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Service and Maintenance Manual

1. amp TURNTABLE 0990 CONNECT I ON J1 42 gt 4 PIN 3 PIN NE x 5 38 d J3 9 49 BLUE 27 3 ME 9 PIN o lt BLUE 28 3 Y J DON NOU WHT RED 57 9 BLACK 2 LEFT 57 6 ov auck 16 3 CABLE SOFT TOUCH p SIDE SWING O OVERRIDE SWITCH BUTS mem IB a SOFT TOUCH E OPTION 9 NC NC 5 WHITE FOOTSWITCH XO AS K G a SOFT TOUCH ORN YEL WEN g TU LIGHT E EN BROWN SWING LIF e VELED 2710 RED over ick ES 4 ASSEMBLY 8 2 8 5 Up 3 B 53 8 2 55 5 ORN RED 49 4 3 WORKLIGHT B SUPPLY COLOR DICTATED BY WORKL IGHT VENDOR 0 9 a 0 404 03 e 88 u OPTIONAL a side z er 8 ge SE geo LEES gt Be Ge 22 WORKLIGHT B SUPPLY 80 7 ge COLOR DICTATED BY AK WORKL IGHT VENDOR f 9 ORG 8 gt RED Z 4 socket p TILT MODULE BLACK G gt 6 PIN E 1 ae 44 12 J5 mE MR
2. 3 46 3 29 Battery Cable 0 3 48 3 30 Batteries and Battery 4 3 49 3 31 Battery Charger uei le eS E N 3 50 3 32 Battery Charger 3 51 3 33 Generator Components 1 1 4 4 3 53 3 34 Generator System Analyzer Flow Chart a saaana aeaaea 3 56 9 35 oet REV RP I e Rede Poe edt 3 60 4 1 Boom Assembly Sheet 1 3 1 4 2 4 2 Boom Assembly Sheet 2 4 3 4 3 Boom Assembly Sheet 3 4 4 4 4 Boom Limit Switch 2 4 6 4 5 Transport Limit Switch CE 4 7 4 6 Platform Support Torque 4 8 4 7 Eoad S rnsor ae ee devs eA 4 9 4 8 Timing Marks th a Dt ev aed wha 4 10 4 9 Platform Rotator Assembly Cutaway
3. TET 5 19 Platformi ddA rnd enn eee aed eer selon 5 19 Platform Level Up 21 5 19 Jib Relief 559 Lar orto emt Decii Lut stor LR ECL sweets 5 19 SECTION 6 JLG CONTROL SYSTEM 6 1 Introductions DEM 6 1 6 2 To Connect the JLG Control System 6 5 6 3 Using the Analyzer x eer EIER UE AE ee et 6 5 6 4 Changing the Access Level of the Hand Held 6 6 6 5 Adjusting Parameters Using the Hand Held Analyzer 6 7 6 6 Machine Setup eR ER RUE RUE RUE eU EROR Kei aos 6 7 6 7 Machine Personality 05 6 9 6 8 Machine Configuration Programming Information 6 12 6 9 Level Vehicle Description 4 6 14 Help Descriptions and Fault Flash 6 14 6 10 Analyzer Diagnostics Menu 5 6 22 6 11 System TeSt roisto eren cer per dated ear ee 6 29 3121813 JLG Lift V TABLE OF CONTENTS SECTION NO TITLE PAGE NO SECTION 7 BASIC ELECTRICAL INFORMATION amp
4. Figure 3 29 Battery Cable Routing 3 48 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE BATTERY BATTERY BATTERY CHARGER BATTERY FORK POCKET BATTERY DISCONNECT Figure 3 30 Batteries and Battery Charger 3121813 JLG Lift 3 49 SECTION 3 CHASSIS amp TURNTABLE x us NOTE Charger Cover removed for clarity Item 5 Not Shown 1 20AmpCircuitBreaker 7 Harness 13 SCR 2 Connector 8 Harness 14 Relay 3 PCBoard 9 FuseHolder 15 ShuntAssembly 4 DCCord 10 ACInletPlug 16 Strain Relief 5 FuseHolder 11 DC Plug 17 Transformer 6 80AmpDCFuse 12 Rectifier 18 Varistor Figure 3 31 Battery Charger 3 50 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE INTERLOCK CONNECTOR SEE D13552 1 ASSY DWG RA 249 Ee S SOLDER CONNECTION BLK DC NEG BLACK conil BLK AC F
5. 1 6 4 7 1 Voltage Measurement 7 1 7 2 Resistance 2 7 2 7 3 Continuity 4 7 2 7 4 Current Measurement 7 8 7 5 Connector Assembly Figure 1 7 5 7 6 pide E Ga RETO 7 5 7 7 Connector Assembly Figure2 7 6 7 8 Connector Assembly Figure 3 7 6 7 9 Connector Assembly Figure 4 7 6 7 10 Connector Disassembly heals ROC OR EAE EUER RE 7 7 7 11 Connector 1 2 7 8 7 12 Contact Installation 7 9 7 13 DT DIP 2 111 1 ee 7 9 7 M4 HD HDP Contact 1 0 7 10 7 15 HD HDP Locking Contacts Into Position
6. 6 29 6 11 System Test 6 30 JLG Lift 3121813 SECTION 1 SPECIFICATIONS 1 1 CAPACITIES SECTION 1 SPECIFICATIONS Table 1 1 Capacities Generator Fuel Tank M Models Only 13gallons 49 2 liters Hydraulic Tank Priorto S N 51941 15 gallons 57 liters S N 51941 to Present 15 9gal 60 2 L 12 4 gal 46 9 L to full mark Drive Hub 0 4 gal 1 5 liters Table 1 2 Operating Specifications Maximum Manual Force 400N Gross Machine Weight Platform Empty E600J M600J 16 300 Ib 7 393 kg E600JP M600JP 16 800 Ib 7 620 kg 1 2 OPERATING SPECIFICATIONS Table 1 2 Operating Specifications Maximum Work Load Capacity Unrestricted 500 Ib 230 kg Maximum Travel Grade Gradeability 30 with Boom retracted and approximately horizontal Tower Boom fully lowered Maximum Travel Grade Side Slope with Boom retracted and approximately hori zontal Tower Boom fully lowered 5 Tilt Alarm Setting See Section 3 ANSI CSA 5 CEE M600 amp E M600J 4 CE E M 600JP 3 Maximum Vertical Platform Height 601 18 29 m Maximum Horizontal Platform Reach E600 43ft 13 11 E600J 42ft 9in 13 11 m Machine Width 2WD Tft 117 16in 2 42 4WD 7 ft 11 3 8 in 2 42 Machine Length E M600 30 ft 11
7. Ue kane toe eios 1 1 1 7 Furicti n Speeds sis cen EE Gp ee 1 2 Machine Orientation When Doing Speed 1 2 Test Notes iun AM gt geen gad ean dad aah alin ECT Rte CR nS 1 2 1 8 Pressure Settings da bath raed giu d epi ERU Eee Pu 1 2 1 9 Torque Requirements prs 1 3 1 10 Major Component 2 4 1 3 1 11 Serial Nuimber Location aet See 1 3 1 12 Hydraulic Ol reru Rr P Pet 1 4 1 13 Operator Maintenance 1 5 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 RF nee 2 1 Preparation Inspection and 2 1 Pre Start Inspection osc eed vane tA ERU ee cea Eu UA ERU ERE EE 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 1 2 4 1 2 1 Preventative 4 1 2 1 2 2 Service and
8. 3 45 Swing Bearing Torque 3 46 Swing Drive Installation RH eens 3 46 Setting Backlash Wages Ie mde ND utes 3 46 3 10 Battery Maintenance and Charging 3 47 Battery Maintenance 3 47 Optional On Board 3 47 Battery Charging On Board Charger 3 47 Removing the Battery 3 48 3 11 Generator Prior to S N 88375 3 52 Timing Sequences i are 3 54 To Connect the JLG Control System Analyzer to the Generator 3 55 Alarms and Fault Flash Codes 3 55 Output Current and Voltage Settings 3 57 Priming the Fuel eere P e tea 3 58 3 12 Generator S N 88375 to Present 3 59 ee MERO TE 3 59 Alternator uet ERRARE PA ERG DG RUE 3 59 Dynamo and Dynamo Voltage
9. 1 11 1 7 Torque Chart METRIC Fasteners Sheet 5 7 1 12 1 8 Torque Chart METRIC Fasteners Sheet 6 7 1 13 1 9 Torque Chart METRIC Fasteners Sheet 7 7 1 14 2 1 Operating Temperature Specifications Kubota 2 10 3 1 Torque Hub sepe ePaper Pa eee Be ead anes 3 4 3 2 Main Disassembly Drawing 1 2 1 24 50 3 8 3 3 Main Disassembly 02 2 3 9 3 4 Output Cartier an catia nds athe Bn en de ERR Dose RET as Soa et 3 10 3 5 Planet Gear zo eov Rete oe har a a eee eine CR UP ud tee 3 11 3 6 Input Carrier assa a eh ied ood whl e dvd att ble od Sopot a 3 12 3 7 5 RE ot eee a een elite alia 3 13 3 8 Cover ASSembly torri e POLI SR ER CURE AES Ger e Ea qa aed 3 14 3 9 Hub Assembly Sheet 1 2 3 18 3 10 Assembly Sheet 1 0 2 3 19 3 115 Pressing TOOL Sig uv ped re Teo re ates Gud ln E Gee ba e Seo y hs 3 20 3 12 RUE En op a CU Enn a d 3 20 9 13 Drive
10. SANAN T3 31 401 TIOHOS NYO gt MOHHV ISIHL 55 Movalno NMOG XVII NIN GM 1HOlH SdWv ovuuisod S OVHLISOd dn 43335 LHOIY dn XVIN dn NMOC XV 2 1457 1431 1431 XYN NIN dn 1331 1331 LNOLNS 131 7 48885 131 13930 13030 13940 139430 13930 131 71 1300W AGOW 4135 3NIHOVIA 43895 T399V 83315 air T399V T399V T399V 7395 ALVLOY 133SV8 F4 I3A31 L338 V8 SNIMS T390V Sal IVNOSH3d 13l1H3MO1 147 L L33HS 6 3 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM GENERATOR CONTROL MODULE GROUND CONTROL MODULE Figure 6 4 Control Module Location JLG Lift POSITRAC TILT MODULE POWER MODULE 3121813 SECTION 6 JLG CONTROL SYSTEM 6 2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 1 Connect the four pin end of the cable supplied with the analyzer to the motor controller module located in the platform box or at the power module and con
11. p M Xe cc a n Ov P 3000 EN UE En cud I temere FANE MPs a LEFT ORIVE MOTOR FLOW DIVIDER GEAR TYPE 0 O RIGHT DRIVE MOTOR 3121813 Figure 7 25 Hydraulic Schematic Sheet 2 of 2 43 PSI BYPASS JLG Lift 2792459 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS LB NOTES 7 20 JLG Lift 3121813 An Oshkos 3121813 h Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 pla B JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 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 USA 717 485 5161 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001
12. 4 11 4 10 Rotary Actuator Exploded View 4 4 14 4 11 Rotary Actuator Assembly Drawing 4 15 4 12 Operating Principle Jib Rotator eee tenes 4 25 3121813 JLG Lift vii LIST OF FIGURES FIGURE NO TITLE PAGE NO 4 12 Jib Rotator Assembly 2252 02 eee edie e ee md beet em E 4 27 4 13 for Removing End 1 4 28 4 14 Rotator Counterbalance 4 31 5 1 Cylinder Barrel Support excea bei nei pe eae ks CURE RA d 5 4 5 2 Capscrew _ _ 5 4 5 3 Axle Lockout Cylinder et eb repe ati a ei eee DERI DA ee ped 5 5 5 4 Eevel C vlinider eae tS 5 6 5 5 Jib Lift Gylinder s sper eb ene ER ehe de T dues Ea x 5 7 5 6 Lift Cylindera Pv 5 8 5 7 Master Cylinder ous A RED EM nk REPRE 5 9 5 8 steer Cylinder a o eae do cet eb cM 5 10 5 9 Telescope Cylinder shits eo eed e RIPE VE dehet 5 11 5 10 Cylinder Rod 5 12 5 11 Tapered Bushing 1 4 5 12 5 12 Bearing
13. kae LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the last fault the sys tem has seen if any are present You may scroll through the fault logs to view what the last 25 faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ESC two times STARTUP 2 1 indicates a power up When a top level menu is selected a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS 3121813 JLG Lift 6 5 SECTION 6 JLG CONTROL SYSTEM Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases such as DRIVE the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus while in access level 2 Remember you may always cancel a selected menu item by pressing the ESC key 6 4 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER When the analyzer is first connected you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level This ensures that a setting can not be accidentally altered To change the access level the correct password must be entered To enter the pass word scroll to the ACCESS LEVEL menu
14. 2 2 Generals a Sui RE dae E NEA a re Neu 2 2 Safety and Workmanship 2 2 Cleanliness ees ceded rite ave E 2 2 Components Removal and 1 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts eme pP p 2 3 Bearings us kA A 2 3 Gaskets delest edi ee Ere d eg to ides RU obe e n edd 2 3 Bolt Usage and Torque Application 2 3 Hydraulic Lines and Electrical Wiring 2 3 Hydraulic System es uen VR ra Re ua 2 3 CERE 2 3 Battery cuc durer Ure eiue uev pd e PE uv P Ua Reedy ee 2 3 Lubrication and Servicing 2 3 2 3 Lubrication and Information 2 1 1 24 0 22242222 2 4 Hydraulic System RI der ETUR Ada Be ea 2 4 Hydra liciOil eR EXT ee ee ee need we bed qx PES 2 4 Changing Hydraulic RR Rae esis epee RR 2 4 Lubrication Specifications 2 4
15. 3121813 4 5 JIB ROTATOR Operating Principle Helac s helical hydraulic rotary actuators use our sliding spline technology which converts linear piston motion into powerful shaft rotation The actuators are composed of a housing and only two moving parts the central shaft and the annular piston Helical spline teeth machined on the shaft engage matching splines on the inside diameter of the piston The outside diameter of the piston carries a second set of splines of opposite hand which engage matching splines in the housing s ring gear As hydraulic pressure powers the piston back and forth within the housing similar to the operation of a hydraulic cylinder the splines cause the shaft to rotate Disassembly 1 Remove all hydraulic fittings Drain the oil from both sides of the piston through the pressure ports 2 Place the actuator horizontally on a clean work bench with ample room to place the internal parts as they are removed 3 Unthread the socket head cap screws 102 from the lockwasher 05 Remove the lock washer from the shaft 02 4 Secure the actuator firmly to the work surface to pre vent movement A pipe vise works well Insert two long screws 1 4 20 into the end cap 04 and using a pry bar unthread the end cap from shaft by Bars indicate starting positions of piston and shaft Arrows indicate direction they will rotate The housing s ring gear remains stationary As fluid pressure i
16. N C amp 3 PIN 22 Ei 5 o E REVERSE B BATTERY ORANGE 55 4 NEGATIVE 9 9 HH ia LL 300 BLUE BLUE 5 RED 5 b EE OPTION ITE WHITE I Gb 2 1 ONLY 5 eamm 7 30 5 1 a d p Ub NS eo mou 5 m 142 3 g UU uw 5 Pos av BATTERY 8 CHARGER 10 8 8 BATTERY 3 8 sev 2 p2 CHARGER DETERMINED PUMP BY COUNTRY OF USE a a MOTOR P1 LOCK AC PROVIDED 2 OUT IN PLATFORM 8 g 3121813 Figure 7 21 Electrical Schematic Sheet 2 of 4 JLG Lift 1870226 A 7 15 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS SEE SHEET 1 OF 2 LOCATION A 3 BLACK 4 AWG GENERATOR POSITIVE BLACK 4 AWG GENERATOR NEGATIVE 134 110 111 a 103 48VDC UA131 TB2 2 3 116 116 115 114 114 UA108 5 8 GENERATOR ENGINE SCHEMATIC G W VR110 g owls F114 20 AMPS 104 105 F112 112 2 4 15 n 106 105 2 105 ___ STARTER 187 t MOTOR K117 87 87a 86 95 30 na o Ts
17. Using a wrench remove Fitting 21 from Brake Housing Remove Motor Control Valve 31 from Motor 10 by removing the four Bolts 34 and washers 33 3121813 SECTION 3 CHASSIS amp TURNTABLE BRAKE HOUSING SUB ASSEMBLY 17 Elbow Fitting 29 Plug 18 Fittings 31 Motor Control Valve 19 Ferrule 33 Washers 20 Tubing Assembly 34 Bolts 21 Fitting Figure 3 18 Motor Control Valve Disassembly 3121813 JLG Lift 29 j he rm UA ASSY 33 i oF ass 3 33 SECTION 3 CHASSIS amp TURNTABLE Motor and Brake Disassembly BRAKE MOTOR SUB ASSEMBLY O ring 11 Thrust Washer 12 HexBolts Figure 3 19 Motor and Brake Disassembly 1 With unit resting on bench with Motor 10 end up 3 Remove Thrust Washer 11 from between Brake loosen Hex Bolts 12 and remove Brake Motor Sub Motor Subassembly and Carrier Frominecrousing 18 See assembly 4 Remove one O Ring Plug 13 from Motor 10 and 9 one O Ring Plug 13 from Brake Housing 6 2 Remove O Ring from between Brake Motor Subassembly and Housing 1G See assembly 5 Remove O Ring Plug 4 from Brake Housing 6 drawing 3 34 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 6 Remove Motor 10 from Brake Housing 6 by removing four Bolts 15 incrementally until spring pressure
18. 1 1 Low Oil Pressure Check oil level Check oil supply lines Refer to Kubota Workshop manual WSM 0C60 80 95 Verify correct operation of oil pressure switch with a test gauge 1 2 High Engine Temp Check for obstructions in the cooling airflow to the engine Check that the ambient temperature is within the design limits of the engine Verify correct operation of engine temperature sensor Overspeed Verify setting of governor lever Readjust if required Refer to Kubota Workshop manual WSM 0C60 80 95 1 4 Underspeed Ensure there is an adequate supply of fuel to the engine Ensure there is an adequate supply of combustion air to the engine Check air Cleaner Verify setting of governor lever Readjust if required Referto Kubota 0060 Engine Manual Overcrank Checkfuel level Checkfuel connections Verify operation of fuel solenoid and fuel pump Checkthe start battery voltage Ifthe engine exhaust contains white smoke then fuel is entering the engine but the engine is notfiring Referto the Kubota 0060 Engine Manual for further checks Ifthe ambient temperature is low verify that the heater and or glow plug are operating 1 5 No Speed Signal Check wiring connections 2 1 Overvoltage Check alternator output voltage 3 68 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Table 3 9 Troubleshooting Flash Code P
19. 822230 s zai SO 1 sus LEVEL FORWARD re AA E RO 2 2 i ETE i RS T res i PLATFORM LEVEL ROTATE i Pressure line for the CE version Pressure line for the Domestic version ION OSCL AXLE LOCK OUT CIRCUIT 0 08646 OSCL AXLE LOCK OUT CIRCUIT FOR CE MACHINES Figure 7 24 Hydraulic Schematic Sheet 1 of 2 7 18 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS WAIN TELE CYLINDER PORT BLOCK 15 REGEN IN EXTEND ONLY BOE 9 000 7 068 0 1K 30 2 280 3 976 5018 Anus 3 082 STRONE 23 CYL STROKE 65001 unas 6000 MAIN VALVE BLOCK MAIN LIFT Cn Boeze o00 26 274 s0 14 Ron 3 000 7 668 ANNULUS 21 206 sa IN STROKE 41 438
20. Figure 3 16 Oscillating Axle 3121813 JLG Lift 3 29 SECTION 3 CHASSIS amp TURNTABLE AXLE OSCILLATION VALVES OSCILLATION CYLINDER P 9 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE WITH TURNTABLE CENTERED ADJUST CAM WITH WASHERS TO PUSH PLUNGER IN 7 9 mm 1 6 mm IDEAL ADJUSTMENT IS 9 5 mm DO NOT PUSH PLUNGER IN MORE THAT 9 5 mm THE EXTRA ADJUSTMENT IS NEEDED FOR T T BEARING PLAY Figure 3 17 Axle Oscillation Lockout Valve 3 30 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3 6 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and cen 10 11 12 3121813 tered between drive wheels prior to beginning lock out cylinder test Place a 6 inches 15 2 cm high block with ascen sion ramp in front of left front wheel From platform control station start engine Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block Carefully activate Swing control lever and position boom over right side of machine With boom over right side of machine place Drive control lever to Reve
21. S A E Viscosity Specific Gravity 0 877 Temperature Range Grade Pour Point Max 40 F 40 C 0 to 180 F TOW Flash Point Min 330 F 166 C 18 to 83 C Viscosity 0 to 210 F 10W 20 10W30 at 40 C 33cSt 18 to 99 at 100 C 6 6 cSt 50 to 210 F 20W 20 at 100 F 169 SUS at210 F 48 SUS NOTE Hydraulic oils must have anti wear qualities at least ae ae F 6 200 to API Service Classification GL 3 and sufficient Viscosity Index 140 chemical stability for mobile hydraulic system ser vice Table 1 14 Mobil EAL H 46 Specs Aside from JLG recommendations it is not advis Type Synthetic Biodegradable able to mix oils of different brands or types as they ISO Viscosity Grade 46 may not contain the same required additives or be of comparable viscosities If use of hydraulic oil Specific Gravity 910 other than Mobil DTE 11M is desired contact JLG Pour Point 44 F 42 C Industries for proper recommendations Flash Point 500 F 260 C Operating Temp Oto 180 F 17 to 162 C Table 1 12 Mobil DTE 11M Specs Weight 7 64 b per gal ISO Viscosity Grade 15 0 9 kg per liter Gravity API 31 9 Viscosity Pour Point Max 40 F 40 at 40 C 45 cSt Flash Point Min 330 F 166 C at 100 C 8 0 cSt Viscosity Viscosity Index 153 at 40 C 15cSt at 100 C 4 1 cSt at 100 F 80 SUS at 210 F 43 SUS cp at 30 F 3
22. 3SV3 13H NVI KINO Z 1nOo1n9 330 93389 lOd LNOLND SAG u air sed alr 3univd3dial Saved YASATVNV 3131 88315 ironed NM anms AYALLVE XVIA 3NTVA ONIMS 330 OVELISOd dnd GAddOLS 03395 WAL NOILOVEL 0 SNOISHSA 501 viva 1631 W31SAS 2 oos L I3A318 399V 3009 OS3 ON H3lN3 3A 21 41 55300 51531 31VALLOV cs LAAHS OL t rin Bi uumeg edeos3 sseid 1 1 t 039907 H ONIHLAHAG U31N3 55384 3121813 JLG Lift 6 2 SECTION 6 JLG CONTROL SYSTEM 5 10 ____ nue 375 ____ dOl u air air HOLINOW AH3 LIVH Oul34sva INHOd V ld CIBAJ1L338 V8 LNOLAD NOLLONNA 131 Z 10 Z 19945 2 2 9 NOILVA313 15 LON OG 31ON ST3A31 85135 3NIHOVW S3LLIVNOSH3d JHL NI S39NVHO NYO 14266 3000 14 21 85320 NIN ii 1331XVI 1331
23. Input Carrier Disassembly 1 3 12 Using a 1 8 diameter punch drive the Roll Pin 4G into the Planet Shaft 3E until it bottoms against the Carrier 3A Using a soft face hammer tap the Planet Shaft 3E out of the Carrier 3A Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 3E NOTE The Roll Pins 4G should not be reused when reassembling the unit Slide the Planet Gear and the two Thrust Wash ers 3B out of the Carrier 3A Remove the 14 needle Bearings 3C from the bore of the Planet Gear Repeat steps 1 through 5 for each of the two remain ing planet gears 3A Carrier 3B Thrust Washer 3C Needle Bearing Planet Shaft Planet Gear 4G RollPin Figure 3 6 Input Carrier JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Hub Spindle Disassembly Place unit on bench with Spindle 1 end down Remove Retaining Ring 1J with appropriate tool Remove Spacer 1N Remove A position Bearing Cone 1C from Bear ing Cup 1D in Hub 1G Lift Hub 1G off of Spindle 1 A Remove Boot Seal 1Q from Hub 1G if applicable If necessary press 9 Studs 1H out of Hub 1G Locate Hub 1G on Seal 1B end Remove Seal 1B from Hub 1G The Seal 1B should NOT be reused when reassem bling the unit Remove B position Bearing Cone 1E from Hub 1G Using a soft steel rod knock both Bear
24. LEVEL DOWN 2 LEVEL FORWARD PLATFORM LEVEL CHECK Figure 5 24 Hydraulic Control Valve Platform Valve JLG Lift 5 21 SECTION 5 HYDRAULICS LB NOTES 5 22 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM SECTION 6 JLG CONTROL SYSTEM 6 1 INTRODUCTION WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CON TROLLER FOR THE PROPER MACHINE CONFIGURATION INCLUD ING OPTIONS IT IS A 6000 PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPO NENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION The JLG designed Control System is a 48 volt based motor control unit installed on the boom lift The JLG Control System has reduced the need for exposed terminal strips diodes and trimpots and provides simplicity in viewing and adjusting the various personality settings for smooth control of acceleration deceleration creep and max speed for all boom drive and steering functions The motor controller will control current
25. seal tool install the pressure seal 205 onto shaft 2 and end cap 4 Use the seal tool in a circular motion 5 Install the wear guide 302 on the end cap 4 and shaft 2 6 Install the inner T seal 200 into the piston 3 using a circular motion Install the outer T seal 202 by stretching it around the groove in a circular motion JLG Lift 4 21 SECTION 4 BOOM amp PLATFORM Each T seal has 2 back up rings see drawing for ori 7 Insert the piston 3 into the housing 1 as shown entation until the outer piston seal 202 is touching inside the housing bore Beginning with the inner seal 200 insert one end of b u ring in the lower groove and feed the rest in 8 Looking from the angle shown rotate the piston 3 using a circular motion Make sure the wedged ends until the marks you put on the piston and the hous overlap correctly ing 1 during disassembly line up as shown Using a rubber mallet tap the piston into the housing up to Repeat this step for the outer seal 202 ihe bointahera the gear laath meet 4 22 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM 9 Looking from the opposite end of the housing 1 11 Looking from the view shown use the existing tim you can see if your timing marks are lining up When ing marks to line up the gear teeth on the shaft 2 they do tap the piston 3 in until the gear teeth with the gear teeth on the
26. 2 4 Loss Of Voltage Sense Alternator output less than 1 2 of the system Shutdown nominal voltage 58VDC steady Unit Enabled no faults Unit can respond to any callto start Unit Off Disabled Unit will not respond to any callto start Notes 1 Enabled once time delay bypass period has elapsed after engine startup 2 Delayed to ensure the fault was not momentary 3 Measured atthe alternator output shutdown is delayed by a factory set period to ensure the fault was not caused by a transient condition 4 Indicates a problem with the engine start battery engine magneto or magneto voltage regulator Alarms must be reset once the fault has been corrected see below Resetting the RBS Controller Maintenance Schedule Check oil level every 24 hours Change engine oil and filter every 150 hours The RBS can be reset using the analyzer or by disabling and re enabling the RBS controller This will clear any cur rent fault condition with the controller 3121813 JLG Lift 3 67 SECTION 3 CHASSIS amp TURNTABLE Troubleshooting Table 3 9 Troubleshooting Flash Code Problem Solution Unit Off Disabled engine will not crank Check position of selector switch Verify that the inhibit run is released Check the warning LED Remedy fault if present and restartthe RBS Check the start battery voltage Check control fuse Check for loose wiring or connection
