensure proper friction torque bolt securing belleville washers to 140 ft Ib 190 Nm 4 16 JLG Lift 3120679 SECTION 5 HYDRAULICS 3120679 SECTION 5 HYDRAULICS 5 1 VALVES THEORY OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solen
210. wn unless main boom is fully lowered Inside of the turn tale on the left side Cam 1 pre vents the tower telescope extend function until tower lift is fully up Cam 2 prevents main boom lift unless tower boom is fully up Main Boom Removal 1 Shut down machine systems NOTE Main Boom Assembly weighs approximately 6 350 2 Ib 2 880 kg Using suitable lifting equipment adequately support boom weight along entire length of retracted boom A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON TAMINANTS INTO SYSTEM 3 10 11 12 13 JLG Lift Tag and disconnect hydraulic lines that run along the side of the boom Remove Bolts and lockwashers attaching upper lift cylinder rod end attach pin to main boom Using a slide hammer or similar tool and taking care not to damage pin remove pin from main boom Using all applicable safety precautions and only if necessary operate main lift down and fully retract main lift cylinder Shut down machine systems Remove bolt and lockwasher securing level link attach pin to tower boom and remove pin from tower boom Remove setscrews securing upper master cylinder attach pin to level links Remove and remove inder rod end from level link Tag and disconnect all wiring to ground control box Loosen and remove 4 bolts and lockwashers secur ing main boom pivot pin t
211. y restricted return line to reservoir Damaged valve seals Remove and repair valve as necessary Remove valve and repair or replace as neces sary Remove line and clear obstruction or replace line as necessary Remove valve and repair or replace as neces sary 3120679 JLG Lift 6 3 SECTION 6 SCHEMATICS Table 6 2 Boom Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM ELEVATION SYSTEM No response to lift control switch Lift control inoperative Repair or replace control lever Dump valve bypass not operating Determine cause and repair or replace valve Hydraulic system oil low Replenish oil as necessary Restricted or broken supply line on valve bankor Clean or replace line hydraulic pump Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace cylinder Hydraulic pump not functioning properly Repair or replace pump Boom will not raise Load capacity exceeded personnel or equip Reduce load Refer to capacity placard menton platform Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fitting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Pressure relief valve not functioning properly Re adjust or replace valve Bypass valve dump not functioning Repair or replace valve L

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