27. Grasp crimped contact about 25mm behind the con tact barrel Hold connector with rear grommet facing you Push contact straight into connector grommet until a click is felt A slight tug will confirm that it is properly locked in place Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way The receptacle is shown use the same procedure for plug JLG Lift DT DTP Series Disassembly Figure 7 13 DT DTP Contact Removal Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screw driver Hold the rear seal in place as removing the contact may displace the seal 7 9 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS HD30 HDP20 Series Assembly Figure 7 14 HD HDP Contact Installation 1 Grasp contact about 25mm behind the contact crimp barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place LOCKING FINGERS CONTACT UNLOCKED POSITION CONTACT LOCKED IN POSITION Figure 7 15 HD HDP Locking Contacts Into Position
28. PLATE DS N LOWER E JIB LINK A cx 2 lt 4 BOOM WITH JIB UPPER JIB LINK JIB CYLINDER ROTATOR BOOM WITH SIDE SWING JIB JIB CYLINDER ROTATOR Figure 4 3 Boom Assembly Sheet 3 of 3 4 4 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM MASTER CYLINDE PIVOT PIN BOOM PIVOT PIN 13 14 15 NOTE Remove the upper master cylinder pivot pin Remove the boom pivot pin Remove the boom link pivot pin The standard boom assembly weighs approximately 1993 Ibs 904 kg 16 Using an adequate lifting device remove the boom from the machine Installation 1 Using an adequate lifting supporting device posi ao BON 3121813 tion the boom into the proper position on the upright Install the boom link pivot pin Install the boom pivot pin Install the upper master cylinder pivot pin Install the upper lift cylinder pivot pin 13 14 15 16 17 JLG Lift Connect the hydraulic lines running to the master cylinder as tagged during removal Connect the hydraulic lines running to the telescope cylinder as tagged during removal Install the covers on the side of the upright to con ceal the pivot pins Install the rear cover on to the upright Connect all the hydraulic and electrical lines at the bulkhead fitting at the rear of the boom Steps 10 and 11 are only applicable if the machine is equipped with a jib Position
29. Pull back on the contact wire with a force of 1 or 2 165 to be sure the retention fingers are holding the contact See Figure 7 7 RETENTION LEG WEDGE LOCK Figure 7 6 AMP Connector JLG Lift 7 5 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS PULL BACK ON WIRE a RETENTION FINGERS HOLDING CONTACT Figure 7 7 Connector Assembly Figure 2 3 After all required contacts have been inserted the 4 Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position with the housing See Figure 7 9 Release the locking latches by squeezing them inward See Figure 7 8 WEDGE LOCK FLUSH WITH i 22222222 N 4 Figure 7 9 Connector Assembly Figure 4 SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 7 8 Connector Assembly Figure 3 7 6 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS SUSAN Figure 7 10 Connector Disassembly Disassembly 1 Insert a 4 8 mm 3 16 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 2 Pry open the wedge lock to the open position 3 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed NOTE The wedge lock should never be removed from the housing for insertion or removal of the c
30. SECTION 3 CHASSIS amp TURNTABLE Hub shaft Disassembly 1 Using retaining ring pliers remove Retaining Ring 11 from groove in Output Shaft 1 and discard CAUTION EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE 2 Remove Thrust Washer 1H 3 While supporting the Housing 1G on the Output Shaft 1A end press the Output Shaft 1A out of the Housing 1G NOTE The Lip Seal 1B may or may not be pressed out of the Housing 1G by the Bearing Cone 1D during this step 1A Output Shaft 1B Lip Seal 1C Bearing Cup 1D Bearing Cone 1E Bearing Cup 7 Remove the Bearing Cone 1D from the Housing 1G Invert the Housing 1G and remove the Lip Seal 1B if not already removed when Output Shaft was pressed out of Housing 1G Using a bearing puller remove the Bearing Cone 1F from the Output Shaft 1A Bearing Cups 1C amp 1E will remain in Housing 1G If bearing replacement is necessary the Bearing Cups 1C amp 1E can be removed with a slide ham mer puller or driven out with a punch 1F Bearing Cone 1G Housing 1H Thrust Washer 11 Retaining Ring Figure 3 22 Hub Shaft Disassembly 3121813 JLG Lift 3 37 SECTION 3 CHASSIS amp TURNTABLE Carrier Disassembly 1 NOTE 3 38 Using a 1 4 punch drive the Roll Pin 3G which holds the Planet Shaft 3E in the Carrier down into the Planet Shaft 3E until it
31. 0 1 3 32 Tightening and Torquing Bolts 3 32 Motor Control Valve 3 32 Motor and Brake Disassembly 3 34 Main Disassembly Lv erue ie el RE 3 36 Hub shaft 1 3 37 Carrier 3 38 Hub Shaft Sub Assembly 1 3 39 Carrier Sub ASSEMDIY eer Rex Ua Ee ck pP Va EN ees 3 39 Main Assembly gt E RARE 3 40 Motor Brake Subassembly 4 3 40 Motor Brake Assembly 3 40 Motor Control Valve Assembly 1 3 41 Tube Fitting Assembly 3 41 Procedure for Setting Gear 3 41 3 9 Swing Bearing a Wa SL pe da dA Rt 3 42 Turntable Bearing Mounting Bolt Condition 3 42 Wear Tolerance eX aaah eee Re 3 43 Replacement of Swing
32. 116 24 FIELD DRIVE 106 25 START BATTERY 2 26 START BATTERY gt 120 27 PRE HEAT SEE SHEET 1 136 28 INHIBIT RUN D 29 ENGINE TEMP SWITCH SPARE 115 30 OUTPUT VOLTAGE 110 31 OUTPUT CURRENT 8V 111 32 OUTPUT CURRENT SENSE 119 33 D 34 116 35 FIELD DRIVE 3121813 Figure 7 23 Electrical Schematic Sheet 4 of 4 JLG Lift 1870226 A 7 17 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS ARTICULATING JIB ROTATOR ACTUNTOR 4 908 50 1K 300 1 500 1 767 0 1 ROTATOR AcTuaToR ROTATOR MOTION CONTROL VALVE amis 3 141 PILOT TIO 3 1 p ig ROTATOR VOTION CONTROL VALVE SPRING SETTING 2500 51 PILOT RATIO 3 1 SPRING SETTING 2500 951 vii m1 so pu Lao MasteR suave Gji sucio Lan SL ore wen unen wen ien sapin LEVEL BACKWARD
33. 2 To prevent shorting silicone grease must be packed around each wire where they enter the outside of the connector housing Also silicone grease must be applied at the joint where the male and female con nectors come together Any other joints around strain reliefs etc where water could enter the con nector should also be sealed NOTE This condition is especially common when machines are pressure washed since the washing solution is much more conductive than water 3 Anderson connectors for the battery boxes and bat tery chargers should have silicone grease applied to the contacts only NOTE Curing type sealants might also be used to prevent shorting and would be less messy but would make future pin removal more difficult 3121813 SECTION 2 GENERAL Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Deli 2 4 e Pesat mee on See 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 or 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 Rotato
34. 3 5 SPEED SENSOR ADJUSTMENT m For proper drive operation the speed sensors must be properly installed and adjusted The sensor operates on a leading pulse to show direction If installed wrong the sensor will not be able to sense the proper direction 3 24 JLG Lift WARNING IF BOTH SPEED SENSORS ARE INSTALLED WRONG THE CON TROLLER WILL THINK THE MACHINE IS ON A HILL AND WILL GO INTO FULL SPEED MODE IMMEDIATELY WHEN DRIVE IS SELECTED THE MACHINE WILL NOT STOP UNLESS THE FOOT SWITCH IS RELEASED OR THE EMS IS PUSHED IN IF ONLY ONE SENSOR IS INSTALLED WRONG THE CONTROLLER SENSES A PROBLEM AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED IF BOTH SENSORS ARE ADJUSTED TOO FAR OUT THE CONTROL SYSTEM CONTROLLER WILL NOT DRIVE THE MACHINE Adjustment Procedure 1 Back off the locking nut and o ring 2 Thread the sensor in until it bottoms out don t use excessive force 3 Back off 1 2 turns and align the notch with the axis of the brake Refer to Figure 3 14 Speed Sensor Orientation 4 Use a 1 2 wrench to hold the sensor and a 11 16 wrench to snug the lock nut to the brake 3121813 SECTION 3 CHASSIS amp TURNTABLE BLACK WIRE NOTCH gt ITE WIRE WIRE E ON Ae 4 SENSOR IN SENSOR IN LEFT MOTOR BRAKE RIGHT MOTOR BRAKE SENSOR IN SENSOR IN CEU MOTOR BT RIGHT MOTOR BRAKE MOTOR A Figure 3 14 Speed Sensor Orientation 3121813 JLG Lift
35. 3 59 Dynamo Output FUSE UN ERU er Lon ER RUE Ee 3 59 Control EUse xui ate eR ipai RU REC 3 59 Start BANON cide nd tee tW eR NCC A Det ie REO SEC NU uud 3 61 Engine Statoro x e eee UA ede Ea Ra E EUR Sager 3 61 Start Control RP Med eS e 3 61 Fuel Control Relay 2 us iere ED E epa bs ua Sete pe id 3 62 Glow Plug Control 1 3 62 PS Melaka Guna ath a San 3 62 3 63 Fuel Solenoid eee Gg P 3 63 3121813 JLG Lift iii TABLE OF CONTENTS SECTION NO TITLE PAGE NO Engine Low Pressure 3 63 Engine Oil Temperature Sensor 3 63 Alternator Output Current 3 64 Engine Speed Sensot aes RE Eve AUR Eus 3 64 RBS Engine Generator 3 64 Warnings and Safety lt 3 65 System ue Re Peay 3 65 System Status and Performance Monitoring
36. 3 65 System Setlifigs te Uie A p Med 3 65 RBS Start Aa E 3 66 RBS Sh tdoWr zx e sod et area uot ire tte i e Bede ve vitre pce itt 3 66 RBS Alarms and Flash 3 67 Resetting the RBS 3 67 Maintenance Schedule 3 67 Troubleshooting nisar 3 68 APU Engine Start Battery 3 69 3 13 Supplementary fuse for Engine Generator Controller 3 70 Tools And Material sce a Deme Ex d we 3 70 Procedure a Te ace a eee ae aa 3 70 SECTION 4 BOOM amp PLATFORM 4 1 BOOM est wane tbls odes ete oe c MONE tba A AER ceo Pp eat at A ob ni ets Rad 4 1 eoe ertet io usw i we o e ete oai AU nerd 4 1 Installation vro REEL ee EET DEM 4 5 4 2 Load Calibration 4 8 4 3 Platform Rotator Prior to S N 0300130810 4 10 Theory of Operation ee oa ee EAR OE I La 4 10 Disassembly and Inspection 4 10 Assembly and Testing ca
37. 3E Place Carrier 3A on bench so that one of the Roll Pin 3G holes is straight up Paying attention to the location of the Roll Pin 3G hole in the Planet Shaft start Planet Shaft through the hole in Carrier 3A Using ample grease to hold it in position slide one Thrust Washer 3B over the Planet Shaft 3E with the tang resting in the cast slot of the Carrier 3A Place the Planet Gear 3F into position in Carrier and push Planet Shaft through the Planet Gear without going all the way through Slide the second Thrust Washer 3B between the Planet Gear 3F and the Carrier 3A with the tang of the washer located in the cast slot of the Carrier 3A Finish sliding the Planet Shaft 3E through the Thrust Washer 3B and into the Carrier 3A Position the non chamfered side on the Planet Shaft SE roll pin hole so that it is in line with the hole in the Carrier 3A using a 1 8 inch diameter punch If Planet Shaft 3E has a flat on the end position the flat toward the center of the Carrier 3A After using a 1 4 punch to align the Roll Pin 3G holes in the Carrier 3A and the Planet Shaft 3E drive the Roll Pin 3G through Carrier 3A and into the Planet Shaft 3E until the Roll Pin 3G is flush with the bottom of the cast tang slot in the Carrier 8A Use a 1 4 pin punch to make sure the Roll Pin is flush in the slot On 6 1 Ratios of S1C s the pin must be
38. 7 10 7 16 HD HDP Contact 7 10 7 17 HD HDP Unlocking Contacts 4 7 10 7 18 Electrical Components Installation Sheet 1 7 12 7 19 Electrical Components Installation 2 7 13 7 20 Electrical Schematic Sheet 1 4 1 7 14 7 21 Electrical Schematic Sheet 2 4 7 15 7 22 Electrical Schematic Sheet 3 4 1 7 16 7 23 Electrical Schematic Sheet 4 4 1 7 17 7 24 Hydraulic Schematic Sheet 1 2 7 18 7 25 Hydraulic Schematic Sheet 2 2 7 19 viii JLG Lift 3121813 LIST OF FIGURES FIGURE NO TITLE PAGE NO This page left blank intentionally 3121813 JLG Lift ix LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 UE ME MUERE 1 1 1 2 Operating 1 1 1 3 oe x 1 1 1 4 Battery Charger esse nicest Sa eed a Ge WOW ee a ee 1 1 1 5 wide tam c eL eos Sas acide ee cS 1 1 1
39. EPGL Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation 3121813 JLG Lift 1 7 SECTION 1 SPECIFICATIONS Size Tensile M Stress Area Clamp Load Torque Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Lubricated Torque Loctite amp 242 or 271 OR Vibra TITE 111 or Torque Loctite amp 262 or Vibra TITE 131 4 Bolt Dia o 0 00661 In IN LB N m IN LB i IN LB N m IN LB N m 0 1120 0 00604 380 B 6 0 1380 0 01015 610 18 0160 ooroo 90 50 7 16 10 48 35 55 3 4 EE 2500 0 0364 2320 120 13 5 86 10 135 15 sem Nm rus 0 3750 0 0775 4940 30 23 35 48 28 38 1 2 0 5000 9050 ak N 5 65 NOTES 1 8 DO PO Co PO OO Co 45 CO 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 9 16 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 163 90 122 0 6250 0 2560 16300 170 230 130 176 190 258 153 207 3 4 1 353 200 271 0 8750 0 4620 29400 430 583 320 434 475 646 386 523 637
40. HWFS CODE 12 The hardware fail safe tests failed because the hardware fail safe tripped too quickly 9 9 Flash code 9 9 indicates problems with the controller continued POWER MODULE FAILURE HWFS CODE 13 The hardware fail safe tests failed because the hardware fail safe remained tripped when the traction MOSFETs were turned off POWER MODULE FAILURE HWFS CODE 14 The hardware fail safe tests failed because the line contactor could still be energized when the hardware fail safe was tripped POWER MODULE FAILURE HWFS CODE 15 The hardware fail safe tests failed because the contactor drive fail safe did nottrip within the allowed test time POWER MODULE FAILURE HWFS CODE 16 The hardware fail safe tests failed because the contactor drive fail safe tripped too slowly POWER MODULE FAILURE HWFS CODE 17 The hardware fail safe tests failed because the contactor drive fail safe tripped too quickly POWER MODULE FAILURE HWFS TEST STALLED The hardware fail safe tests did not complete but no reason can be determined POWER MODULE FAILURE BAD TEMPERATURE SENSOR The temperature sensor measurementis invalid this is probably due to a disconnected wire within the power module The possibility of other disconnected wires which could cause dangerous system function means that the controller is shut down POWER MODULE FAILURE S C LINE CONTACTOR DRIVER The line contactor energized when the footswitch was closed
41. Input Shaft First Stage Sun Gear Second Stage Sun Gear O ring Flat Head Bolts Retaining Ring Figure 3 3 Main Disassembly Drawing 2 JLG Lift SECTION 3 CHASSIS amp TURNTABLE Output Carrier Disassembly 1 3 10 Using a 1 8 diameter punch drive the Roll Pin 4G into the Planet Shaft 4E until it bottoms against the Carrier 3A Using a soft face hammer tap the Planet Shaft 4E out of the Carrier 4A Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 4E NOTE The Roll Pins 4G should not be reused when reassembling the unit Slide the Planet Gear Sub assembly 4 out of the Output Carrier 4A being careful to not drop the Needle Bearings 4C in the process 4A Output Carrier 4B Thrust Washer 4C Needle Bearing 4D ThrustSpacer Planet Shaft 4F Planet Gear 4H Thrust Washer Figure 3 4 Output Carrier JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 5 Remove 4 Thrust Washers 4B 28 Needle Rollers 6 Repeat Steps 1 though 5 for the remaining two 4C and the Thrust Spacer 4D from the Second Planet Gears 4 t PI staga Planet MF 7 Remove the Thrust Washer 4H from the counter bore in the Output Carrier 4A 1F Output Carrier 4B Thrust Washer 4C Needle Bearing 4D ThrustSpacer 4F Planet Gear Figure 3 5 Planet Gear 3121813 JLG Lift 3 11 SECTION 3 CHASSIS amp TURNTABLE
42. JLG France SAS 2 1 de Baulieu 47400 Fauillet France FF 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 2 49 0 421 69 350 20 49 0 421 69 350 45 S JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 S Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 4 65 6591 9030 65 6591 9031 A Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelo Spain 4 34 93 772 4700 34 93 771 1762 A JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla na Sweden 4 46 0 850 659 500 46 0 850 659 534 Xm www jlg com
43. RACINE 1 3 8 HEX 1 3 16 12 THDS 75 80 Ibs 102 109 Nm RACINE 1 7 8 HEX 1 5 8 12 THDS 100 110ft Ibs 136 149 Nm JLG Lift 3121813 SECTION 5 HYDRAULICS 1 Hydraulic Tank 7 TankStrap 2 Filter amp Pressure Switch 8 Electric Motor 3 SuctionStrainer 9 Hydraulic Pump 4 Magnetic Plug 10 Contactor Module 5 SightGauge 11 Fuel Tank M Models Only 6 FilterIndicator Figure 5 21 Hydraulic Tank and Pump Prior to S N 51941 3121813 JLG Lift 5 17 SECTION 5 HYDRAULICS 1 Hydraulic Tank 7 TankStrap 2 Filter amp Pressure Switch 8 Electric Motor 3 Suction Strainer 9 Hydraulic Pump 4 Magnetic Plug 10 Contactor Module 5 SightGauge 11 Fuel Tank M Models Only 6 FilterIndicator Figure 5 22 Hydraulic Tank and Pump S N 51941 to Present 5 18 JLG Lift 3121813 SECTION 5 HYDRAULICS 5 5 PRESSURE SETTINGS Proportional Main Relief 3200 psi 220 Bar Bang Bang Main Relief 3000 psi 207 Bar Lift Down 1100 psi 76 Bar Lift Up 2500 172 Bar Swing 2500 psi 172 Bar Flow Control 3000 psi 207 Bar Steer 1800 124 Bar Platform Level Up 2500 psi 172 Bar Platform Level Down 1500 psi 103 Bar Jib Up 2300 psi 158 5 Bar Jib Down 2300 psi 158 5 Bar NOTE All functions must be activated from the platform control station when adjusting pressures at th
44. This should be done by plac ing a tool NOT THE SAME TOOL USED IN STEP 9 on the end of the spindle and then striking the tool with a piece of barstock This should be adequate to remove any additional bearing pre load 3121813 SECTION 3 CHASSIS amp TURNTABLE Cover Subassembly Refer to Figure 3 8 Cover Assembly 1 NOTE 3121813 Grease O Ring 6E and insert into internal groove in Cover 6A Assemble Disengage Cap 6B onto Cover 6A using two Hex Head Bolts 6C Torque bolts to 70 80 in Ibs Insert Disengage Rod 6D into hole in Cover 6A until it touches the inside of the Disengage Cap 6B The Disengage Rod can be inserted either end first Grease Face of Thrust Washer 2 and place in Cover 6A making sure that tangs on washer seat into pockets in cover Install O Ring Pipe Plugs 6F into Cover 6A The plugs should be hand tight according to SAE stan dard Main Assembly Refer to Figure 3 2 Main Disassembly Drawing 1 and Figure 3 3 Main Disassembly Drawing 2 NOTE All components should receive a generous amount NOTE 10 11 12 13 14 JLG Lift of lubricant oil as they are being assembled Place Hub Spindle Sub Assembly on the bench Grease O Ring 18 and place it into groove of Hub 1G Place Ring Gear 1F onto Hub 1G Align the three shipping Cap Screw Holes on Hub 1G and Ring Gear 1F Install three shipping Cap Screws 19 into
45. before it was turned on this is probably due to a failed driver within the power module although it could be due to bad power module wiring 3121813 JLG Lift 6 21 SECTION 6 JLG CONTROL SYSTEM 6 10 ANALYZER DIAGNOSTICS MENU the next outer level The LEFT RIGHT arrow keys move between items in the same level The UP DOWN arrow STRUCTURE keys alter a value if allowed In the following structure descriptions an intended item is selected by pressing ENTER pressing ESC steps back to Table 6 6 ADJUSTMENTS Personality Descriptions DRIVE ACCEL Displays adjusts drive acceleration DECEL Displays adjusts drive deceleration MIN Displays adjusts minimum drive speed Displays adjusts maximum drive speed ELEVATED MAX Displays adjusts maximum drive speed NOTE used when elevation cutout switches are limiting maximum speed CREEP MAX Displays adjusts maximum drive speed NOTE used when creep switch on pump potis active TRACTION Displays adjusts the amount of time traction control is enabled after each input activation POSITRAC Displays adjusts the maximum traction motor current at which positrac will activate 4WD MIN Displays adjusts the minimum 4WD assist speed 4WD MAX Displays adjusts the maximum 4WD assist speed 4WD CUTBACK Displays adjusts the maximum 4WD assist speed NOTE used when elevation cuto
46. 1 2 18 ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY PF 10 F 20 F 2 34 40 30 F 40 F SAE 5W 30 SAE 20 NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 OR ABOVE 180 F 82 C HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE HYDRAULIC SPECIFICATIONS EXXON UNIVIS HVI 26 t 4 MOBIL 424 10W 30 4 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE p lt MOBIL DTE 13 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE 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 SEA LEVEL 3 WITH COLD WEATHER PK
47. 1 of 2 3 18 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3121813 Spindle Lip Seal Tapered Bearing Cone Tapered Bearing Cup Tapered Bearing Cone Ring Gear Hub Housing Stud Retaining Ring Ext Retaining Ring Int Spring 1 460 1 500 Thrust Washer Seal Boot Thrust Spacer Input Carrier Thrust Washer 3C Needle Bearing 3E Planet Shaft 3F Planet Gear 4A Output Carrier 4B Thrust Washer 4C Needle Bearing 4D ThrustSpacer Planet Shaft 4F Planet Gear 4G RollPin 4H Thrust Washer 5 Retaining Ring Ext 6A Cover 6B Disengage Cap Bolt Hex 250 20 Unc 500 Gr5 Dowel Pin O ring Pipe Plug Retaining Ring Int 7 086 Coupling Input Shaft Input Sun Gear Output Sun Gear ID Plate Drive Screw O ring O ring Bolt Flat Head Hex Skt 375 16 Retaining Ring Ext Figure 3 10 Hub Assembly Sheet 1 of 2 JLG Lift 3 19 SECTION 3 CHASSIS amp TURNTABLE a 115 2 5 CE SAO E Draw RAK C 27 40 Figure 3 11 Cup Pressing Tool OuE 42402TL HON Draw To Rock 34 37 Figure 3 12 Cup Pressing Tool 3 20 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3 4 DRIVE BRAKE MICO Disassembly 1 Remove pressure plate 3 from cover 21 by removing the capscrews 1 and washers 2 A CAU
48. 1A until it seats against the bearing shoulder Place Thrust Washer 1H onto Bearing Cone 1D CAUTION EYE PROTECTION SHOULD BE WORN DURING THE NEXT STEP OF THIS PROCEDURE NOTE 10 3121813 Retaining Ring 11 should never be reused a repair or rebuild Using retaining ring pliers install Retaining Ring 11 into groove in Output Shaft 1A If Retaining Ring 11 will not seat completely into groove use appropriate pressing tool to press down on Bearing Cone 1D while rotating Housing 1G Reinstall Thrust Washer 1H and Retaining Ring according to preceding procedures Tap the Retaining Ring 11 with a soft metal punch to ensure that the Retaining Ring 11 is completely seated in the groove of the Output Shaft 1A Using a soft face hammer hit the end of the Shaft 1A to remove the bearing preload Install O ring Plug 1J and torque to 23 to 24 ft Ibs Carrier Sub Assembly See Figure 3 23 Carrier Disassembly 1 NOTE 10 NOTE 11 JLG Lift Apply a liberal coat of grease to the bore of Planet Gear 3F This will enable the Needle Rollers 3C to be held in place during assembly Install the first row of 16 Needle Rollers 3C into the bore of Planet Gear 3F Insert Spacer 3D into bore of Planet Gear 3F on top of the Needle Rollers 3C Place second row of Needle Rollers 3C into bore of Planet Gear against Spacer 3D and remove Planet Shaft
49. 3 25 SECTION 3 CHASSIS amp TURNTABLE POWER MODULE CONTROLLER POSITRAC MODULE TRACTION TORQUE CONTACTOR PANEL TRACTION MOTOR A 81 snare O Y E TORQUE HUB Figure 3 15 Drive Components 3 26 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3121813 Speed Sensor Installation Verification The motor controller averages the readings from the right and left speed sensors and therefore it can be difficult to detect if the speed sensors are adjusted properly When the positrac keeps coming in and out while on level sur faces this is a sure indication that one of the speed sen sors is not adjusted properly The worse case condition of speed sensor misadjustment occurs when both sensors are installed in a manner that allows them to indicate the exact opposite direction that the machine is traveling This situation causes the control ler to believe that the machine is rolling in opposite direc tion than that selected by the operator The controllers reaction to this situation is to put more power into the drive motors to attempt to overcome the fact that it believes the machine is rolling backwards This presents itself as uncontrolled movement in the direction selected by the operator until the controller recognizes that it is placing maximum power in the motors and the controller and the speed sensors are still reporting movement in the opposite direction The contro
50. 350 475 1 0000 0 6630 42200 700 949 530 719 735 1000 633 858 1085 600 813 114 1 2500 0 9690 53800 1120 1518 840 1139 1175 1598 1009 1368 1681 920 1247 1979 1100 1491 2278 1260 1708 117 2630 1460 1979 2983 2224 5000059 REV J REF ERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100011 _ 242 Vibra TITE 121 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 7 JLG Lift 3121813 SECTION 1 SPECIFICATIONS 3121813 Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Toga Torque Torque B TM TM p TM Size Dty of Loctite 212 Stress Area ase OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 et 4 40 0 1120 0 00604 onzo p oost f 6 32 01380 600009 40 013380 00010015 32 01640 y l 36 01640 001444 55 5 10 24 04900 0 01750 1580 60 7 3 01900 002000 1800 68 8 1 4 20 Esa REFUSES 25 25 3 8 16 03750 007
51. 4 10 Rotary Actuator Exploded View 4 14 JLG Lift ACCESSORIES 400 Stop Tube 420 1 Bushing 420 2 Bushing 421 1 Bushing 3121813 SECTION 4 BOOM amp PLATFORM 66664 IZ pee 24 Z LLLA AY AY FILA Wi Z A OPTIONAL VALVE MANIFOLD COUNTERBALANCE ITEM 401 MOTION CONTROL ITEM 403 PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1 Housing 103 1 Screw 200 T Seal 302 Wear Guide 400 Stop Tube 2 Shaft 103 2 Washer 202 T Seal 304 ThrustWasher 420 1 Bushing 3 PistonSleeve 106 1 PortPlug 204 O ring 420 2 Bushing 4 EndCap 106 2 PortPlug 205 CupSeal 421 1 Bushing 109 LockPin 207 Backup Ring 113 Capscrew 3041 Wiper Seal Figure 4 11 Rotary Actuator Assembly Drawing 3121813 JLG Lift 4 15 SECTION 4 BOOM amp PLATFORM Disassembly 5 1 6 drill bit to a depth of 1 2 12 7mm to drill out the entire pin 1 Remove the capscrews 113 over end cap lock pins 109 e 4 Install the end cap 4 removal tools provided with the Helac seal kit 2 Using a 1 8 3 18mm drill bit drill a hole in the cen ter of each lock pin to a depth of approximately 3 5 Using a metal bar or something similar unscrew the 16 4 76mm end cap 4 by turning it counter clockwise 3 Remove the lock pins using an Easy Out a size 2 is shown If the pin will not come out with the Easy O
52. 6 TRIOS e certe iet Aa eti 1 1 1 7 Function Speeds e a erre Shans dog poe ME Ret PRU Perd Egon dora 1 2 1 8 Pressure Settings de qol Sa tae v S bp DE 1 2 1 9 Torque Requiremeris i I NERA PE deed 1 3 1 10 Component Weights o eR de te Ae oy 1 3 1 11 Hydraulic Oil z DRE Ded LED Ro OR 1 4 1 12 MOobILDTE T1M eae ie Wee eee ne PER A 1 4 1 13 Mobil DTE 19M SpeGs oreet e ee amd ATP p e eR c eee 1 4 1 14 Mobili EAL H 46 Sp6CS irin Ee QUT p AURA eT A rd 1 4 1 15 Lubrication Specifications 4 1 5 2 1 Inspection and 71 1 2 2 2 2 Gylirider Drift Ee RP eet dep eiae es EE 2 5 2 3 Inspection and Preventive Maintenance Schedule 2 7 3 1 Wheel Torq e Chart 3 2 3 2 Drive Brake Diagnosis ootad ams RR RR REGERE PER 3 23 3 3 RBS Prestart Sequence deu pere Dade ged Pe E EP MM 3 54 3 4 RBS Startup 3 54 3 5 RBS Shutdown 3 54 3 6 Generat
53. 9 16 5 8 34 78 9 08750 0 4620 41600 515 70 485 660 45 620 1 1000 0 6060 5150 70 95 685 90 645 875 11 8 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS REV 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 5 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift 3121813 SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Torque TM TM T Bolt Dia Tensile Clamp Load 242 bud 271 Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 PI 0 18 LL Los Toe owe 4 40 0120 0 00604 OT AP T 9 1488 _0 1120 0067 J 12 14 41 6 32 01380 0 00909 T Jh T J 1 0 01380 000015 J AJ j J Jl B 32 060 00400 J T T JJ 16 01640 00474 TO 10 24 0190
54. 94 socket head bolts to 420 foot pounds 588 Nm Recover the shim and throw it away 3121813 SECTION 3 CHASSIS amp TURNTABLE 3 10 BATTERY MAINTENANCE AND CHARGING WARNING IF REPLACING A BATTERY EACH NEW BATTERY MUST WEIGH AT LEAST 115 POUNDS 52 KG FAILURE TO REPLACE THE BAT TERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH Battery Maintenance Quarterly 1 Open battery compartment cover to allow access to battery terminals and vent caps CAUTION WHEN ADDING WATER TO BATTERIES ADD WATER UNTIL ELEC TROLYTE COVERS PLATES DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE PLATES NOTE When adding distilled water to batteries non metallic containers and or funnels must be used To avoid electrolyte overflow add distilled water to batteries after charging When adding water to the battery fill only to level indicated or 3 8 above separators 2 Remove all vent caps and inspect electrolyte level of each cell Electrolyte level should be to the ring approximately one inch from top of battery Fill bat teries with distilled water only Replace and secure all vent caps 3 Remove battery cables from each battery post one at a time negative first Clean cables with acid neu tralizing solution e g baking soda and water or ammonia and wire brush Replace cables and or cable clamp bolts as required 4 Clean battery post
55. A is near battery supply when neither direction contactor is energized and the traction MOSFETs are off This could be dueto a welded direction contactor or a power wiring error TRACTION POINT A LOW CHECK POWER MOTOR WIRING Traction point is near when neither direction contactor is energized and the traction MOSFETs are off This could be due to a power wiring error 6 20 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 9 9 Flash code 9 9 indicates problems with the controller POWER MODULE FAILURE CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off POWER MODULE FAILURE HWFS CODE 2 The hardware fail safe tests did not complete because traction point A is not safe or the hardware fail safe is permanently tripped POWER MODULE FAILURE HWFS CODE 3 The hardware fail safe tests did not complete because a contactor was energized when all should be turned off POWER MODULE FAILURE HWFS CODE 4 The hardware fail safe tests did not complete because the hardware fail safe tripped immediately when the traction MOSFETs were turned on POWER MODULE FAILURE HWFS CODE 10 The hardware fail safe tests failed because the hardware fail safe did nottrip within the allowed test time POWER MODULE FAILURE HWFS CODE 11 The hardware fail safe tests failed because the hardware fail safe tripped too slowly POWER MODULE FAILURE
56. CHARGING ALTERNATOR MUST NEVER BE ENERGIZED WHILE BOOSTING DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS WILL RESULT NOTICE THE MAIN BATTERY OF THE LIFT MUST NEVER BE USED TO BOOST THE APU DAMAGE TO SENSITIVE ELECTRONIC COMPO NENTS WILL RESULT JLG Lift 3 69 SECTION 3 CHASSIS amp TURNTABLE 3 13 SUPPLEMENTARY FUSE FOR ENGINE 2 Find where the harness attaches to the rear cover of the generator and the connection point for the new GENERATOR CONTROLLER ae E The purpose of this section is to describe the procedure to add a supplementary fuse for the Engine Generator Con troller for the APU Tools And Material Weather proof fuse holder JLG P N 2400081 AGC1 1 Amp fuse JLG P N 2400080 45 of 16 AWG wire JLG P N 4920019 2 X insulated butt splice connectors JLG P N 4460035 6X medium length wire ties JLG P N 4240033 Wire Side cutters 5 32 Allen Key Crimping tool 3 Remove the socket head drive screw with a 5 32 Procedure Allen key Next remove the cable clamp from the harness A WARNING lt BEFORE BEGINNING THIS PROCEDURE ENSURE THAT ALL SOURCES OF POWER ARE DISCONNECTED FROM THE APU This procedure is common for all applications of the APU The photos contained in this document illustrate the mod ification performed to an APU supplied in a JLG 450 lift 1 Locate the harness at the rear of the APU 4 Cut and remove the Wire Ties holding
57. Defaults Calibration Range Defaults E600 M600 BRAKE 010100 25 PUMP 096 0to50 6 PUMP 210096 50to 100 100 FLOW VALVE 0 04050 44 FLOW VALVE 100 50 to 100 60 LIFT VALVE 0 Oto 100 40 LIFT VALVE 100 Oto 100 70 SWING VALVE 0 Oto 100 45 SWING VALVE 100 Oto 100 52 TEMPERATURE Oto 100 50 TRACTION 0 50 to 2 00 1 00 PUMP 0 50 to 2 00 1 00 SPEEDprop1 04030 8 SPEEDprop2 01030 16 SPEEDint 0 0102 5 0 3 PLUGmax 30to 100 75 TILTdelayIN 0 0105 0 1 0 TiLTdelayOUT 0 0105 0 0 1 NOTE TiltdelayIN and TILTdelayOUT are adjusted in internal units not in 0 1s increments JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM 6 11 SYSTEM SELF TEST The system self test is utilized to locate typical problems See Table 6 10 System Test Descriptions and Table 6 11 System Test Messages for information concerning the tests performed and available messages in this mode 1 When the keyswitch is in the platform position and the self test enabled the self test function will test all valves contactors platform inputs indicator lamps and system alarms for various fault conditions When the keyswitch is in the ground position the self test function will test all valves the line contac tor ground control inputs and the ground alarm out put for various fault conditions switch has been closed it will move on to the next input lower lif
58. 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 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 Inspection must be performed by a Factory Certified Service Technician on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc rec ognizes a Factory Certified Service Technician as a per son who has successfully completed the JLG Service Training School for the subject JLG product model Refer ence the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the pe
59. NOTE For unused wire cavities insert sealing plugs for full environmental sealing 7 10 JLG Lift HD30 HDP20 Series Disassembly C Figure 7 16 HD HDP Contact Removal 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 2 Slide tool along into the insert cavity until it engages contact and resistance is felt 3 Pull contact wire assembly out of connector TOOL INSERTED TO T AND CONTACT UNLOCK CONTACT REMOVED Figure 7 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS This page left blank intentionally 3121813 JLG Lift 7 11 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS INVERTOR 7 RECEPTACLE AT PLATFORM PLATFORM CONSOLE BEACON LIGHT GROUND Kw LIGHTS marc Figure 7 18 Electrical Components Installation Sheet 1 7 12 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS TO GENERATOR PUMP BATTERY MOTOR BATTERIES GENERATOR MODULE POSI TRACK TILT MODULE LIMIT SWITCHES Figure 7 19 Electrical Components Installation Sheet 2 3121813 JLG Lift 7 13 SECTION 7 BASIC ELECTRICAL INFORMAT
60. Rollers 4C The last roller installed must be installed end wise That is the end of the last roller must be placed in between the ends of the two rollers which form the space and then slid parallel to the other rollers into place Place Spacer 4D into the bore of the Output Planet 4F Repeat Step 2 to put in second roll of Needle Rollers 4C Apply grease to hold two Thrust Washers 48 together and onto Output Planet Gear counter bore Do the same to the other side Repeat Steps 1 5 to finish the assembly of the two remaining Output Planet Gears 46 3 15 SECTION 3 CHASSIS amp TURNTABLE Output Carrier Assembly Refer to Figure 3 4 Output Carrier 1 NOTE 3 16 Hub Spindle Assembly Refer to Figure 3 7 Hub Spindle Place Thrust Washer 4H into counterbore of Carrier NOTE 4A BE SURE the small diameter side of Washer 4H facing planet gear side 1 Place Planet Gear Sub assembly 4 into Carrier 4A Visually align the planet gear bore with one of the planet shaft holes on the Carrier 4A NOTE Insert a Planet Shaft 4E into the planet shaft hole described in Step 2 on Carrier 4A The end of the planet shaft that does NOT have the roll pin hole NOTE should be inserted into the Carrier 4A FIRST Now insert Planet Shaft 4E through the first set of 2 Thrust Washers 4B Planet gear then the second set of Thrust Washers 4B Use an alignment punch 3 or similar tool t
61. SCHEMATICS 7 6 General ote ot eta oa Teak a n dean n aodio RO ond eaa oa p anh od 7 1 77 Multimeter Basics x AE 7 1 curte eee beo det pee MEM eon e ardet 7 1 Backprobing 225 252 Eee dug Sree a eae andy at 7 1 MIN MAX lt UR Ic RR RS doe dd dais Shela 7 1 a ee hd Ae nde M dir wr 7 1 x d nem actae Soc vs Mit isto At d ont 7 1 Voltage 2 2 2 1 7 1 Resistance Measurement 2 2 7 2 Continuity 7 2 Current 7 3 7 8 Checking Switches sa Sed e e vete RE pt E 7 8 Basic Check RUIDEMWE RE OAM IDE NY EE I RE P RC M ea 7 8 Limit Switches yu Se reed deba o d vae ee vob a 7 8 SWIICIIes tme cte ed C ed and per tac eot e weed 7 4 Switch Wiring Low Side High 7 4 7 9 Applying Silicone Dielectric Compound to Electrical 7 4 7 10 AMP GOn
62. STARTER MOTOR 108 RED FUEL BLACK PUMP 103 RED BLACK 2 K119 87 870 LOW OIL 86 785 sc PRESSURE SWITCH FUEL PS108 SOLENOID I 128 0 120 109 ENGINE OIL P BLK 117 TEMPERATURE UA128 SENSOR J WHT 118 ENGINE GRDI BLK 137 SPEED UA135 V OUT BRN 112 SENSOR Vs RED 113 DIESEL ENGINE RELAY K122 86 85 30 120 KUBOTA ENGINE GLOW PLUG 7 YANMAR ENGINE INTAKE AIR HEATER UA123 Figure 7 22 Electrical Schematic Sheet 3 of 4 JLG Lift Wa 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS J2 PLUG ASSEMBLY GENERATOR CONTROL MODULE EC104 SEE SHEET 1 125 1 SYSTEM 48 VDC 114 2 SYSTEM 0 VDC 109 3 FUEL SOLENOID 108 4 STARTER SOLENOLD SEE SHEET 1 127 5 MANUAL CALL TO START 128 6 LOW OIL PRESSURE o 7 AMBIENT TEMP 118 8 ENGINE OIL TEMP 112 9 SPEED SENSING INPUT 129 10 RS232 12V 65252 130 11 RXD 131 12 TXD SEE SHEET 1 133 13 LED DRIVER GND SEE SHEET 1 135 14 LED DRIVER 48V 137 15 SPEED SENSOR GRD b 16 AUTO SPARE b 17 FUEL SWITCH SPARE 114 18 OUTPUT VOLTAGE 117 19 ENGINE OIL TEMP AMBIENT TEMF 113 20 SPEED SENSING 8V 134 21 OUTPUT CURRENT SENSOR GRD 22 NC 132 23 RS232 CND
63. The setting should be adjusted to minimize speed variations when functions are used individually and in combina tions PUMP 210096 Displays adjusts maximum The setting should be adjusted to minimize speed variations when functions are used individually and in combina tions 096 Displays adjusts minimum flow control proportional valve on Vilow 100 Displays adjusts maximum flow control proportional valve on 000 Displays adjusts minimum lift proportional valve on Vliftt 100 Displays adjusts maximum lift proportional valve on Vswing 0 Displays adjusts minimum swing proportional valve on Vswing 100 Displays adjusts maximum swing proportional valve on SPEEDprop1 Displays adjusts speed control PID algorithm proportional term in traction mode The setting should be adjusted to optimize speed control SPEEDprop2 Displays adjusts speed control PID algorithm proportional term in plugging mode The setting should be adjusted to optimize speed control SPEEDint Displays adjusts speed control PID algorithm integral term in traction amp plugging mode The setting should be adjusted to optimize speed control PLUGmax Displays adjusts maximum plugging current The setting should be adjusted to ensure that the vehicle can be safely stopped when being driven down maximum grade 3121813 JLG Lift 6 27 SECTION 6 JLG CONTROL SYSTEM 6 28 Table 6 9 Calibration Ranges
64. Ul UO SQ JSMLU YOLIMS eui PUD NO pend eq snw SJ punoi 3ION 5 66660 Jequinw SYUBID yue spuooeg YUBID spuodes SHOA GL spuooeg 1009 GL ung AL ssed g GL eBind AL Spuooeg uei J9 U3 SSeJd Josey SS ld PUD 55914 PWD snes Say YOUME 10129195 OG SHOA ueis dwa peeds sgu 2g peo indino oa Od SHOA 1ndino ON 99999 N S 3121813 JLG Lift 3 56 SECTION 3 CHASSIS amp TURNTABLE 3121813 Underspeed Enabled once TDBP time delay bypass period has elapsed after engine startup If the engine speed drops below the underspeed limit the engine will stop immedi ately and an engine underspeed alarm will be indicated Overcrank If the engine fails to start after a set number of start attempts the RBS will cease attempts to restart and an engine overcrank alarm will be indicated No Speed Signal In the event of a loss of speed signa
65. 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 8 10 11 5 12 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel ROD SUPPORT SUPPORT TABLE Figure 5 10 Cylinder Rod Support Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Loosen and remove the cap screw s if applicable which attach the tapered bushing to the piston Insert the cap screw s in the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the piston 12 13 14 15 16 JLG Lift Remove the bushing from the piston PISTON TAPERED BUSHING Figure 5 11 Tapered Bushing Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings Remove piston spacer if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tap
66. a fault is found to confirm that the fault has been noted and to continue the system NOTE aflashing message is critical and prevents the system test running 3121813 JLG Lift 6 29 SECTION 6 JLG CONTROL SYSTEM Table 6 11 System Test Messages RUNNING 6 30 Initial display when system test is run certain critical checks are made Problems which can be reported include ONLY 1 ANALYZER Do not connecttwo Analyzers while running the system test BAD POWER WIRING The capacitor bank is not charged or pump point A is low ortraction point A is high or low Check all power wiring LINE CONT WELDED The capacitor bank is at battery voltage Check line contactor Check all power wiring BATTERY TOO LOW The system test cannot run with battery voltage below minimum BATTERY TOO HIGH The system test cannot run with battery voltage above maximum CHECK CAN WIRING The system test can t run in platform mode unless data is being received from the platform ground amp positrac tilt modules The system test cannotrun in ground mode unless data is being received from the ground and positrac tilt modules CHECK LEFT SPD There is an open or short circuit in the left speed encoder wiring Check left speed encoder CHECK RIGHT SPD There is an open or short circuit in the right speed encoder wiring Check right speed encoder CHECK SHUNT The traction current measurement is open circuit Check wiring between power
67. air to pop the cover out of the unit Washer 2 may have to be removed separately because of the loose attach ment Remove the First Stage Sun Gear 10 if applicable On units with ratios greater than 36 1 numerically there will not be a separate First Stage Sun Gear 10 as the gear teeth will be integral to the Input Shatt 9 Remove the Input Carrier Sub assembly 3 Contin ued on next page Remove the Second Stage Sun Gear 11 Remove the Input Shaft 9 On units with a ratio 48 1 the Sun Gear 11 and the Input Shaft 9 will need to be removed together Remove the Output Stage Carrier Sub assembly 4 Loosen and remove the three Flat Head Bolts 19 that retain the Ring Gear 1F to the Housing 1G Lift the Ring Gear 1F off of the Housing 1G Remove the O ring 18 from between the Housing 1G and the Ring Gear 1F 3 7 SECTION 3 CHASSIS amp TURNTABLE Ring Gear T 1G Housing 9 2 Washer 10 3 Input Carrier Subassembly 11 4 Output Carrier Subassembly 15 6 Cover Assembly 18 6G Retaining Ring 19 Coupling Input Shaft First Stage Sun Gear Second Stage Sun Gear 1 0 Plate O ring Flat Head Bolts Figure 3 2 Main Disassembly Drawing 1 3 8 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3121813 1F 1G eG Ring Gear 9 Housing 10 Output Carrier Subassembly 11 Retaining Ring 18 Cover Assembly 19 Retaining Ring 20
68. and holding for 1 minute Check for leaks at the control valve motor interface and the tube connections Release pressure JLG Lift Procedure for Setting Gear Backlash Shoulder Screw Capscrew Setscrew Jam Nut Figure 3 24 Setting Gear Backlash NOTE The bearing high spot will be marked with yellow paint Place a shim JLG P N 4071008 between the pinion and bearing high spot Torque the shoulder screw 1 to 420 1 165 588 Nm with Loctite 271 Remove the turntable lock pin Pre torque the 3 4 inch capscrews 2 to 120 1 165 168 Nm with Loctite 271 8 41 SECTION 3 CHASSIS amp TURNTABLE Tighten the setscrew 3 until the pinion is com pletely snug against the shim and bearing and then back off the setscrew Torque the setscrew to 50 165 70 Nm Tighten the jam nut 4 Torque the four 3 4 inch capscrews 2 to 420 1 165 588 Nm Remove and discard the shim 3 9 SWING BEARING Turntable Bearing Mounting Bolt Condition Check NOTE This check is designed to replace the existing bear 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 torqu
69. applied to connectors with external seals 1 To prevent oxidation silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly This is most easily achieved by using a syringe NOTE Over a period of time oxidation increases electrical resistance at the connection eventually causing cir cuit failure 2 To prevent shorting silicone grease must be packed around each wire where they enter the outside of the connector housing Also silicone grease must be applied at the joint where the male and female con nectors come together Any other joints around strain reliefs etc where water could enter the con nector should also be sealed NOTE This condition is especially common when machines are pressure washed since the washing solution is much more conductive than water 3 Anderson connectors for the battery boxes and bat tery chargers should have silicone grease applied to the contacts only NOTE Curing type sealants might also be used to prevent shorting and would be less messy but would make future pin removal more difficult 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS 7 10 AMP CONNECTOR Applying Silicone Dielectric Compound to AMP Connectors Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 7 5 Proceed as follows Silicone Dielectric Compound must be used on the AMP CON
70. below 45V and flash below 40V BRAKES RELEASED Indicates manual brake release in ground mode DRIVING AT CREEP TILTED Drive speed is limited to creep because the vehicle is tilted FSW OPEN A drive or boom function has been selected but footswitch is open PUMP MOTOR AT CURRENT LIMIT Pump current has reached controller current limit or safe operating area limit RUNNING AT CREEP CREEP SWITCH OPEN All function speeds are limited to creep because the creep switch is open RUNNING AT CREEP TILTED amp ABOVE ELEVATION All function speeds are limited to creep because the vehicle is tilted and above elevation RUNNING AT CUTBACK ABOVE ELEVATION Drive speed is limited to cutback because the vehicle is above elevation TESTS ACTIVE RECYCLE EMS TO END The system tests have been activated normal vehicle operation is not allowed TILT MODULE FAILURE BAD TILT SENSOR There is a problem with the tilt sensor in the positilt module the controller defaults to massively tilted and does nottry to prevent vehicle roll onthe grade TRACTION MOTOR AT CURRENT LIMIT Traction current has reached controller current limit or safe operating area limit 21 Flash code 21 indicates problems with footswitch FSW FAULTY Thetwo footswitch signals do not agree EMS recycle required STARTUP Neither EMS inputis active the system is just switching on oris discharging the capacitor bank A welded
71. 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 upper boom fully extended with the rated load in the platform and power off Maximum allowable drift is 2 inches 5 cm in 10 minutes If the machine does not pass this test proceed with the following Cylinder Drift Table 2 2 Cylinder Drift Cylinder Bore Diameter inches mm inches mm 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 1524 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 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
72. ean be ee eS eg 4 10 4 4 Platform Rotator S N 0300130810 to Present 4 12 Theoty of Operation ep COS IKE ae 4 12 Required Tools cock pe UR EGER EEUU REG 4 13 Disassembly 4 nere aeter i ui oe Ee wae La 4 16 INSPECTION n e DEAE Er ei mL e Pet 4 20 Assembly 4 ouod dtd me s ec voe ete A Reb D Roda 4 20 4 5 Jib ROtatOE o eet ep vr toe o e eere Ep tae t 4 25 Operating PrNGI IE D Ne cs eb 4 25 Disassembly i v E bd aah ea iat ee PV Uis 4 25 Inspection cssc un AeA eee ied ace ORA eae 4 29 Reassemibly Aoi ead sp dae od eger i ie tle pith Gon A meee 4 29 Installing Counterbalance Valve 4 31 Testing the Actuator crece lb e RA REI A Pee a teed T 4 32 Installation and RII III 4 32 Trou bleshooting eed PES 4 33 iv JLG Lift 3121813 TABLE OF CONTENTS SECTION NO TITLE PAGE NO SECTION 5 HYDRAULICS 5 1 Lubricating O Rings in the Hydraulic 5 1 Cup and ad ire PURO Patin teu ee 5 1 Dip Method gt Babi R
73. engine starter and the pull coil of the engine fuel solenoid The start control relay is energized by the engine genera tor controller from pin J2 4 The start control relay is located on the fuel solenoid bracket on the right side of the engine The engine is equipped with a 12VDC starter which pro vides the mechanical power to crank the engine Electrical power for the starter is provided by the start battery The starter is energized by the start control relay 3121813 JLG Lift 3 61 SECTION 3 CHASSIS amp TURNTABLE Fuel Control Relay Glow Plug Control Relay X The fuel control relay energizes the hold coil of the fuel The glow plug control relay energizes the glow plug It is solenoid energized by the engine generator controller pin J2 27 The fuel control relay is energized by the engine The glow plug control relay is located on the fuel solenoid generator controller from pin J2 3 bracket on the right side of the engine The fuel control relay is located on the fuel solenoid bracket on the right side of the engine Glow Plug The glow plug is a resistive heating element located in the combustion chamber It is used during starting at temper atures below 32 F 0 C The heater is energized by the glow plug control relay 3 62 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Fuel Pump Engine Low Oil Pressure Switch The fuel pump runs in parallel with the fuel solenoid hold co
74. fied insert in Figure 5 16 The split of seals and JLG Lift backup rings are to be positioned so as not to be in alignment with each other PISTON BACKUP SPLIT SEAL RINGS T RING SPLIT SEAL SPLIT BACKUP RING Figure 5 16 Piston Seal Kit Installation Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged Thread piston onto rod until it abuts the spacer end and install the tapered bushing When installing the tapered bushing piston and mat ing end of rod must be free of oil A WARNING WHEN REBUILDING THE STEER LOWER LIFT LEVEL CYLINDER OR UPPER LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN SECURELY Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap 3121813 SECTION 5 HYDRAULICS 12 13 3121813 screws through the drilled holes in the bushing and into the tapped holes in the piston PISTON TAPERED BUSHING SCREWS 2 Figure 5 17 Tapered Bushing Installation Tighten the capscrews evenly and progressively in rotation to the specified torque value See Table 5 1 Cylinder Head and Tapered Bushing Torque Specifi cations After the screws have been torqued tap the tapered bushing with
75. head gland can be inserted into the barrel cyl inder 20 Secure the cylinder head gland using the washer ring and socket head bolts SPACER HEAD ASSY CYLINDER BARREL PISTON ASSY Ae CAP SCREWS WASHER RING Figure 5 20 Rod Assembly Installation 21 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 22 lf applicable install the cartridge type holding valve and fittings in the rod port block using new o rings as applicable See Table 5 2 Holding Valve Torque Specifications 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 FORK LIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD 5 16 Table 5 1 Cylinder Head and Tapered Bushing Torque Specifications dE Lift Cylinder En Slave Cylinder NS Telescope Cylinder N A NT Table 5 2 Holding Valve Torque Specifications Description Torque Value SUN 7 8 20 1 5 THDS 30 35 ft Ibs 41 48 Nm SUN 1 1 8 HEX 1 14 UNS THDS 45 50 ft Ibs 61 68 Nm SUN 1 1 4 HEX M36 X2 THDS 150 160 ft Ibs 204 217 Nm RACINE 1 1 8 HEX 1 1 16 12 THDS 50 55 ft lbs 68 75 Nm
76. inside of the piston 3 mesh together Tap the piston into the housing the Now tap the flange end of the shaft with a rubber rest of the way until it bottoms out mallet until the gear teeth engage 10 Install the shaft 2 into the piston 3 Be careful not 12 Install 2 bolts in the threaded holes in the flange to damage the seals Do not engage the piston gear Using a bar rotate the shaft in a clockwise direction teeth yet until the wear guides are seated inside the housing bore 13 Install the stop tube onto the shaft end Stop tube is an available option to limit the rotation of an actua tor 3121813 JLG Lift 4 23 SECTION 4 BOOM amp PLATFORM 14 Coat the threads on the end of the shaft with anti 17 Tighten the end cap 4 In most cases the original seize grease to prevent galling holes for the lock pins will line up 18 Place the lock pins 109 provided in the Helac seal kit in the holes with the dimple side up Then using a punch tap the lock pins to the bottom of the hole 15 Install the O ring 204 and back up ring 207 into the inner seal groove on the end cap 4 16 Thread the end cap 4 onto the shaft 2 end Make sure the wear guide stays in place on the end cap as 19 Insert the set screws 113 over the lock pins itis threaded into the housing 1 Tighten them to 25 in Ibs 2 825 Nm m _ 4 24 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM
77. is relieved 7 Remove O Ring 26 from between Motor 10 and Brake Housing 6 8 Remove Springs 8 6 amp 8 7 from Brake Piston 8 2 CAUTION WEAR EYE PROTECTION DURING THE NEXT STEP OF THIS PRO CEDURE 10 11 12 13 4 O ring Plug 8 2 Brake Piston 6 Brake Housing 8 3 Outer Plates 8 1A O ring 8 4 Inner Plates 8 1B Backup Ring 8 5 Thrust Spacer 8 1C O ring 8 6 Spring 8 1D Backup Ring 8 7 Spring Remove Brake Piston 8 2 from Brake Housing 6 by slowly pressurizing brake port in Brake Housing 6 with air Remove O Rings 8 1A amp 8 1C and Backup Rings 8 1B amp 8 1D from Brake Piston 8 2 Remove Sun Gear 9 Remove Outer Plates 8 3 and Inner Plates 8 4 from the Brake Housing 6 Remove the Thrust Spacer 8 5 9 Sun Gear 10 Motor 13 O ring Plug 15 Bolts 26 O ring Figure 3 20 Brake Disassembly 3121813 JLG Lift 3 35 SECTION 3 CHASSIS amp TURNTABLE Main Disassembly 3 1 With the unit resting on the Output Shaft Pinion 1A remove the Carrier Subassembly 2 Remove Ring Gear 2 from Housing Subassembly HOUSIN SUB ASSEMBLY 2 Ring Gear 5 O Ring 14 Dowel Pins 28 Input Spacer Remove O ring 5 from between Ring Gear 2 and Housing Subassembly Remove four Dowel Pins 14 from Housing Subas sembly CARRIER SUB ASSEMBLY Figure 3 21 Main Disassembly 3 36 JLG Lift 3121813
78. is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can measure the voltage at both power ter minals with respect to battery ground The difference between those two measurements is the voltage applied to the load 7 4 JLG Lift 7 9 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS Silicone Dielectric Compound must be used on all electri cal connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors This procedure applies to all plug connections not enclosed in a box Sili cone grease should not be
79. line contactor might also cause this 3121813 JLG Lift 6 15 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 2 2 Flash code 2 2 indicates problems with drive amp steer selection DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range orthe wiper is wire off DRIVE LOCKED JOYSTICK MOVED BEFORE EMS FSW Drive was selected before and during footswitch closure or at EMS switch on FSW INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected STEER LOCKED SELECTED BEFORE EMS FSW Steer was selected before and during footswitch closure or at EMS switch on STEER SWITCHES FAULTY Both steer switches are active together WAITING FOR FSW TO BE OPEN Footswitch was closed when platform mode was selected 4WD ASSIST DISABLED NOT AVAILABLE WITH BOOM 4WD Assist has been selected and is not available due to a boom function being operated at the same time JOYSTICK FAULTS CHECK PLATFORM BOX WIRING There are drive lift or swing joystick faults but the exact cause cannot be determined a short circuit of any one joystick or the pump pot could cause this 2 3 Flash code 2 3 indicates problems with boom function selection LIFT SWING JOYSTICK FAULTY The lift or swing joystick center tap is out of valid range or the wiper is wire off LIFT SWING LOCKED JOYSTICK MOVED BEFORE EMS FSW Platfor
80. mo m M a 3 SOCKET 4 SOCKET 3 PIN 80 a 8 8 g s3289 BH S S 3 3 2 T pre BES Las as PN Horn 54 5 268 58 2u ZE ees C bo h E HI 5 5321 E 51 60 8 8 5 B a 55 25 i xi 88 155 as age 5 oooo oo 99 NS gi 5 2222 22 22 592 tre Y E sg 854 nn TB zee 5 q 555 05 J4 J8 N C 4 PIN 2 2 PIN 4 SOCKET gt ANALZER gt CONNECT ION 9 J3 gt 35 6 PINE iii ge N C amp ces N C amp 58 YEL RED 2 3 T PET YEL RED 2 6 esci 5 YEL RED 2 4 2 2 12 PIN FEES ARMATURE WHT RED 57 1 4 E o bli MAD 57 2 if 2 i E WHT BLK 58 1 8 POWER MODULE 5 WHT BLK 58 2 lt 0 ur 49 1 ma BRAKE PRESSURE O ORVRED 49 2 SWITCH OPENS ORG 55 1 4 THIS 1 FOR THE OPTION OF 4 WHEEL ASSIST g 2 ON RISING THE WIRING FOR THIS FUNCTION CONNECTS INTO a PRESSURE BRAKE lt gt THE FRAME HARNESS AROUND THE BEARING AREA lt N C 9 An 4WD FORWARD A BLACK 49 iem e mm 1 L 4WD REVERSE B 6 SOCKET gt uns 8 t LEFT lt 5 a a qup ORANGE e AUS J7 XN C 8 le FORWARD 15 PIN a N C hs a ORANGE 55 2 LO E REVERSE Orr REDAT 50 1 6 gs z Y JONE 55 5 lt I gt im UE FORWARD lt A P2 o
81. module and contactor panel BAD PUMP WIRING Pump point A is not high probably caused by an open circuit pump motor or wiring Check all power wiring Check pump motor BAD POWER MODULE An internal problem was detected in the power module BAD POWER WIRING Traction point A is high probably caused by incorrecttraction motor wiring Check all power wiring Check traction motor HIGH TILT ANGLE The vehicle is very tilted orthe tilt sensor has been damaged Check tilt sensor HOT POWER MODULE The heatsink temperature exceeds 75 C this is only a warning BAD I O PORTS The controller detected a problem with its internal circuits at switchon If other problems are also detected the controller may need replacing SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on Check and if necessary correct all personality settings WAIT CAPBANK HI This message can be displayed ifthe system testis run shortly after the vehicle was used after a short wait it should Clear OPEN FSW In platform mode the footswitch must be open at the start of the test CLOSE FSW In platform mode the footswitch must be closed when this message is displayed the footswitch MUST BE KEPT CLOSED during the valve amp contactor tests BAD FSW The two footswitch signals are not changing together probably because one is open circuit One footswitch signal FSW1 is routed to the power module the other FSW2 is ro
82. nect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on 6 3 USING THE ANALYZER With the machine power on and the analyzer connected properly the analyzer will display the following ALET HELP PRESS ENTER gt Je HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACTIVATE TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE level 1 only CALIBRATIONS view only If you press ENTER at the HELP PRESS ENTER display and a fault is present the analyzer display will scroll the fault across the screen If there was no fault detected the display will read HELP EVERYTHING OK If powered up at the ground station the display will read GROUND OK If ENTER is pressed again the display moves to the fol lowing display 2 3 ALE LOGGED HELP 1 STARTUP 2 1
83. of hydraulic fluid which can be caught in a suitable container After initial discharge there should be no further leakage from the retract port 3 Activate hydraulic system and activate cylinder extend function 4 If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate hydraulic system and activate cylinder retract function Check extend port for leakage 7 lf extend port leakage is less than 6 8 drops per min ute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 3121813 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valve Lift Cylinder and Oscillation Cylinder NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system WARNING WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER TO HORIZONTAL AND PLACE A PROP APPROXIMATELY 1 INCH 2 54 CM BELOW THE MAIN IF WORKING ON LOWER BOOM LIFT CYLINDER RAISE LOWER BOOM HALFWAY FULLY ELEVATE UPPER BOOM AND ATTACH OV
84. output as pro grammed for smooth operation and maximum cycle time Ground control speeds for all boom functions can also be programmed into the motor controller The motor control ler also features an adjustable time limit for positive trac tion The JLG Control System controller has a built in LED to indicate any faults The system stores recent faults which may be accessed for troubleshooting Optional equip ment includes an hour meter beacon light function cut out and ground alarm These options may be added later but must be programmed into the motor controller when installed The Control System may be accessed utilizing a custom designed hand held analyzer Analyzer Kit JLG part no 2901443 which will display two lines of information at a time by scrolling through the program NOTE Each module has a label with the JLG part number and a serial number which contains a date code The following instructions are for using the hand held ana lyzer i MENU Escape Key To return home or access previous menu gt Up amp Down Arrow Keys Value Selector d mm Enter Key Stores and selects Top Level Sub Level and item menus Left amp Right Arrow Keys Usedto move between Top Level Sub Level and item menus Figure 6 1 Hand Held Analyzer 3121813 JLG Lift 6 1 SECTION 6 JLG CONTROL SYSTEM 2 JO 19945 2 9
85. purged oil The oil can be returned to the reservoir after this procedure is completed With an operator in the platform open both bleed nipples 1 4 turn Hydraulically rotate the platform to the end of rotation either clockwise or counterclock wise and maintain hydraulic pressure Oil with small air bubbles will be seen flowing through the tubes Allow a 1 2 gallon of fluid to be purged from the actuator Keep the fittings open and rotate the platform in the opposite direction to the end position Maintain hydraulic pressure until an additional 1 4 gallon of fluid is pumped into the container Repeat steps 2 amp 3 After the last 1 2 gallon is purged close both bleed nipples before rotating away from the end position 3121813 SECTION 4 BOOM amp PLATFORM Troubleshooting Table 4 1 Troubleshooting Problem 1 Shaftrotates slowly or not at all Cause a Insufficient torque output b Lowrate of fluid flow c Control or counterbalance valve has internal leak d Piston and or shaft seal leak e Corrosion build up on the thrust surfaces f Swollen seals and composite bearings caused by incompatible hydraulic fluid Solution a Verify correct operating pressure Do not exceed OEM s pressure specifications Load may be above maximum capacity of the actuator b Inspect ports for obstructions and hydraulic lines for restrictions and leaks c Disconnect hydraulic lines and bypass
86. running to the jib cylin der If equipped with a side swing jib also tag and disconnect the hydraulic lines running to the jib rota tor JIB PIVOT PIN p SLAVE CYLINDER PIVOT PIN p PIVOT P A e SLAVE CYLINDER PIVOT PIN 6 Remove the jib pivot pin and the slave cylinder pivot 1 pin and remove the jib 1 1 3121813 JLG Lift amp PLATFORM 7 Disconnect the hydraulic and electrical lines from the bulkhead fittings at the rear of the boom 8 Remove the cover at the rear of the upright MASTER CYLINDER PIVOT COVER BOOM LINK PIVOT COVER Remove the covers on the side of the upright for the pivot pins 0 Tag and disconnect the hydraulic lines running to the telescope cylinder 1 Tag and disconnect the hydraulic lines running to the master cylinder 2 Remove the upper lift cylinder pivot pin 4 1 SECTION 4 BOOM amp PLATFORM UPRIGHT MASTER CYLINDER SECTION TELE CYLINDER Figure 4 1 Boom Assembly Sheet 1 of 3 4 2 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM BOOM BASE SECTION CYLINDER BASE SECTION BOOM FLY SECTION PLATFORM ROTATOR Figure 4 2 Boom Assembly Sheet 2 of 3 3121813 JLG Lift 4 3 SECTION 4 BOOM amp PLATFORM d Lat CS s D s gt stave LOS xc CYLINDER Pd BS x JIB LINK COVER PLATE CYLINDER JIB PIVOT COVER
87. shutdown occurs This protects the load from abnormally high voltages Finish Charging Current The finish charging current determines the level of the cur rent alternator output must drop below for a low battery voltage CTS to be removed This ensures that the batter ies have accepted sufficient charge prior to shutting down the RBS This level is used along with the low battery volt age remove CTS level to determine when the RBS removes the CTS after a low battery voltage CTS If the charging current falls below the finish charging current while another CTS is active the RBS will continue to oper ate at the normal extended output voltage until all CTS s are removed JLG Lift 3 57 SECTION 3 CHASSIS amp TURNTABLE Priming the Fuel Line The following procedure is for re priming the fuel line on the generator engine in the event fuel system components have been replaced or the unit has been run dry of fuel 1 Make sure the fuel line isn t blocked or kinked 2 Make sure fuel tank has fuel 3 Disconnect the rubber fuel line at the fuel injector C i 333 o I 4 When fuel starts to flow out of the rubber line re connect the fuel line to the fuel injector pump 10 3 58 JLG Lift Clean up any spilled fuel and try to start the genera tor engine If the engine still doesn t start remove the steel line from the fuel injector pump Once fuel starts to flow re connect the f
88. specific cylinder will be so noted Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 5 4 JLG Lift 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3 If applicable remove the cartridge 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 BARREL CLAMP CLAMP SUPPORT TABLE Figure 5 1 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen the cylinder head retainer cap screws and remove cap screws from cylinder barrel CAPSCREWS WASHER RING Figure 5 2 Capscrew Removal 3121813 SECTION 5 HYDRAULICS Prior to S N 64016 S N 64016 to Present 1 Barrel 6 O ring 11 Cap 16 Bushing 2 NotUsed 7 BackupRing 12 WasherRing 17 O ring Plug 3 WearRing 8 WiperRing 13 Bolt 18 Loctite 242 4 T Seal 9 Seal 14 Counterbalance Valve 19 Locking Primer Not Shown 5 WearRing 10 Rod 15 Bleeder Val
89. the engine generator controller The output current is regu lated at 45ADC The alternator output current sensor is connected to the engine generator controller at pins J2 21 J2 31 and J2 32 The alternator output current sensor is located inside the rear cover of the alternator Engine Speed Sensor The engine speed sensor provides a signal proportional to the rotational speed of the engine to the engine genera tor controller This signal is used by the engine generator controller to determine starter cut out overspeed fault and underspeed fault If the signal is not present at the engine generator controller the unit will fault with a loss of speed signal indication The engine speed sensor is connected to the engine gen erator controller at pins J2 9 J2 15 and J2 20 The engine speed sensor is located inside the recoil starter cover at the front of the engine 3 64 JLG Lift RBS Engine Generator Controller The control system enclosure houses the RBS engine generator controller which performs all control tasks associated with the RBS The engine generator controller interface is via a J2 35 pin connector Table 3 7 Controller Interface Pin Assignments PIN FUNCTION 1 System 48VDC 2 System OV DC 3 Fuel solenoid 4 Starter Solenoid 5 Manual callto start 6 Low oil pressure 7 Not used 8 Engine
90. the jib to the pivot points and install the jib pivot pin and the slave cylinder pivot pin Connect the hydraulic lines running to the jib cylin der as tagged during removal If equipped with a side swing jib connect the hydraulic lines running to the jib rotator Install the platform support and platform Install the hydraulic lines to the platform valve and rotator as tagged during removal Reconnect the electrical leads at the platform and platform valve as tagged during disassembly Cycle test the boom from the ground station to ensure all functions operate properly After verifying that all functions operate properly from the ground station cycle test the boom from the platform station to ensure all functions operate properly from the platform station as well 4 5 SECTION 4 BOOM amp PLATFORM 12 0 RESET DETAIL B SWITCH TO RESET WHEN SEE DETAIL SWITCH RESET 30 0 TRIP DETAIL SEE DETAIL BOOM IS 2 7 ABOVE HORIZONTAL 4 8 IS THE PREFERRED RESET ANGLE 4 1 9 SWITCH TRIP WHEN BOOM IS 9 14 ABOVE HORIZONTAL 11 IS THE PREFERRED TRIP ANGLE v SWITCH TRIP Figure 4 4 Boom Limit Switch Adjustment 4 6 JLG Lift 3121
91. there are basic tools required The tools and their intended func tions are as follows 7 Rubber mallet removal and installation of shaft and piston sleeve assembly 8 Nylon drift installation of piston sleeve 9 End cap dowel pins removal and installation of end cap sold with Helac seal kit The seal tool is merely a customized standard flat head screwdriver To make this tool you will need to heat the flat end with a torch Secure the heated end of the screwdriver in a vice and physically bend the heated end to a slight radius Once the radius is achieved round off all sharp edges of the heated end by using a grinder There may be some slight modifications for your own personal prefer ence 1 Flashlight helps examine timing marks component failure and overall condition in d 2 Felt Marker match mark the timing marks and out TN m TRA M line troubled areas 3 Allen wrench removal of port plugs and set screws 4 knife removal of seals 5 Seal tool assembly and disassembly of seals and wear guides 3121813 JLG Lift 4 13 SECTION 4 BOOM amp PLATFORM PARTS HARDWARE SEALS BEARINGS 1 Housing 103 1 Screw 200 T Seal 302 Wear Guide 2 Shaft 103 2 Washer 202 T Seal 304 Thrust Washer 3 PistonSleeve 106 1 PortPlug 204 O ring 4 EndCap 106 2 Port Plug 205 CupSeal 109 LockPin 207 Backup Ring 113 304 1 Wiper Seal Figure
92. two hex head bolts 3 Torque the hex head bolts 6 3 ft lbs 8 8 Nm NOTICE PULL VERY SLOWLY WITH THE TOWING VEHICLE CONNECTED TO THE MACHINE TO ALLOW THE SPLINE OF THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT A CAUTION DO NOT OPERATE THE MOTOR TO MAKE THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT 4 Check to ensure all bolts are tight and all compo nents are returned to their original positions 5 The gear drive should now be reengaged and the machine can be disconnected from the towing vehi cle JLG Lift 3 3 SECTION 3 CHASSIS amp TURNTABLE f jjj gs Lai 22 2 zl j m SNNNNNN 25 24 1 11 15 17 E FA ie 11 1 25561 Ii 4 NL 5 22 53 SX s51 aaa Mid gt Tn 1h c 1 PlanetGear 13 NotUsed 2 PlanetGear 14 Retaining Ring 3 SunGear 15 Retaining Ring 4 ShaftNut 16 Retaining Ring 5 PlanetBolt 17 Support Disk 6 SupportRing 18 NotUsed 7 Planet Carrier 19 O ring 8 Cover 20 Ring Seal 9 NotUsed 21 Plug 10 Roller Bearing 22 Ring Seal 11 Roller Bearing 23 Bolt 12 Roller Bearing 3 4 24 Ball 25 Expander 26 to 28 Not Used 29 Housing Washer 29 Ring Gear 31 amp 32 Not Used 33 O ring 34 Retaining Ring 35to 42 NotUsed 43 S
93. valve Leave valve ports open and operate the actuator through housing ports do not exceed OEM s operating pressure The valve mustbe replacedif a steady flow of fluid is seen coming from the valve ports d Remove the plug and the housing s valve ports Operate the actuator through the housing ports Conduct the internal leakage test as described in the Testing section on page 24 of this manual e Re build the actuator Remove all rust then pol ish Replacement parts may be needed f Re build the actuator Use fluid that is compati ble with seals and bearings 2 Operationis erratic or not responsive a Airinactuator a Purgeair from actuator See bleeding proce dures 3 Shaftwill notfully rotate Twisted or chipped gear teeth b Portfittings are obstructing the piston a Check for gear binding Actuator may not be able to be re built and may need to be replaced Damage could bea resultof overload or shock b Checkthread length of port fittings Fittings should during stroke not reach inside the housing bore 4 Selected position cannot be maintained a Control or counterbalance valve has internal leak b Piston and or shaft seal leak c Airinactuator Disconnect hydraulic lines and bypass valve Leave valve ports open and operate the actuator through housing ports do not exceed OEM s operating pressure The valve mustbe replacedif a steady flow of fluid is seen coming f
94. with wire brush then re connect cable to post Coat non contact surfaces with min eral grease or petroleum jelly 5 When all cables and terminal posts have been cleaned ensure all cables are properly positioned and do not get pinched Close battery compartment cover 6 Start hydraulic system and ensure that it functions properly 3121813 Optional On Board Generator A WARNING EXHAUST GAS HAZARD RUN THE GENERATOR IN A WELL VEN TILATED AREA ONLY NOTICE WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IN ON PULLED OUT THE GENERATOR WILL START AUTOMATICALLY WHEN THE BATTER IES REACH A LOW CHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES NOTE The engine will automatically shut down under the following conditions Charged Batteries High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage A WARNING TO AVOID INJURY FROM AN EXPLOSION DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC ING ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER VICING BATTERIES Battery Charging 0n Board Charger 1 For maximum battery life a Avoid completely discharging the batteries b Fully charge the batteries each day the machine is used c Charge the batteries at available times between charging d Be sure the battery fluid covers the battery plates before charging but to avoid ov
95. 0 00175 4 11 L 1 32 01900 0 02000 T A4 9 14 20 0250 0 0318 280 143 16 129 15 1 28 0250 0 0364 32800 164 19 148 17 Sam 18 F8 Nm _ 24 03125 0 0580 520 25 35 25 35 20 25 LT 24 0 3750 0 0878 790 50 70 45 35 50 716 14 0435 0 1063 950 70 95 6 9 50 70 LT 20 0437 0 1187 1070 80 no 70 95 6 80 v2 13 0 5000 01419 1250 105 145 95 130 80 10 20 05000 01599 _ 14400 120 165 10 150 90 120 L 1 18 0 625 0 2030 1 0 6250 0 2260 0 2030 2 18250 170 230 20350 210 285 8 12 7 12 12 6 2 6 5 8 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 280 380 16 0 7500 0 3730 380 515 315 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 12 1000 06630 5970 95 1355 85 125 745 1015 12 14250 0860 77000 1445 1965 1300 170 1085 1475 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3121813 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 L
96. 0 GROUND ALARM 1 Travel Alarm Sounds whenthe drive function is active Option 2 Descent Alarm Sounds when either lift down is active Option 3 Motion Alarm Sounds when any function is active Option 6 12 Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 3 Machine Configuration Programming Information Default Configuration Digit Number Description Number 7 0 Sounds continuously when above elevation and tilted only 0 PLATFORM ALARM 1 Sounds continuously when above elevation and tilted and in conjunction with fault code flashes Option 8 0 0 Soft Touch system installed 0 SOFT TOUCH 1 12 Soft Touch system installed Option 9 0 No Load Cell Installed 0 LOAD CELL 1 Warn Only 2 Warn amp Cutout NOTE The following information is to be used when working with the MACHINE SETUP menu When configuring the machine the machine configuration must be completed before any personality settings can be changed Changing the personality settings first and then changing the model number of the machine configuration will cause the per sonality settings to return to default values Default settings will be shown in bold type 3121813 JLG Lift 4150342 3 6 13 SECTION 6 JLG CONTROL SYSTEM 6 9 LEVEL VEHICLE DESCRIPTION Help Descriptions and Fault Flash Codes Table 6 4 JLG Control System Flash Codes E A NEW TILT MODULE WILL ACT AS IF I
97. 0 125 below the surface of the outside diameter Repeat Steps 1 through 10 for the remaining two Planet Gears 3 39 SECTION 3 CHASSIS amp TURNTABLE Main Assembly See Figure 3 21 Main Disassembly 1 With the Housing Shaft Subassembly resting on the Shaft 1A install one Dowel Pin 14 into each of the four counter bored holes in the Housing 1G See assembly drawing until they bottom out Also at this time mark the four Dowel Pin 14 holes on the O D of the Housing 1G See assembly drawing This is for identification later in the assembly Install Thrust Spacer 28 into counter bore in splined end of the Output Shaft 1A Place O Ring 5 into Housing 1G counter bore Use grease to hold O ring in place CAUTION BEWARE SHARP EDGES OF THE COUNTER WHILE SEATING THIS O RING 4 Install Carrier Subassembly with splined end down so that the spline of the Carrier Subassembly is in mesh with the spline of the Housing Shaft Subas sembly Rotate carrier in assembly to check for free dom of rotation With large shoulder side of Ring Gear 2 facing down place Ring Gear 2 onto Housing Shaft Sub assembly with gear teeth in mesh with the Planet Gears 3f in the Carrier 3A The side of the Ring Gear 4 with an X or punch mark stamped on it should be up and the marked hole should be at a Dowel Pin 14 location Motor Brake Subassembly See Figure 3 19 Motor and Br
98. 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 and 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 EMI Manuals Handbooks Installed 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 21 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 2 8 Lift 3121813 SECTION 2 GENERAL Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL AREA Pre Start Inspection Weekly Preventive Maintenance Monthly Preventive Maintenance Pre Delivery or Frequent Inspection Annual Yearly Inspection Every 2 Years All Relevant Safety Publications Incorporated 21 21 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 1 2 Grease and Lubricate to Specifications 22 22 Function Testof All Systems 21 21 21 22 Paintand Appearance 7 7 Stamp Inspection Date on Frame 22 Notify JLG of Machine Ownership 22 Footnotes 1 Prior to use each day or at each
99. 10 bar and maintain pressure Remove the hydraulic line from the non pressurized side Continuous oil flow from the open housing port indicates internal leakage across the piston Replace the line and rotate the shaft to the end of rotation in the opposite direc tion Repeat the test procedure outlined above for the other port If there is an internal leak disassemble inspect and repair Installation and Bleeding After installation of the actuator on the equipment it is important that all safety devices such as tie rods or safety cables are properly reattached To purge air from the hydraulic lines connect them together to create a closed loop and pump hydraulic fluid through them Review the hydraulic schematic to deter mine which hydraulic lines to connect The linear feet and inside diameter of the hydraulic supply lines together with pump capacity will determine the amount of pumping time required to fully purge the hydraulic system Bleeding may be necessary if excessive backlash is exhib ited after the actuator is connected to the hydraulic sys tem The following steps are recommended when a minimum of two gallons 8 liters is purged 1 Connect a 3 16 inside diameter x 5 16 outside diameter x 5 foot clear vinyl drain tube to each of the two bleed nipples Secure them with hose clamps Place the vinyl tubes in a clean 5 gallon container to 4 32 TYPICAL CONFIGURATION OF ACTUATOR JLG Lift collect the
100. 200 Viscosity Index 140 Lift 3121813 SECTION 1 SPECIFICATIONS Figure 1 2 Operator Maintenance and Lubrication Diagram 1 13 OPERATOR MAINTENANCE NOTE The following numbers correspond to those in Fig ure 1 2 Operator Maintenance and Lubrication Diagram Table 1 15 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API Service Classification GL 5 or Mil Spec Mil L 2105 HO Hydraulic Oil Mobil DTE 11M 0G Open Gear Lube Tribol Molub Alloy 936 Open Gear Com pound JLG Part No 3020027 BG Bearing Grease JLG Part No 3020029 Mobilith SHA 460 LL Synthetic Lithium Lubricant Gredag 741 Grease JLG Part No 3020022 EO Engine crankcase Oil Gas API SF SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C MPG may be substituted for these lubricants if neces sary but service intervals will be reduced 3121813 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
101. 3 54 Crank Time The RBS will crank for a period up to the crank time or until the engine starts Rest Time If the engine does not successfully start the RBS will wait for the rest time before attempting to crank the engine again Crank Cycles The RBS will attempt to start the engine up until the number of crank cycles is reached If the RBS does not start an Overcrank fault is indicated Time Delay Bypass TDBP Once the engine starts TDBP must elapse before low oil pressure and underspeed shutdowns are activated This allows the engine to come up to nor mal operating conditions before enabling these shutdowns are monitored Table 3 4 RBS Startup Sequence Crank Time gt Rest Time Until Engine Start or of Crank Cycles TDBP Bypass Normal Running Operation RBS Shutdown Sequence Once all CTS conditions have been removed the RBS will begin the shutdown sequence If a CTS condition is initi ated during the shutdown sequence the RBS will return to normal running operation until the CTS is removed 1 JLG Lift Time Delay Engine Run TDER Once the CTS condition is removed the TDER period begins This period ensures that no further CTS conditions occur prior to the cooldown period Time Delay Cooldown TDC Once the TDER period ends the alternator output is reduced to a minimal level in order to allow the engine to cool down for the TDC period If a CTS is received dur
102. 3121813 JLG Lift TABLE OF CONTENTS SECTION NO 2 4 2 5 2 6 2 7 TITLE PAGE NO Cylinder Drift Test i eee RE ERR 2 5 zer 2 5 Cylinder Drift sv cle Ide TA REIR 2 5 Pins and Composite Bearing Repair Guidelines 2 5 Welding on JLG Equipment 2 6 Do the Following When Welding on JLG 2 6 Do NOT Do the Following When Welding on JLG 2 6 Applying Silicone Dielectric Compound to Electrical Connections 2 6 SECTION 3 CHASSIS amp TURNTABLE 3 1 3 2 3 3 3 4 3 5 Tires amp Wheels en teer sett S toas dE OM Il od folet ox 3 1 ee eae te eh asl Ghee ees 3 1 Tire Damage uu verso Cl der hen ee 3 1 Tire Replacement Je Rae keane ig Rare Eger Phe reni utet m ero 3 1 Wheel Replacement scite Red Re eR ORO EU ET 3 1 Wheel Installation i i eed Rescue oe ee RR dard Pewee Pe he we 3 1 Drive Hub REAR Prior to S N 0300112585 3 2 Disengaging for Towing 3 2 Engaging after Towing is Complete 3 3 Disassembly gt ese Pees we oa abet Siew ta S
103. 5 700 45 60 40 55 35 50 50 70 20 0437 0 1187 10700 80 10 70 95 60 80 1 2 13 110 120 155 L 18280 ato 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 um sis 509 60 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 4 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 Torque Torque Si TPI Bolt Di Tensile Clamp Load Torque gocmen Loctite 262 07778 Stress Area See Note 4 Dy K 17 ORVibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 4o onzo 00064 1 111 48 J T T T T T e 32 01380 00099 fo o LL 8 32 0 1640 0 01400 10 24 0 1900 0 01750 32 01900 oo00 T 5S 1646 20 0 2500 0 0318 2860 122 14 1 T 28 02050 0 0364 3280 139 16 131 75 T 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7716 12
104. 5 16 in 9 43 E M600J 30 ft 8 15 16 in 9 37 m E M600JP 33 ft 33 4 in 10 15 m Turning Radius outside 15ft 3in 4 65 Turning Radius inside Aft 1 23m Maximum Tire Load 7700 Ibs 3500 kg Maximum Ground Bearing Pressure E600J M600J 52 psi 3 7 kg cm E600JP M600JP 51 psi 3 6 kg cm Maximum Drive Speed 3 0 mph 1 3 m s Electrical System Voltage 48 volts Maximum Hydraulic System Pressure 3200 psi 221 Bar Maximum Wind Speed 28 mph 12 5 m s 3121813 1 3 GENERATOR Table 1 3 Generator Alternator Output 58 volts 45 Amps RPM s under max load 3100 Start Battery 12 volts Engine Oil 10W30 Refer to Engine Manual Dynamo 12 volt 15 amp DC Dynamo Output Fuse 20 amps DC Control Fuse 15 amps DC 1 4 BATTERY CHARGER Table 1 4 Battery Charger AC Input 120V 240V Auto Seeking AC Draw 17 amps at start of charging DC Output 48 volts 23 amps 1 5 DRIVE STEER SYSTEM Table 1 5 Drive System Drive Motor 48 VDC 12 5 H P 3200 rpm con tinuous rotation reversible Drive Brake spring applied hydraulically released 1 6 TIRES Table 1 6 Tires Size Type Pressure 36 14 LL 22 5 pneumatic 55 psi 4 0 Bar 36 14 LL 22 5 foam filled N A JLG Lift 1 1 SECTION 1 SPECIFICATIONS 1 7 FUNCTION SPEEDS Table 1 7 Function Speeds L
105. 5 ft Ibs 115 Nm Remove the weight from the basket Adjust P2 until the load 0 Place 500 Ibs 230kg in the center of the basket Adjust P1 until the load 95 Add 5515 25kg in center of the basket Verify that the overload lamp lights continuously and the alarm sounds continuously during an overload condition Remove weight from the basket Seal Potentiometers with fingernail polish When an overload condition is reached the machine will give an indication by activating the tilt alarm lighting the overload light put all platform functions into creep cutout lift up and telescope out at platform and ground The horn will be activated when MTB ground control switch is selected to ground and overload condition is reached NOTE any rotator bolts are replaced all bolts on the rotator should be retorqued Figure 4 6 Platform Support Torque Values JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM LOAD SENSING CIRCUIT CARD a 2 lt or lt or TO LOAD CELL TO MASTER SEE VIEW B LOAD CELL Figure 4 7 Load Sensor 4 9 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM 4 3 PLATFORM ROTATOR PRIOR TO S N 0300130810 Theory of Operation See Figure 4 9 Platform Rotator Assembly Cutaway Fluid entering Port P2 under pressure will bear on the pis ton 4 and force the
106. 813 SECTION 4 BOOM amp PLATFORM SWITCH TO ACTIVATE WHEN BOOM IS EXTENDED 18 1 46 2 5 Figure 4 5 Transport Limit Switch CE Only 3121813 JLG Lift 4 7 SECTION 4 BOOM amp PLATFORM 4 2 10 11 12 LOAD CELL CALIBRATION PROCEDURE Place the machine in the stowed position Activate both emergency stop switches and turn the key switch to the platform position Remove all loads from the basket including the operator Turn P1 clockwise in until the potentiometer begins to click Plug the analyzer into the port in the platform Enter the password 33271 Select Machine Set Up Load 1 Warn Only Select Diagnostics System Load Cell on the Ana lyzer Adjust P2 until the load 0 Place 455 Ibs in the center of the basket Adjust P1 until the load 100 Verify that the overload lamp lights continuously and the alarm sounds continuously during an overload condition Loctite 242 13 14 15 16 17 18 19 20 21 Torque to 50 ft lbs 68 Nm Torque to 480 ft Ibs 650 Nm Check torque every 150 hours of operation Torque to 8
107. ACCORDINGLY NOTE It is recommended as a good practice to replace all filters at the same time 1 Swing Bearing Internal Ball Bearing Lube Point s 1 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation JLG Lift 1 5 SECTION 1 SPECIFICATIONS 4 Hydraulic Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator Comments Under certain conditions it may be necessary to replace the filter on a more frequent basis 5 Swing Drive Hub S N 58845 to Present Lube Point s Fill Cap Capacity Refer to Engine Manual Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accor dance with engine manual FILL 3 Hydraulic Tank DRAIN Lube Point s Level Fill Plug Capacity 24 oz 0 7 L Lube EPGL Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation Lube Point s Fill Cap Capacity Prior to S N 51941 15 gal tank 56 7 L S N 51941 to present 15 9 gal system 56 7L 12 4 gal 46 9 L to Full Mark Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 1 6 JLG Lift 3121813 SECTION 1 SPECIFICATIONS 6 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 0 4 gal 1 5 L Lube
108. ANALYSER Displays Analyzer software version JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 8 Calibration Descriptions CALIBRATIONS Not available at password level 2 can be viewed but not changed at level 1 CONTROLLER CALS TEMPERATURE Displays adjusts heatsink temperature calibration The setting should not be altered from that set during manufacture TRACTIONI Displays adjusts traction motor current calibration The setting should not be altered from that set during manufacture PUMPI Displays adjusts pump motor current calibration The setting should not be altered from that set during manufacture TILTdelaylN Displays adjusts how long the tilt sensor must indicate a tilted condition before it is registered The setting should be adjusted to optimize controller response to a sudden tilt while minimizing spurious tilt indica tions during acceleration amp deceleration TILTdelayOUT Displays adjusts how long the tilt sensor must indicate a not tilted condition before itis registered The setting should be adjusted to optimize controller response to a sudden tilt while minimizing spurious tilt indica tions during acceleration amp deceleration MACHINE CALS BRAKE Displays adjusts brake release speed The setting should be adjusted to release the brakes in the desired time with minimal effect on other boom functions PUMP 0095 Displays adjusts minimum pump on
109. Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connec tor is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this tech nique especially on sealed connectors Whenever possi ble insert probes into the side of the connector such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed connec tor by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the con tact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent condi tions while alone For example you can read the Voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the loca 3121813 tion of the signal and that the leads are connected to the device under test correctly Also check that the lead on the p
110. Brake bep baee VE ee qe ES 3 22 3 14 Speed Sensor 2 3 25 3 15 Brive Cormponents see quee RU d RR pee ar barge 3 26 3 16 Oscillating Axle uli EV Denis pA ED RIEN OR 3 29 3 17 Axle Oscillation Lockout Valve 7 3 30 3 18 Motor Control Valve 3 33 3 19 Motor and Brake Disassembly 1 2 3 34 3 20 Brake 2 12 4 244 2 2 3 35 3 21 Main Disassembly ccarpa nendi iR UR e RR 3 36 3 22 Shaft 3 37 3 23 Carrier Disassembly 3 38 3 24 Setting Gear 3 41 3 25 Swing Bearing Feeler Gauge 3 43 3 26 Swing Bearing Tolerance Measuring 3 43 3 27 Swing Drive and Bearing Installation 3 44 3 28 Swing Bearing Torque
111. CTION CONTACTOR OR TRACTION MOTOR Traction point A is collapsing when the traction MOSFETS are pulsed This is probably due to an open circuittraction motor or direc tional contactor or wiring error NOTE This fault is unlikely to be seen due to interaction with speed control PUMP POINT A LOW CHECK POWER MOTOR WIRING Pump pointA is near 0V when the pump MOSFETS are off This is probably due to a motor or power wiring error STALLED TRACTION MOTOR The power module traction MOSFET protection circuit is active This is due to massive current drain and could be a stalled traction motor or a power wiring error 1 1 Flash code 7 7 indicates problems with a motor continued STALLED PUMP MOTOR The power module pump MOSFET protection circuit is active This is due to massive current drain and could be a stalled pump motor or a power wiring error TRACTION MOTOR OVERLOADED Thetraction motor is drawing Excessive current for an extended period of time the system shuts down to prevent destruction of the motor or power module PUMP MOTOR OVERLOADED The pump motor has been operating in current limit at a low percentage on for a period of time greater than 10 seconds TRACTION CURRENT AT ZERO CHECK SHUNT WIRING Traction current measurement is at zero This is probably due to an open circuit between the current measurement shunt and the power module TRACTION POINT A HIGH CHECK POWER MOTOR WIRING Traction point
112. CUTOUT Displays drive cutout switch status ELEV CUTOUT Displays elevation cutout switch status FUNC CUTOUT Displays function cutout switch status BRAKES Displays brake pressure switch status MAN RELEASE Displays manual brake release switch status TILT Displays measured vehicle tilt The first value indicates tilt in the forward reverse direction pitch The second value indicates tilt in the left right direction roll DATALOG MAX TEMP Displays maximum measured heatsink temp MIN TEMP Displays minimum measured heatsink temp MAX BATTERY Displays maximum measured battery voltage ON Displays total controller on EMS time DRIVE Displays total controller drive operation time PUMP Displays total controller pump running time NOTE includes all boom functions steer and brake release LIFT Displays total controller lift operation time SWING Displays total controller swing operation time TELE Displays total controllertele operation time RENTAL Displays total controller operation time NOTE can be reset ERASE RENTAL Not available at password level 2 YES ENTER NO ESC ENTER resets rental datalog time to zero VERSIONS POWER Displays power module software version PLATFORM Displays platform module software version GROUND Displays ground module software version POSITILT Displays positrac tilt module software version
113. Check Valve Bushing Figure 5 6 Lift Cylinder JLG Lift 3121813 SECTION 5 HYDRAULICS 3121813 1 2 3 4 5 6 Locknut O ring Wear Ring Piston Piston Seal O ring 7 Spacer 11 Backup Ring 8 Barrel 12 Setscrew 8A Bushing 13 Guide 9 Rod 14 Seal 9A Bushing 15 Wiper 10 O ring Figure 5 7 Master Cylinder JLG Lift 5 9 SECTION 5 HYDRAULICS 1 Loctite 242 NotShown 5 Barrel 9 WearRing 2 Locking Primer NotShown 6 Head 10 Loctite Not Shown 7 NotUsed 11 Wiper 4 Rod 8 WearRing 12 Backup Ring Figure 5 8 Steer Cylinder 5 10 JLG Lift 3121813 SECTION 5 HYDRAULICS 1 Loctite 242 NotShown 7 Barrel 13 Piston 19 O ring 24 Wiper 2 Locking Primer NotShown 8 Rod 14 SupportPlate 20 O ring 25 Seal 3 Loctite Not Shown 9 Head 15 Wear Ring 21 Bolt 26 Rod Seal 4 Bolt 10 O ringPlug 16 BackupRing 22 Bolt 27 Spacer 5 Bolt 11 NotUsed 17 Wear Ring 23 BackupRing 28 Valve 6 Tapered Bushing 12 SupportPad 18 O ring Figure 5 9 Telescope Cylinder 3121813 JLG Lift 5 11 SECTION 5 HYDRAULICS NOTE Steps 6 applies only to the telescope cylinders Using a spanner wrench loosen the end cap or head retainer and remove from cylinder barrel Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable NOTICE EXTREME CARE SHOULD BE TAKEN
114. E a 5 2 Spray Method iet urbc ebd Ye E OE EA nud 5 2 Brush On Method 92 dee zcv Hanes ape dote a OR Ed Ee EU 5 2 5 2 Cylinders Theory of Operation 4 5 3 Lift Telescope Slave Master Oscillation if equipped if equipped and Steer 5 8 5 3 Cylinder Checking 5 3 Cylinder Without Counterbalance 5 3 Cylinders With Single Counterbalance Valve 5 3 Cylinders With Dual Counterbalance 5 4 5 4 2 24 Lei hr AIRE ui heey ERR 5 4 Disassembly e eue i eta 5 4 Cleaning and 5 12 Assembly dare a Var eee Ede noted Puede tech 5 13 5 5 Pressure settings su cad Rh ae a e Gea MR rud s AMETE i p RP ER RE 5 19 Proportional Main 1 4 5 19 Lift DOWD ics ee UL UC LEE Red a 5 19 LIU pec Tx 5 19 SWING uA M Re RH DER E 5 19 Flow Control Bang Bang Relief 5 19
115. ECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable cylinder head gland groove CYLINDER HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head JLG Lift Figure 5 14 Wiper Seal Installation 5 13 SECTION 5 HYDRAULICS 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD O RING BACKUP RING NOTE 5 14 Figure 5 15 Installation of Head Seal Kit Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable Carefully slide the piston spacer on the rod If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved If applicable correctly place new seals and guide lock rings in the outer piston diameter groove A tube with 1 0 slightly larger than the O D of the pis ton is recommended to install the solid seal The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni
116. ERHEAD CRANE TO THE UPRIGHT FOR SUPPORT LEAVING APPROXIMATELY 1 INCH 2 54 CM OF SLACK IN CHAIN OR SLING FOR TEST PURPOSES 2 After completing the above shut down hydraulic system and allow machine to sit for 10 15 minutes This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appro priate cylinder port block 3 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the following cylinder repairs must be made If the retract port is leaking the piston is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterbalance is defective and must be replaced 4 no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 5 Remove boom prop overhead crane activate hydraulic system and run cylinder through complete cycle to check for leaks and operation JLG Lift 5 3 SECTION 5 HYDRAULICS Cylinders With Dual Counterbalance Valve Telescope and Slave Cylinders NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system 2 When working on the platform slave cylinder stroke platform slave level cylinder forwa
117. ETRIC Fasteners Sheet 6 of 7 3121813 JLG Lift 1 13 SECTION 1 SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE i TM Tensile Dry or Loctite 2427 or 271 Loctite 262 Size PITCH Stress OR Vibra TITE Anda OR Vibra TITE Ae pe or 140 bu 15 678 78 8 78 36 60 12 5 18 0 22 8 36 1 52 5 115 e as mm sen em m 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 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 9 Torque Chart METRIC Fasteners Sheet 7 of 7 1 14 JLG Lift 3121813 SECTION 2 GENERAL 3121813 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 ha
118. FAULTS DRIVE ACCELeration 0 5510 5 05 1 0 DECELeration 0 1s to 2 0s 0 5 MINimum speed Oto 25 3 MAXimum speed Oto 100 72 ELEVATED MAXimum speed Oto 25 12 CREEP MAXimum speed Oto 45 30 POSITRAC time 010 60s 10 POSITRAC current 50 400A 300A 4WD MINimum 010 50 20 4WD MAXimum Oto 100 50 AWD Cutback 0 to 50 30 LIFT ACCELeration 0 5105 0 0 7 DECELeration 0 1 to 3 0 1 0 MINimum UP speed Oto 20 8 MAXimum UP speed Oto 100 85 CREEP Maximum UP speed 04050 25 MINimum DOWN speed 0to10 1 MAXimum DOWN speed 0to 100 53 CREEP maximum DOWN speed 01030 15 SWING ACCELeration 0 5105 05 0 7 DECELeration 0 1 to 3 0s 1 5 MINimum LEFT speed Oto 10 1 MAXimum LEFT speed Oto 60 6 CREEP maximum LEFT speed 010 35 4 MINimum RIGHT speed Oto 10 1 MAXimum RIGHT speed 010 60 6 CREEP maximum RIGHT speed 010 35 4 NOTE Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance SECTION 6 JLG CONTROL SYSTEM 6 10 Table 6 2 Personality Ranges Defaults JLG Lift FUNCTION PERSONALITY RANGE DEFAULTS TELEscope ACCELeration 0 5t05 0 0 7 DECELeration 0 1103 0 0 5 MINimum IN speed 0to20 20 MAXimum IN speed 010100 50 MINimum OUT speed 0to20 20 MAXimum OUT speed Oto 100 55 BASKET LEVEL ACCELeration 0 5t05 0 1 5 DECELeration 0 1103 0 1 3 MINimum UP speed 0to20 3 MAXimum UP speed 0
119. For example 2 MENU ACCESS LEVEL 2 ej MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 33271 6 6 JLG Lift Once the correct password is displayed press ENTER The access level should display the following if the pass word was entered correctly 4 He MENU ACCESS LEVEL 1 ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings 3121813 SECTION 6 JLG CONTROL SYSTEM 6 5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example 2 ALG PERSONALITIES DRIVE ACCEL 1 0s 2 PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value dec
120. G GASOLINE COLD START POSSIBLE 5 F 15 C 4150548 D Figure 2 1 Operating Temperature Specifications Kubota 2 10 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE 3121813 SECTION 3 CHASSIS 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 insur
121. ION amp SCHEMATICS 7 14 INDICATOR LAMP PANEL BRN WHT 47 4 o 47 5 sr 47 1 J6 PLATFORM CONTROL MODULE N ans enim 47 2 9 SOCKET JE BRN WHT 47 3 p BRNAMHT 47 6 45 J11 17 4 SOCKET 15 PIN 4 Vd 904909 QQ SON N BE raur 2 922715 173 17 2 5292455 3 8 E 54 X xx VESSZEE B 884 2 jS 5 tow S BATTERY STEER RIGHT 8 4 aloe E 18 kis 51 DRIVE STEER SPEED DIE gt soc IR RM 4 44 4 ASSEMBLY TRACTION TELE PLATFROM REY GEN CONTROL ROTATE WHT BLK z ENABLE ag e I SWETECH 18 9 BSE CONDUCTOR 55 g 1871 JIB JIB BASKET BA
122. LTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE 6 Following the torque sequence diagram shown in Figure 3 28 Swing Bearing Torque Sequence tighten the bolts to an initial torque of 130 ft 16 175 Nm Then following the same sequence tighten to a final torque of 190 ft Ibs 260 Nm 7 Remove lifting equipment from bearing 8 Use suitable lifting equipment to carefully position the turntable assembly above the machine frame 9 Carefully lower the turntable onto the swing bearing Ensure that the scribed line of the inner race of the bearing aligns with the scribed mark on the turnta ble If a new swing bearing is used ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the turntable 10 Apply a light coating of Loctite 271 to the new bear ing bolts and install through the turntable and inner race of bearing 3 45 SECTION 3 CHASSIS amp TURNTABLE 11 12 13 14 Following the torque sequence shown in Figure 3 28 Swing Bearing Torque Sequence tighten the bolts to an initial torque of 130 ft Ibs 175 Nm Then following the same sequence tighten the bolts to 190 ft Ibs 260 Nm Remove the lifting equipment Route hydraulic lines through center of turntable and frame and connect as tagged prior to removal Using all applicable safety precautions activate the hydraulic system and functionally check swing sys tem for pro
123. OAD 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 6 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift SECTION 1 SPEC IFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 68 6 1 201 874 n 79 12 19 125 36 60 15 9 28 55 12 175 8430 367 ss 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 4290 5000059 REV J NOTES 1 THESE TORQUE VALUES DO 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 7 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift 3121813 SECTION 1 SPECIFICATI
124. ONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING 1 Install brake in system and connect pressure lines 2 Bleed pressure release section of brake by pressur izing side inlet port and allowing air to escape from top port Pressure should not exceed 100 psi 6 9 bar during bleeding 3 Apply sufficient pressure to release brake and check for proper operation in system JLG Lift 3 21 SECTION 3 CHASSIS amp TURNTABLE 6 1 Capscrew 7 Piston 13 Rotor Disc 19 Retaining Ring 2 Washer 8 O ring 14 Plate 20 Dowel Pin 3 PressurePlate 9 BackupRing 15 Spring 21 Cover 4 Case Seal 10 Shaft 16 SpringRetainer 22 Rotary Oil Seal 5 O ring 11 Stator Disc 17 RetainingRing 23 Gasket 6 BackupRing 12 SensorRing 18 Bearing Figure 3 13 Drive Brake 3 22 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Table 3 2 Drive Brake Diagnosis Problem Cause Explanation Action Brake slips Excessive pressure In hydraulic Ifthereisback pressure in the actuation line of the Checkfilters hose size restrictions system brake holding torque will be reduced inother hydraulic components Oil In brake if designed for dry Wetlinings generate 67 of the dry torque rating If Replace oil seal in brake Check use the brake has oil Init check the type of oil hydraulic motor seal Check piston seals or gearbox Note Internal components will 1 Gearbox oil need to be inspected cle
125. ONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M5 Torque em Torque Lub OR Loctite amp Torque Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress TM INGA 263 Vibra TITE 111 Vibra TITE 131 K 0 20 140 0 15 0 18 3 os sos s13 M oz ez sea 0 8 25 2 22 7 18 9 1 25 36 5 32 8 DC DE DN rm 2 wm ze 200 150 e 2 157 98 cem ONT he 20 25 245 1525 io sso 40 24 3 353 2220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses 525 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 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 8 Torque Chart M
126. 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 C MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON NEL INJURY OR DEATH AND IS A SAFETY VIOLATION ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES e 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 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 CHECKING A HOT PRESSUR IZED COOLAN
127. 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 Check for proper and secure installation Visual inspection for damage cracks distortion or excessive wear Check for proper adjustment Check for cracked or broken welds Operates Properly 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 19 Fully charged 20 No loose connections corrosion or abrasions 21 Verify 22 Perform 23 Sealed Properly 24 Drain Clean Refill CO CO CO TM 1 a x ca 3121813 JLG Lift SECTION 2 GENERAL AMBIENT AIR TEMPERATURE A NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ASAE 10W 30 4 20 7
128. Platform Level Up Relief 1 Connect a pressure gauge to the M1 port on the platform control valve bank 2 Activate and bottom out Platform Level Up Adjust to 2500 psi 172 Bar Jib Relief 1 Connect a pressure gauge at the M1 port on the platform control valve bank 2 Activate and bottom out either Jib Up or Down Adjust the relief to 2300 psi 158 5 Bar JLG Lift 5 19 SECTION 5 HYDRAULICS NOTE WHEN CHECKING MAIN RELIEF PRESSURE UNPLUG LIFT UP COIL NOTE NEED TO HAVE 207 BAR ON FLOW CONTROL RELIEF IN ORDER TO GET CORRECT ROTATE PRESSURE BOTTOM OUT TELESCOPE FUNCTION FLOW CONTROL TELE IN RELIEF TELE OUT NOTE Torque all cartridges to 20 ft Ibs 28 Nm Figure 5 23 Hydraulic Control Valve Main Valve 5 20 JLG Lift 3121813 SECTION 5 HYDRAULICS NOTE Torque all cartridges to 20 ft Ibs 28 Nm JIB RIGHT JIB LEFT JIB DOWN LOAD SHUTTLE JIB UP ROTATE RIGHT ep E D Ua l JIB ROTATE LEFT ROTATE REGULATOR JIB PLUS qM 520 j MODELS 7 SUN LEVEL BACKWARD a LEVEL FORWARD PLATFORM LEVEL CHECK ROTATE RIGHT ROTATE LEFT ROTATE REGULATOR STRAIGHT 11 vL V LEVEL BACKWARD BOOM LEVEL UP MODELS LEVEL DOWN LEVEL FORWARD PLATFORM LEVEL CHECK 3121813 NOTE Torque all cartridges to 20 ft Ibs 28 Nm JIB DOWN JIB LOAD SHUTTLE V LEVEL BACKWARD LEVEL UP
129. R FORMANCE OF YOUR MACHINE ITS IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC RECOM MENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPO NENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION Table 6 1 Machine Setup Descriptions MODEL NUMBER Displays adjusts machine model NOTE all personalities resetto default when model number is altered TILT Displays adjusts tilt sensor function DRIVE CUTOUT Displays adjusts drive cutout switch presence function FUNCTION CUTOUT Displays adjusts function cutout switch presence function JIB Displays adjusts jib presence GROUND ALARM Displays adjusts ground alarm presence function PLATFORM ALARM Displays adjusts platform alarm pres ence function 4WD ASSIST Displays adjusts 4WD assist presence SOFTTOUCH Displays adjusts soft touch system presence 6 8 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM 6 7 MACHINE PERSONALITY SETTINGS Table 6 2 Personality Ranges Defaults 3121813 JLG Lift FUNCTION PERSONALITY RANGE DE
130. R6CIOF e Waitt meo IR RI TEN Rr wage bates ited 7 5 Applying Silicone Dielectric Compound to AMP 7 5 Assembly cce eet dece S guttur ud EUR GE e OE ER RU RO Dee S DEPO UR ees 7 5 Disassembly ee WE quw E TEN CC BA We wb AO 7 7 Wedge Locks eue ede pee EG 7 7 Service Voltage 7 7 7 11 Deutsch Connectors LU Rs E LEE Meee ee es 7 9 DI DIP Series Assembly EE EVER 7 9 DT DTP Series 7 9 HD30 HDP20 Series 7 10 HD30 HDP20 Series 7 10 vi JLG Lift 3121813 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 SerialNumber Location 2 A E M RERO 1 3 1 2 Operator Maintenance and Lubrication 1 5 1 3 Torque Chart SAE Fasteners Sheet 1 7 1 8 1 4 Torque Chart SAE Fasteners Sheet 2 7 1 9 1 5 Torque Chart SAE Fasteners Sheet 3 7 1 10 1 6 Torque Chart SAE Fasteners Sheet 4 7
131. SKET ROTATE JIB ROTATE JIB 5 BOUM SCALE LEVEL TEVED UP RIGHT g UP E 45 5 5 t k 8 xg 8 8 4 Sd ES 589 gi sy Es ss 555 RN zs 804 23 El X Ban e Ed E ass 58 ee 8 8 288 58 igo 5 5 5 5 2 274 goo 5 0 0 0 9 8 56 3 8 8 4 x i 8 5 B B E 5 z H g s i 2 e 4 a 3 gag E 5 a 5 m OPTIONAL GENERATOR g 2 geez 8 CONTROL BOX 4 42 1 125 lt p 102 14 135 1 GENERATOR ENGINE FAULT LED 1J2 13 133 BLACK e BLACK 7 2 YEL RED 2 7 SOT J2 28 136 GENERATOR 8 22 42 5 127 WHTAVEL 48 2 O MANUAL fos rcm em YEL RED 2 7 1 a 4 SWING E GROUND HET ALARM E 20 mio se d Lic WHT BLK 58 4 2 55 BLUE 28 1 3 BLACK GRAY 24 1 8 CE penc BLUE 27 1 2 GRAY 23 1 5 Tas 55 e gt 4 i AAAAASS a S g g 5 8 8 QXAXSX98 2 2 QO 2502 r 2538 FOURVETER 8 Sees INDICATOR i PINK 25 1 2 21314151116 pine 28 1 SG abu aola d WHITE 60 1 8 RED 1 4 12 WHITE 59 1 7 RED 1 2 12 Cu TAN 4 1 Oa 57 1 LIFT N C2 J12 57 2 6 PIN Seri ve Me J4 58 2 WHITE 22 1 15 SOCKET ind BROWN 13 1 9 THE 2
132. SPEED ENCODER FAULTY The speed encoder on the right wheel connected to the power module has a short circuit or open circuit fault drive is still possible at creep speed automatic positrac is disabled SPEED ENCODERS READING INVALID SPEED One or both speed encoders is indicating an impossible number of pulses This is probably due to a faulty speed encoder TILT MODULE FAILURE NOT COMMUNICATING No information is being received fromthe positilt module it may be miswired the system will drive at creep speed using the speed encoder connected to the power module the controller defaults to massively tilted and does nottry to prevent vehicle roll on the grade VEHICLE RUNAWAY CHECK SPEED ENCODERS Speed in the wrong direction was measured with traction motor full on This is probably due to the speed encoder being fitted incor rectly it could also be due to a speed encoder fault or faults as for NO VEHICLE MOVEMENT DETECTED with the vehicle on a grade 6 6 Flash code 6 6 indicates problems with the CANbus 48V PROTECTION TRIPPED CHECK INTER MODULE WIRING The power module is not receiving acknowledgements from the platform ground modules or positilt modules to transmitted data and the protection circuit which supplies the platform ground and positilt modules has tripped This is probably due to wiring prob lems atthe platform ground or positilt module CANbus FAILURE GROUND MODULE The power module is receiving from the platform
133. T IS TILTED ALL OF THE Code Description TIME UNTIL THE FOLLOWING PROCEDURE 1 PERFORMED 2 1 Faulty Footswitch EMS 2 2 Drive Steer inputs Footswitch Interlocks WARNING 2 3 Boom function inputs Lift Swing Joystick DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE 2 5 Function Cutout Drive Cutout 5 3 1 Contactors miswired Motors miswired MG 3 2 Line contactor welded LEVEL VEHICLE 3 3 Contactor short circuit or valve short circuit YES ENTER NO ESQ 3 5 Brake pressure input 4 2 Controller Overtemperature ESC ENTER 4 4 Battery voltage out of range 5 5 Speed Sensor input 6 6 CANbus inputs 7 7 Traction Pump motor wiring or motor faulty 9 9 Power Module Failure LEVEL VEHICLE YES ENTER NO ESC Not available at password level 2 ENTER confirms that vehicle is currently level and zeroes the tilt sensor mea surements 6 14 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages they are intended to hint at a possible problem if the vehicle is not behaving as expected EVERYTHING OK The normal help message in platform mode GROUND MODE OK The normal help message in ground mode BATTERY LOW Battery voltage is below 40V This is a warning the controller does not shut down the low battery lamp will light
134. T 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 JLG Lift 1 INTRODUCTION Original Issue Revised Revised Revised Revised A 2 REVISON LOG August 10 2000 November 22 2000 April 15 2003 February 11 2008 December 18 2012 JLG Lift 3121813 TABLE OF CONTENTS SECTION NO TITLE PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A General pm cT A 1 B Hydraulic System A 1 C Maintenance aeg e eR ELE A 1 SECTION 1 SPECIFICATIONS 1 1 EE IRE Dx Rb Ree YA EUR dr EO OR eh 1 1 1 2 Operating 1 1 1 3 Generatore Eee ME CIV ELO 1 1 1 4 Battery Chargers xci eec NER DUAE e 1 1 1 5 Drive Steer ten so ries 1 1 1 6
135. TACT PARTIALLY INSERTED connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet RETENTION FINGERS Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 3121813 To prevent oxidation and low level conductivity sili cone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging Pierce one of the unused wire seals to allow the trapped air inside the housing to escape Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY DIAPHRAGM WEDGE LOCK SHOWN IN OPEN POSITION MATING SEAL Figure 7 5 Connector Assembly Figure 1 To insert a contact push it straight into the appropri ate circuit cavity as far as it will go See Figure 7 7
136. TION PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI MATELY 1500 LBS 680 KGF THE FOUR CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAU LIC PRESS IS AVAILABLE 3000 LBS 1361 KGF MINIMUM THE PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS AND WASHERS 2 Remove case seal 4 from cover 21 3 Remove piston 7 from pressure plate 3 4 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9 from piston 7 NOTICE IF THE SENSOR RING 12 IS DAMAGED OR NEEDS REPLACED THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT THE SEN SOR RING IS NOT AVAILABLE AS A SERVICE PART 5 Remove stack assembly consisting of stator disc 11 sensor ring 12 rotor disc 13 and plate 14 from cover 21 6 Remove dowel pins 20 springs 15 and spring retainer 16 from cover 21 NOTE Note number and pattern of springs for reassembly purposes 7 Remove retaining ring 17 from cover 21 8 Remove shaft 10 by pressing or using a soft mallet on male end of the shaft 9 Remove retaining ring 19 and bearing 18 from shaft 10 10 Press rotary oil seal 20 from cover 18 Assembly NOTE Lubricate all rubber components from the repair kit with clean type fluid used in the system 1 Clean all parts thoroughly before assembly 2 Press new rotary seal 22 into cover 21 Note direction of seal 3 Install new bearing 18 and retaining ring 19 on s
137. USE OR obi CIRCUIT BREAKER HEATSINK OHN oo A A SHUNT a lt AC BLK Dyson EM OR BRN GROUND 7 DC FUSE OR SCREW Pal CAP CAP CIRCUIT BREAKER AC GRN OR z c m VARISTOR YAVAN RED AC GRN WHT OR BLUE 2 d SCR HEATSINK NOTE ON CE CHARGERS VARISTOR LEADS MUST 9 zi o x m BE COVERED WITH VARFLEX a S 2 10 11 15 6 16 17 OPTIONAL CAPACITORS REQUIRED IN CE CHARGERS 8 MET 7 GRN 7 5 GPN 7 WHT 9 9 CIRCUIT BOARD 4 HARNESS 13 WHT 3 1 2 BLK 12 3 r WHT 14 4321 2 IN SOME CHARGERS D 2 1 BLACK 14 THIS MAY BE AN 2 WHITE 2 WHT AUTOMOTIVE FUSE 5 3 25 GREEN 2 GRN TO 4POS CONN CONNECTORS ARE SAME g A L4 2 RED 4 RED OF MAIN BOARD YYYY m J 2 PIN 1 CONNECTOR PIN 3 WHT PIN 4 BLK 3121813 Figure 3 32 Battery Charger Schematic JLG Lift 3 51 SECTION 3 CHASSIS amp TURNTABLE 3 11 GENERATOR PRIOR TO S N 88375 NOTE Throughout the Generator section the abbreviations RBS and CTS are used RBS stands for Rotary Bat tery System which is the generator system CTS stands for Call To Start which is the electronic inputs which signal the generator to start and charge the batteries The generator consists of a drive engine controller and related components Alternator The alternator is a brushless DC output alternator The 3 phase output of the alternator is full wave rectified and d
138. WAY AS IT WILL MAR THE CYLINDER BORE THE TIMING MARKS THE SMALL PUNCH MARKS ON THE FACE OF EACH GEAR MUST BE ALIGNED FOR PROPER SHAFT ORIENTATION REFER TO FIGURE 4 8 TIMING MARKS MATCHED TIMING MATCHED TIMING MARKS ON PISTON MARKS ON SHAFT SLEEVE AND RING GEAR AND PISTON SLEEVE 1 Integral Housing amp Ring Gear 2 Shaft 3 Piston Sleeve Figure 4 8 Timing Marks JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM gt 22222255 D Es e 4 a on CN N 1 Housing amp Ring Gear 5 End Cap 15 O ring 21 O ring 2A Shaft 6 Locknut 16 Exclusion Seals 22 O ring 2B Flange 7 Capscrew 17 Piston Bearing P1 Pressure Port 2C Bearing Tube 9 Piston Seal 18 Radial Bearing P2 Pressure Port 3 Piston Sleeve 11 Piston Seal 19 Radial Bearing 4 Piston 14 O ring 20 Thrust Bearing Figure 4 9 Platform Rotator Assembly Cutaway 3121813 JLG Lift SECTION 4 BOOM amp PLATFORM If the actuator is not equipped with grease fittings the thrust bearings 20 are coated with good grease before sliding on the shaft and end cap The shaft is installed by again aligning the proper punched timing marks Tempo rarily taping the threaded portion of the shaft will help installation past the shaft seals masking tape works well Apply anti seize to threaded and surrounding areas of the end caps Also depending on the size of the actuator 60K and larger t
139. a hammer 16 to 24 oz and brass shaft approximately 3 4 in diameter as follows a Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews 14 15 16 b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON TAPERED BRASS SHAFT Figure 5 18 Seating the Tapered Bearing Retorque the capscrews evenly and progressively in rotation to the specified torque value See Table 5 1 Cylinder Head and Tapered Bushing Torque Specifi cations Remove the cylinder rod from the holding fixture Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 5 19 Poly Pak Piston Seal Installation PISTON REF JLG Lift Figure 5 19 Poly Pak Piston Seal Installation 5 15 SECTION 5 HYDRAULICS 17 Position the cylinder barrel in a suitable holding fix ture NOTICE 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 18 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 19 Continue pushing the rod into the barrel until the cyl inder
140. a short between two inputs TESTS COMPLETE Indicates thatthe system test is complete Any problems reported should have been noted and should now be rectified Press ESC to return to the RUN SYSTEM TEST Analyzer menu 3121813 JLG Lift 6 33 SECTION 6 JLG CONTROL SYSTEM LB NOTES 6 34 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS 7 6 GENERAL This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions techni cally qualified guidance should be obtained before pro ceeding with any maintenance 7 7 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment This section shows diagrams of a common digital VOM con figured for several different circuit measurements Instruc tions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the Voltage source
141. ake Disassembly 1 3 40 Place Brake Housing 6 on bench with flange end down Either block Brake Housing 6 up or place over hole in bench large enough for the shoulder of the Sun Gear 9 to rest on the bottom of the Brake Housing 6 Then install Sun Gear 9 with gear end down into Brake Housing 6 Place Spacer 8 5 into Brake Housing 6 in bottom of small counter bore below splines Install brake disks starting with an Outer Plate 8 3 then alternating Inner Plates 8 4 and Outer Plates 8 3 into splined bore Grease the O Rings 8 1A amp 8 1C and Backup Rings 8 1B amp 8 1D and place them in their respective grooves in the Piston 8 2 Make sure the backup rings are correctly positioned as per the assembly print NOTE Be sure that Backup Rings 8 1B amp 8 1D are 10 11 12 13 located as tightly into the grooves in the Piston 8 2 as possible to prevent them from being shaved when Piston 8 2 is installed into Brake Housing 6 Apply grease sparingly to Piston 8 2 O D and the cylinder bore of Brake Housing 6 Insert Piston 8 2 into cylinder of Brake Housing 6 be sure not to cut the O Rings 8 1A amp 8 1C or Backup Rings 8 1B amp 8 1D Install Compression Springs 8 6 into spring pock ets in Piston 8 2 Install Compression Springs 8 7 into Compression Springs 8 6 in spring pockets in Piston 8 2 Grease O Ring 26 and install into c
142. and steer speed valve 4 2 Flash code 4 2 indicates that the controller is overtemperature SYSTEM TOO HOT PLEASE WAIT The controller heatsink temperature reached 75 degrees The controller is shut down until it cools to below 70 degrees 4 4 Flash code 4 4 indicates problems with the battery supply BATTERY LOW Battery voltage is below 40V This is a warning the controller does not shut down BATTERY TOO HIGH SYSTEM SHUT DOWN Battery voltage is above 62V EMS recycle required BATTERY TOO LOW SYSTEM SHUT DOWN Battery voltage is below 33V EMS recycle required 6 18 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 9 5 Flash code 5 5 indicates problems with vehicle speed or the encoder NO VEHICLE MOVEMENT DETECTED AT MAXIMUM POWER No speed was measured with traction motor full on This could be due to a traction motor fault a power wiring error a speed encoder fault the brakes not releasing although brake pressure is OK orthe vehicle being overloaded so that motor cannotturn the wheels DRIVE PREVENTED BOTH SPEED ENCODERS FAULTY Both speed encoder input voltages are out of range LEFT SPEED ENCODER FAULTY The speed encoder on the left wheel connected to the positilt module has a short circuit or open circuit fault drive is still possible at creep speed automatic positrac is disabled RIGHT
143. aned and 2 Hydraulic oil replaced as required Disc plates worn The thickness of the disc stack sets the torque level Checkdisc thickness Athin stack reduces torque Springs broken or have takena Broken or set springs can cause reduced torque Check release pressure permanent set rare occurrence See spring replacement Brake drags or runs Low actuation pressure The brake should be pressurized to minimum of Place pressure gauge in bleed port hot 1 38 bar 20 psi over the full release pressure under normal operating conditions Lower pressures will cause the brake to drag thus generating heat amp check pressure with system on Bearing failure Ifthe bearing should fall a large amount of drag can be generated Replace bearing Brake will not release Stuckor clogged valve Brakes are designed to come on when system pres Place pressure gauge in bleed port sure drops below stated release pressure If pres check for adequate pressure sure cannot getto brake the brake will notrelease Replace defective line or compo nent Bad O rings frelease piston will not hold pressure brake willnot Replaceo rings release Discs frozen These brakes are designed for only limited dynamic Replace disc stack braking severe emergency stop or prolonged reduced release pressure operation may result in thistype of damage 3121813 JLG Lift 3 23 SECTION 3 CHASSIS amp TURNTABLE
144. asket 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 a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 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 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 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 interva
145. be in neutral In platform mode any non neutral platform switch or joystick is reported any active cutouts are reported In ground mode any non neutral ground switches is reported any active cutouts are reported NOTE switches which are not in use due to the settings of machine digits are not checked NOTE the pump potis checked only for a wire off condition it can be at any demand from creep to maximum Problems which can be reported include CHECK switchname The named switch is notin its normal position Check switch amp wiring CHECK switchname JOY The named joystick appears to be faulty Check joystick Indicates thatthe inputs test is complete with or without faults TESTING LAMPS Indicates thatthe lamps test is beginning Each lamp is energized in turn a prompt asks for confirmation that lamp is lit ENTER must be pressed to continue the test NOTE lamps which are notin use due to the settings of machine digits are not checked NOTE lamps are only tested in platform mode Problems which can be reported include lampname S C Ashort circuit condition appeared while the named lamp was being tested presumably because it is short circuit LAMP TEST DONE Indicates thatthe lamps test is complete TESTING ALARMS ALARM TEST DONE Indicates thatthe alarms test is beginning Each alarm is energized in turn a prompt asks for confirmation that the alarm is sounding ENTER must be pressed
146. bottoms Make sure that the Roll Pin has bottomed Other wise damage to the carrier could occur when the Slide the Planet Gear 3F and the two Thrust Wash ers 3B out of the Carrier 3A Remove both rows of Needle Bearings 3C and the Spacer 3D from the bore of the Planet Gear Using a 1 4 punch drive the Roll Pin 3G out of the Planet Shaft 3E Planet Shaft is removed 6 Repeat Steps 1 through 5 for the remaining two Planet Gears Remove the Planet Shaft 3E from the Carrier PLANET GEAR SUB ASSEMBLY 3A Carrier 3B Thrust Washers 3C Needle Bearings 3D Spacer 3E Planet Shaft 3F Planet Gear 3G Roll Pin Figure 3 23 Carrier Disassembly JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Hub Shaft Sub Assembly See Figure 3 22 Hub Shaft Disassembly 1 NOTE Press Bearing Cup 1E into Motor end of Housing 1G using an appropriate pressing tool Invert Housing 1G and press Bearing Cup 1C into Housing 1G using an appropriate pressing tool Set Bearing Cone 1F onto Bearing Cup 1E Using an appropriate pressing tool press Seal 1B into Housing 1G until it is flush with the end of the Housing 1G Apply liberal amount of grease to lip of Seal 1B Invert Housing 1G and lower onto Output Shaft 1A Be careful not to damage seal while lowering Hous ing onto Output Shaft Press Bearing Cone 1D onto Output Shaft
147. ce and Maintenance Inspection rental delivery Mechanic Manual and applicable JLG inspection form Frequent Inspection Inservice for 3 months or 150 hours which Owner Dealer or User Qualified JLG Service and Maintenance ever comes first or Mechanic Manual and 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 Certified 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 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 The most important single item in preserving the long service life of a machine is to keep dirt an
148. cect teenies 5 13 5 13 Rod 1 5 13 5 14 Wiper Seal 1 4 20 5 13 5 15 Installation of Head Seal 5 14 5 16 Piston Seal Kit Installation 0 2 lisse I m en 5 14 5 17 Tapered Bushing Installation 140 5 15 5 18 Seating the Tapered Bearing 4 5 15 5 19 Poly Pak Piston Seal cect eh 5 15 5 20 Rod Assembly 2 1 5 16 5 21 Hydraulic Tank and Pump Prior to S N 51944 5 17 5 22 Hydraulic Tank and Pump S N 51941 to Present 5 18 5 23 Hydraulic Control Valve 1 5 20 5 24 Hydraulic Control Valve Platform Valve 2 4 5 21 6 1 Hand Held Analyzer ies RR e RO Ede ee E E do 6 1 6 2 Analyzer Flow Chart Sheet 1 2 1 6 2 6 3 Analyzer Flow Chart Sheet 2 2 4 6 3 6 4 Control Module
149. cilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod barrel must be replaced Lubricate inside of the steel bushing with WD40 prior to bearing installation d Using an arbor of the correct size carefully press the bearing into steel bushing Install pin into the Gar Max bearing dry Lubrication is not required with nickel plated pins and bearings STEEL GAR MAX BUSHING BUSHING ARBOR Figure 5 12 Gar Max Bearing 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 Apply a light film of hydraulic oil to all components prior to assembly A special tool is used to install a new rod seal into the applicable cylinder head gland groove ROD SEAL SEAL TOOL SMOOTH SIDE CYLINDER HEAD Figure 5 13 Rod Seal Installation NOTICE WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION FOR CORR
150. d every 600 hours thereafter See Swing Bearing in Section 3 NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart to determine proper torque value 1 10 MAJOR COMPONENT WEIGHTS Table 1 10 Component Weights 1 11 SERIAL NUMBER LOCATION A serial number plate is affixed to the right side of the frame If the serial number plate is damaged or missing the machine serial number is stamped on the left side of the frame at the top SERIAL NUMBER STAMPED ON FRAME Component Pounds Kilograms Frame bare 1381 626 T T bare 2093 950 Boom Assembly E M 600 4464 2025 Boom Assembly E M 600J 4464 2025 Tire amp Wheel 226 102 5 Swing Drive 70 32 Swing Bearing 100 45 4 Platform Console 25 11 Side Entry Platform 30x72 bare 175 80 Side Entry Platform 30x48 bare 144 66 Counterweight 2560 1161 Foam Fill Filled Tires 441 200 3121813 Figure 1 1 Serial Number Location JLG Lift 1 3 SECTION 1 SPECIFICATIONS 1 12 HYDRAULIC OIL Table 1 13 Mobil DTE 13M Specs Table 1 11 Hydraulic Oil 150 Viscosity Grade 32
151. d 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 2 2 JLG Lift 1 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 ready to be used Components Removal and Installation Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an 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 rem
152. diodes and output current sensor are located in the alternator endbell 3121813 Dynamo and Dynamo Voltage Regulator The engine is equipped with a dynamo and dynamo volt age regulator Dynamo output 12V 7A DC Refer to the Engine Manual for a complete description of the dynamo and dynamo voltage regulator Dynamo Output Fuse p This fuse protects the dynamo output it is located on the left side of the engine Rating 20ADC Control Fuse The control fuse provides power to the engine generator controller and the relays for start control fuel control and glow plug Rating 15ADC This fuse is located on the right side of the engine JLG Lift 3 59 SECTION 3 CHASSIS amp TURNTABLE 3 60 Glow Plug Relay 8 Temperature Sensor Fuel Control Relay 9 Voltage Regulator StartControl Relay 10 Alternator FuelSolenoid 11 Starter FuelFilter 12 Starter Solenoid LowOilPressure Switch 13 Oil Filter Glow Plug Figure 3 35 Generator JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead acid start battery not sup dm plied with the system which provides starting power and power for the RBS controls This battery is charged by the engine dynamo and dynamo regulator when the engine is running Engine Starter The start control relay energizes the solenoid of the
153. e Plat form Control and Main Valve Blocks Proportional Main Relief 1 Connect the pressure gauge at the MP port on the main valve and disconnect the lift up coil on the main valve block 2 Activate the lift up switch from the platform Adjust pressure to 3200 psi 220 Bar Lift Down 1 Connect the pressure gauge at the MP port on the main valve 2 Activate and bottom out lift down Adjust pressure to 1100 psi 76 Bar Lift Up 1 Connect the pressure gauge at the MP port on the main valve 2 Activate lift up until end of lift cylinder stroke Adjust pressure to 2600 psi 179 Bar If ceiling height will not allow elevation disconnect lift up hose port 8 on valve bank and cap the port to make the setting Swing 1 Connect the pressure gauge at the MP port on the main valve 2 Activate the swing function with the turntable lock pin engaged Adjust pressure to 2500 psi 172 Bar 3121813 Flow Control Bang Bang Main Relief 1 Connect the pressure gauge at the MP port on the main valve 2 Activate and bottom out telescope in Adjust pres sure to 3000 psi 207 Bar 1 Connect the pressure gauge at the MP port on the main valve 2 Activate and bottom out steer right or left Adjust pressure to 1800 psi 124 Bar Platform Level Down 1 Connect a pressure gauge to the M1 port on the platform control valve bank 2 Activate and bottom out Platform Level Down Adjust to 1500 psi 103 Bar
154. e chart after lubricating the bolt threads with loctite 271 After replacing and retorquing bolt or bolts recheck all existing bolts for looseness Check the frame to bearing Attach bolts as follows 1 3 42 Elevate the fully retracted boom to full elevation and rotate platform 90 Swing turntable over the side On the frame at the rear of the turntable try to insert the 0 0015 feeler gauge between the bolt head and hardened washer at the indicated position Figure 3 25 Swing Bearing Feeler Gauge Check 10 11 12 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 Lower the boom to horizontal and fully extend the boom Swing the turntable over the side On the frame at the front of the turntable try to insert the 0 0015 feeler gauge between the bolt head and hardened washer at the indicated posi tion 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 Check the turntable to bearing Attach bolts a
155. e 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 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 extrem
156. e your foot from the foot switch if the machine lunges forward The analyzer display should read the following if the RIGHT speed sensor is adjusted properly SPEED 20 FWD If the speed sensor is adjusted improperly the ana lyzer will display SPEED 20 REV and the machine will lunge forward Adjust the right speed sensor using the preceding Adjustment Procedure until the analyzer displays SPEED 20 FWD when forward is selected at the platform The percentage displayed is not critical just the direction After obtaining the display in step 10 operate the machine in both forward and reverse directions The machine should be controllable in both directions and will only drive at a maximum of creep speed The display on the analyzer should match the direc tion selected After completing adjustment of the right sensor plug the left sensor into the posi tilt module Unplug the right sensor from the power module Power up the machine in platform mode and plug in the analyzer in the platform Use the right left cursor keys on the analyzer to high light diagnostics and press enter 16 17 18 19 20 21 22 23 24 JLG Lift Use the right and left cursor keys on the analyzer to highlight drive and press enter Use the right and left cursor keys to display speed 096 ON THE ANALYZER while watching the analyzer display select drive for ward Be ready to remove your foot from the foo
157. each port Assemble the Motor control Valve 31 onto the Motor 10 with Bolts 34 and Washers 83 Torque Bolts 34 to 23 27 ft Ibs Be sure to align the holes in the control valve with the motor ports and make sure o ring is in hole Install Straight Fitting 21 into Brake Housing 6 and torque to 13 15 ft Ibs Install Elbow Fitting 17 into Motor Control Valve 31 with chamfered end of fitting pointing towards straight Fitting 21 Thread fitting all the way in until in the correct position then torque jam nut to 13 15 ft lbs Assemble Tubing 20 Nuts 18 and Ferrules 19 per the procedures below Tube Fitting Assembly Procedures NOTE NOTE 3121813 Be sure the tube is inline with the fitting If required gently modify the tube bends to be inline Assemble nut onto tubing with threaded end toward the assembled end of the tube Assemble ferrule onto tube with the large tapered end into the nut Place tube tight against the flared fitting in the assembly Lubricate threads and fitting end with hydraulic oil Slide ferrule and nut against fitting and hand tighten nut to the fitting Mark nut in relation to the fitting Hold tube tight against fitting and tighten nut 1 1 4 turns of the nut past the marked location Be sure to align the holes in the control valve with the motor ports Pressure test brake tube and control valve connec tions by applying 3000psi pressure to the brake bleed port
158. ee ea erie 3 5 Disassembly 3 5 Disassembly of the first stage planetary assembly 7 3 5 Disassembly of second stage planet gears 1 3 5 Assembly of first stage planetary assembly 7 3 5 Assembly of end cover unit 8 1 3 6 Final Assemb en ani tees hae ae ak d aha Weta ped Laeta 3 6 Initial Start Up and After 3 6 Oil Change Interval Gear 3 6 Drive Hub S N 115723 to 24 3 6 Roll and Leak Testing 2 22 ee ERR RERO 3 6 Tightening and Torquing Bolts 3 7 Main Disassembly ER EG EGER 3 7 Output Carrier Disassembly 3 10 Input Carrier 3 12 Hub Spindle cee eee eee eee 3 13 Cover Disassembly rni ec oy ea cade ee ee 3 14 Input Carrier Assembly 3 15 Output Planet Gear cece n 3 15 Outp
159. ely important to apply and maintain proper wheel mounting torque WARNING WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque 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 JLG Lift 3 4 SECTION 3 CHASSIS amp TURNTABLE 3 The 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 40 ft Ibs 100 ft Ibs 170 ft Ibs 55 Nm 130 Nm 255 Nm 4 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 HUB REAR PRIOR TO S N 0300112585 The final drive consis
160. enoid bracket on the right side of the engine The start control relay is energized by the engine generator controller Fuel Control Relay The fuel control relay energizes the hold coil of the fuel solenoid The fuel control relay is energized by the engine generator controller Fuel Solenoid The fuel solenoid actuates the run stop lever of the engine This solenoid has a pull and hold coil The pull coil is energized by the start control relay and the hold coil is energized by the fuel control relay Engine Oil Temperature Sensor The engine oil temperature sensor is used to sense the temperature of the oil in the sump of the engine This sen sor provides a signal to the engine generator controller for high engine temperature shutdown Alternator Output Current Sensor The alternator output current sensor provides a signal pro portional to the output current of the alternator to the engine generator controller This signal is used by the controller to regulate the current output of the alternator The output current is regulated at 55 Amps DC The alter nator output current sensor is located inside the rear cover of the alternator Engine Speed Sensor The engine speed sensor provides a signal proportional to the rotational speed of the engine to the engine genera tor controller This signal is used by the controller to deter mine starter cut out overspeed fault and underspeed fault This signal has failsafe pro
161. erflow do not top off the fluid level until charging 2 To charge the batteries connect the charger to a 115 volt source with a 15 amp minimum capacity 3 The charge cycle is complete when the 10096 LED is lit Any other reading indicates the charge cycle is not complete 4 The Charger will shut off automatically when the bat teries are fully charged Depleted batteries will take approximately 23 hours to charge JLG Lift 3 47 SECTION 3 CHASSIS amp TURNTABLE NOTE The battery box and batteries complete weigh Removing the Battery Box approximately 668 pounds 303 kg To remove the battery box perform the following steps 1 Pull the pull ring to disconnect the batteries at the 3 2 4 d Dox nea is m battery disconnect beside the box AlS ANG remove the battery box from the machine 2 Remove the two attachment bolts that secure the battery box to the turntable POWER MODULE B CABLE
162. erial If the thickness mea sures less than 0 113 in 2 870 mm or if contaminants are noticed imbedded in the material the thrust washers should be replaced Reassembly It is recommended that you first practice assembling the actuator with the bearings and thrust washers installed but without the seals The seals are easily damaged and their increased friction makes assembly more difficult Be sure that the timing marks on the gear components are engaged in the correct orientation Mark the timing marks with a felt tip marker for better visibility to make assembly easier 1 Wash all parts thoroughly in cleaning solvent and blow dry 2 Pump a high quality NLGI 2 lithium based grease into the grease fittings 111 to flush any contami nants out of the fittings and passages and to insure the fittings are functioning properly Replace any non functioning fittings Wipe off all excess grease The set screws of the relief valves 112 must be flush with the countersunk bore to ensure proper tension on the spring as seen in Photo F If the set screws are threaded in too far the seals will be extruded during greasing and damaged Secure the set screws with Loctite 242 JLG Lift Lightly coat the thrust washers 304 with grease and install them on the shaft 02 and end cap 04 prior to seal installation Lightly coat all sealing and working surfaces with a good grade of hydraulic oil Install all seals in their respecti
163. ering 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 threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary 3121813 SECTION 5 HYDRAULICS 10 11 12 13 NOTE 14 15 16 17 3121813 Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct excessive wear or damage Replace as necessary a Thoroughly clean hole steel bushing of burrs dirt etc to fa
164. etween the swing bearing and turntable front With the boom positioned over the side of the machine the Boom fully elevated retracted and platform rotated 909 using a magnetic base dial indicator measure and record the distance between the swing bearing and turntable rear POINT Figure 3 26 Swing Bearing Tolerance Measuring Point 3 JLG Lift If a difference greater than 0 057 in 1 40 mm is determined the swing bearing should be replaced If a difference less than 0 057 in 1 40 mm is deter mined and any of the following conditions exist the bearing should be removed a Metal particles in the grease b Increased drive power Noise Rough rotation If bearing inspection shows no defects reassemble bearing and return to service 3 43 SECTION 3 CHASSIS amp TURNTABLE TURNTABLE LOCK PIN SHOULDER BOLT BEARING GREASE FITTING Wh BEARING SWING DRIVE SWING DRIVE MOUNTING PLATE MOUNTING PLATE BOLT ADJUSTMENT BOLT TURNTABLE FRAME REF Figure 3 27 Swing Drive and Bearing Installation 3 44 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Replacement of Swing Bearing Removal of the swing bearing is as follows 1 NOTE Attach an adequate support sling to the boom and draw all slack from sling Prop or block the boom if feasible Tag and disconnect hydraulic lines run
165. gt BROWN 14 1 GROUND CONTROL MODULE TAN 3 1 TELE J10 ZN t q re 2 SOCKET __ UP WHT BLK 58 3 N C 2 E N C 2 N C 2 LIFT o N C 2 lt N C gt lt N C 2 J6 J3 lt N c mr LEFT WHITE 59 2 E 9 SOCKET 6 SOCKET T 1 SWING 0 N C 2 lt s AOR GT WHITE 60 2 lt 8 SIDE SWIN lt N C a JIB a ur LEVEL o J8 DOWN TAN 3 2 ORN RED 49 7 EG 2 SOCKET ORN RED 49 6 WHITE 21 2 WHITE 16 2 CABLE v UE ELEVAT ION R TELESCOPE o AS NORMALLY OPEN PINK 26 2 J9 2 HELD CLOSED BROWN 14 2 2 PIN d BROWN 13 2 J7 GRAY 24 2 15 PIN yO ict GRAY 23 2 0 BLUE 27 2 FoR CE ONLY ADDED 1 A OLET BLUE 28 2 WI BOOM we m mae 57 9 ENABLE LIMIT EN ron ETE WHT RED 57 11 5 Figure 7 20 Electrical Schematic Sheet 1 of 4 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS
166. haft 10 3121813 4 Install shaft assembly and retaining ring 17 in cover 21 NOTE Be sure io use the same number of springs and spring pattern as recorded during disassembly 5 Install dowel pins 20 spring retainer 16 and springs 5 in cover plate 21 6 Position plate 14 on springs 15 NOTE Disc 13 amp 11 and plate 14 must remain dry during installation No oil residue must be allowed to contaminate disc surfaces 7 Press the speed sensor ring 12 onto the rotor disc 13 8 Place a new rotor disc 13 on the shaft 10 until it contacts the plate 14 Install stator disc 11 9 Install new o ring 5 new back up ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and backup rings Insert piston 7 into pressure plate 3 Be careful not to shear o rings or back up rings 10 Install new case seal 4 in cover 21 11 Position pressure plate 3 on cover 21 aligning dowel pins 20 with holes in pressure plate NOTE A hyaraulic press will simplify installation of pressure plate on cover Clamp pressure plate in position while tightening the cap screws 12 Install capscrews 1 and washers 2 and tighten evenly to draw pressure plate 3 to cover 21 Torque capscrews to 55 1 165 74 6 Nm A CAUTION IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI 137 9 BAR UNLESS TWO ADDITI
167. haft hole in the end of the Carrier 3A opposite the splined end The end of the planet shaft that does NOT have the roll pin hole should be inserted into the carrier FIRST Place one Thrust Washer 3B onto the end of Planet Shaft 3E Make sure the flat faces towards the inside of the carrier and make sure the button fits in the pocket on the inside of the Carrier 3A towards the OD Following the thrust washer place Planet Gear 3F with needle rollers onto Planet Shaft 3E Following the planet gear place one more Thrust Washer 3B onto Planet Shaft 3E Align the Thrust Washer 3B in the same manner described in Step 5 Now insert Planet Shaft 3E through the opposite planet shaft hole on Carrier 3A Use an alignment punch or similar tool to align the roll pin holes on Carrier 3A and Planet Shaft 3E Be sure not to hit the Planet Gears SF when driving in the Roll Pins 4G Drive Roll Pin 4G down into the aligned roll pin holes Pin should be flush with the flat of carrier Repeat Steps 1 9 for the installation of the two remaining Planet Gears Some grease may need to be applied to the Thrust Washers 3B to hold them in place while installing the planet gears Output Planet Gear Assembly Refer to Figure 3 5 Planet Gear 1 NOTE JLG Lift Apply a liberal coat of grease to the bore of one Out put Planet Gear AF Line the inside of the Planet Gear AF with 14 Nee dle
168. he Analyzer See vehicle or control system documenta tion on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The Switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to fol low mounting instructions and properly set the gap between the switch and object sensed JLG Lift 7 3 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pres sure for example to the switch These switches may need to be energized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Ana lyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or tempera ture for example The state indicated in the control system should change Switch Wiring Low Side High Side When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch
169. he brake test should be performed prior to disassembly and after reassembly to ensure that the brake functions properly and does not leak The brake test procedure can be found in the Motor Brake Subassembly section of this manual NOTE Failure to perform this test may result in damaged or ineffective brake parts Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts extreme care should be taken to ensure that the bolts are not tight ened beyond their specified torque The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle 3 32 BOLT A 8 BOLT B Tighten but do not torque bolt until snug Go to the opposite side of the bolt circle and tighten bolt B until equally snug Crisscross around the bolt circle and tighten remain ing bolts Now use a torque wrench to apply the specified torque to bolt A Using the same sequence crisscross around the bolt circle and apply an equal torque to the remain ing bolts Motor Control Valve Disassembly 1 2 NOTE JLG Lift Place unit on bench with the motor end up Remove Hydraulic Tubing Assembly 20 by loosen ing Fittings 18 on both ends of tube with a wrench Items 18 amp 19 are included on 20 when ordering a replacement Tubing Assembly Using a wrench loosen jam nut on Elbow Fitting 17 and remove fitting from Motor Control Valve 31
170. he cover sufficiently against the shift rod to insert the bolts at least 2 to 3 threads into the cover This will subject the shift rod to spring force 5 Install the bolts and torque 6 3 ft Ibs 8 8 Nm until they are flush with the cover 6 The sun gear shaft and input shaft are now discon nected and the machine is ready to be towed WARNING BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHI CLE EITHER THE GEAR DRIVE HAS TO BE REENGAGED OR SUIT ABLE MEASURES MUST BE TAKEN TO SECURE THE MACHINE FROM MOVEMENT Engaging after Towing is Complete NOTICE PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT I E VIA TOW BAR TO PULLING VEHICLE THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY A CAUTION ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL 3121813 A WARNING THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY A CAUTION ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE A WARNING THE COVER IS UNDER SPRING FORCE 1 Remove the 2 hex head bolts securing the cover evenly and remove the cover 2 Rotate the cover 180 degrees and secure with the
171. he downward position 3 Brush hyaraulic oil on the entire o ring applying an even coat of oil 3121813 SECTION 5 HYDRAULICS 5 2 CYLINDERS THEORY OF OPERATION Lift Telescope Slave Master Oscillation if equipped Jib if equipped and Steer A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the pis ton side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod pis ton attached to rod When the oil flow is stopped move ment of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direc tion and the cylinder rod will retract Holding valves are used in the Lift circuits to prevent retraction of the cylinder rod should a hydraulic line rup ture or leak develop between the cylinder and its related control valve 5 3 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder Without Counterbalance Valves Steer Cylinder and Master Cylinder 1 Using all applicable safety precautions activate hydraulic system and fully extend cylinder to be checked Shut down hydraulic system 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping
172. he end cap may need to be installed with the actuator in a vertical position The end cap 5 is torqued to 60 400 ft Ib 84 560 Nm depending on the actuator size such that the actuator begins rotation at approximately 100 psi 6 9 bar pres sure The shaft flange cannot be rotated by hand the combined backdrive efficiency and friction prevent man ual rotation If the end cap is torqued too high the actua tor may require as much as 300 psi 20 7 bar to rotate If the end cap is not torqued high enough shaft axial motion and radial backlash will result The end cap must be secured against the shaft by tightening cap screws 7 or by installing axial setscrews depending on the model Apply hydraulic pressure and check for breakaway pressure and shaft axial motion To test for leakage pressurize Port P2 to 3000 psi 206 8 bar No oil should seep from Port P1 or from around end cap 5 Repeat test by pressurizing Port P1 and check for leakage out of Port P2 around shaft flange 2B and from ring gear pin welds 4 4 PLATFORM ROTATOR S N 0300130810 TO PRESENT Theory of Operation The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation Each actuator is composed of a housing with integrated gear teeth 01 and only two moving parts the central shaft with inte grated bearing tube and mounting flange 02 and the annular
173. he o ring on the other side of the fitting and repeat the previous step ensuring the entire o ring is coated with hydraulic oil 5 1 SECTION 5 HYDRAULICS Dip Method NOTE This method works best with Face Seal o rings but Will work for all o ring fitting types The following is needed to correctly oil the o ring in this manner small leak proof container Sponge cut to fit inside the container Asmall amount of hydraulic oil to saturate the sponge 1 Place the sponge inside the container and add hydraulic oil to the sponge until it is fully saturated 2 Dip the fitting into the sponge using firm pressure Upon lifting the fitting a small droplet will form and drip from the bottom of the fitting This should signify an even coating of oil on the fitting 3 Boss type fittings will require more pressure in able to immerse more of the fitting into the satu rated sponge This will also cause more oil to be dis persed from the sponge 5 2 JLG Lift Spray Method This method requires a pump or trigger spray bottle 1 Fill the spray bottle with hydraulic oil 2 Hold the fitting over a suitable catch can 3 Spray the entire o ring surface with a medium coat of oil Brush on Method This method requires a sealed bottle brush 1 Fill the bottle with hydraulic oil 2 Using slight pressure to the body of the spray bottle invert the bottle so the brush end is in t
174. hem using a sharp razor blade being careful not to damage the seal groove 17 Remove the thrust washers 304 from the end cap 4 and shaft 2 18 Remove the wiper seal 304 1 from its groove in the end cap 4 and shaft 2 3121813 19 Remove the piston O D seal 202 20 Remove the piston 1 0 seal 200 You may now pro ceed to the inspection process JLG Lift 4 19 SECTION 4 BOOM amp PLATFORM Inspection 3 Inspect the wear guide condition and measure thick ness not less than 0 123 or 3 12 mm 1 Clean all parts in a solvent tank and dry with com pressed air prior to inspecting Carefully inspect all critical areas for any surface finish abnormalities Seal grooves bearing grooves thrust surfaces rod surface housing bore and gear teeth Assembly 1 Gather all the components and tools into one loca tion prior to re assembly Use the cut away drawing to reference the seal orientations 2 Inspect the thrust washers 304 for rough or worn edges and surfaces Measure it s thickness to make sure it is within specifications Not less than 0 092 or 2 34 mm 4 20 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM 2 Install the thrust washer 304 onto shaft 2 and end cap 4 3 Install the wiper seal 304 1 green O ring into it s groove on the shaft 2 and end cap 4 around the outside edge of the thrust washer 304 3121813 4 Using
175. hown below Support the piston sleeve as it is removed from the housing Great care should be taken to insure that the gear teeth are not damaged and the piston sleeve does not damage the housing bore as it is removed Remove all seals and bearings from their grooves Note the orientation of the sealing lips prior to removal Clean all components thoroughly with solvent or in a parts washer Be sure to flush all grease and con taminants from the grease fittings and grease relief passages 3121813 SECTION 4 BOOM amp PLATFORM 3121813 Inspection Inspect all parts for wear damage cracks etc HOUSING Inspect the cylinder bore for wear and scratches The sur face finish should be 32 RMS or better Rehone if neces sary Minor scratches and damage can be repaired by local polishing Inspect all bearing contact surfaces for damage and or contamination and repair and clean as necessary Inspect the exterior of the housing for damage cracks integrity of welds etc SHAFT Check the sealing surface of the shaft for scratches and damage Polish if necessary GEAR COMPONENTS Check gearing for excessive wear Nominal movement between gear components in excess of 1 5 degrees can result in sloppy response BEARINGS All radial bearings are of a reinforced nylon material If the thickness measures less than 0 123 in 3 125 mm the bearings should be replaced THRUST WASHERS Manufactured from an orkot mat
176. ication Chart in Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or 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 or 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 recommends Mobil DTE 11M hydraulic oil for this machine 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 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 Changing Hydraulic Oil 1 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis However filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use o
177. ift Up 55 61 Lift Down 55 61 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 Jib Swing 30 40 High Drive 200 ft 42 46 3 0 mph Drive above Horizontal 50 ft 65 71 0 5 mph 4150273 N Machine Orientation When Doing Speed Tests Lift Boom Retracted Telescope Retracted Lift Up Record Time Lift Down Record Time Swing Boom at Full Elevation Telescope Retracted Swing the Turntable to the end stop Swing the Opposite Direction Record Time Telescope Boom at Full Elevation Telescope Retracted Telescope Out Record Time Telescope In Record Time Drive Test to be done on a smooth level surface Start approximately 25 ft 7 62 m from starting point so that the unit is at maximum speed when starting the test Results should be recorded for a 200 ft 60 96 m course Drive Forward record time Drive Reverse Record Time Drive Above Horizontal Test should be done on a smooth level surface The Platform Speed Knob should be selected out of the creep speed This verifies that the switches are working when the boom is above horizontal Results should be recorded for a 50 ft course Drive For ward Record Time Drive Reverse Record Time Platform Rotate Platform level and completely rotated one direction Rotate the opposite direction Record Time Rotate the other direction Record Time Articulating Jib Pla
178. il which is run by the fuel control relay The pump runs whenever the engine runs and keeps the fuel filter filled Excess fuel flows through the return line pack te Stans The engine is equipped with a low oil pressure switch The fuel pump is located on the right side of the engine This switch is closed when the oil pressure is below 7psi 2 It is mounted on the side cover Fuel Solenoid Engine Oil Temperature Sensor The fuel solenoid actuates the run stop lever of the engine This solenoid has a pull coil energized by the start control relay and a hold coil energized by the fuel control The engine oil temperature sensor is used to sense the relay temperature of the oil in the sump of the engine The fuel solenoid is located on the right side of the engine This sensor provides an analog signal to the engine gen erator controller The primary use of this signal is for high engine temperature shutdown 248 F 120 C for the 3121813 JLG Lift 3 63 SECTION 3 CHASSIS amp TURNTABLE engine The signal is also used in determining if the air glow plug should be energized The engine oil temperature sensor is connected to the engine generator controller at pins J2 8 and J2 19 The engine oil temperature sensor is located on the left side of the engine Alternator Output Current Sensor The alternator output current sensor provides a signal pro portional to the output current of the alternator to
179. including old Loctite 2 Make sure the new valve has the O rings in the counterbores of the valve to seal it to the actuator housing The bolts that come with the valve are grade 8 bolts New bolts should be installed with a new valve Loc tite 242 should be applied to the shank of the three bolts at the time of installation Torque the 1 4 inch bolts 110 to 120 inch pounds 12 4 to 18 5 Nm Do not torque over 125 inch pounds 14 1 Nm Torque the 5 16 inch bolts 140 inch pounds 15 8 Nm Do not torque over 145 inch pounds 16 3 Nm COUNTERBALANCE VALVE Figure 4 14 Rotator Counterbalance Valve 3121813 JLG Lift 4 81 SECTION 4 BOOM amp PLATFORM Testing the Actuator If the equipment is available the actuator should be tested on a hydraulic test bench The breakaway pressure the pressure at which the shaft begins to rotate should be approximately 400 psi 28 bar Cycle the actuator at least 25 times at 3000 psi 210 bar pressure After the 25 rota tions increase the pressure to 4500 psi 315 bar to check for leaks and cracks Perform the test again at the end of the rotation in the opposite direction TESTING THE ACTUATOR FOR INTERNAL LEAKAGE If the actuator is equipped with a counterbalance valve plug the valve ports Connect the hydraulic lines to the housing ports Bleed all air from the actuator see Installa tion and Bleeding Rotate the shaft to the end of rotation at 3000 psi 2
180. ing Cups 1D out of Hub 1G Spindie 1H Stud 1D Tapered Bearing Cup 1J Retaining Ring Ext 1 TaperedBearing Cone 1N Spacer 1G Hub Housing 10 SealBoot Figure 3 7 Hub Spindle 3121813 JLG Lift 3 13 SECTION 3 CHASSIS amp TURNTABLE Cover Disassembly 4 Pull Disengage Rod 6D out from Cover 6A 1 Remove O Ring 17 from groove in Cover 6A 3 Use appropriate ioo tO remove Cena GE TOM internal groove in Cover 64 2 Remove Thrust Washer 2 from Cover 6A pockets 6 Remove wo O Ring Pips Plugs 6F om Cover Unscrew two Hex Head Bolts 6C and remove Dis 6A engage Cap 6B from Cover 6A 2 ThrustSpacer Input Carrier 6A Cover 6B Disengage Cap 6C Bolt Hex 6D DowelPin 6E O ring 6F PipePlug 17 O ring Figure 3 8 Cover Assembly 3 14 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE Input Carrier Assembly Refer to Figure 3 6 Input Carrier 1 NOTE NOTE 10 NOTE 3121813 Apply a liberal coat of grease to the bore of one Input Planet Gear 3F Line the inside of the Planet Gear 3F with 14 Nee dle Rollers 3C The last roller installed must be installed end wise That is the end of the last roller must be placed in between the ends of the two rollers which form the space and then slid parallel to the other rollers into place Set Carrier 3A in an upright position Insert a Planet Shaft 3E into the planet s
181. ing the TDC period the CTS must last for at least the TDES period for the RBS to return to normal running operation Table 3 5 RBS Shutdown Sequence Remove CTS TDER Engine Run TDC Cooldown Engine Stop 3121813 SECTION 3 CHASSIS amp TURNTABLE To Connect the JLG Control System Analyzer Alarms and Fault Flash Codes to the Generator In the event of an RBS alarm a flash code will be issued The JLG Control System Analyzer can be used to monitor And an Alarmi indicated onthe analyzer generator settings and conditions Connect the analyzer NOTE Alarms must be reset once the fault has been cor as follows rected 1 Connect the four pin end of the cable supplied with the analyzer to the connector behind the ground Table 3 6 Generator System Flash Codes control module located on the left side of the machine next to the ground control station and con Code Alarm Description nect the remaining end of the cable to the analyzer 1 1 LOW Oil Pressure Shutdown due to low engine The ground control module contains the settings for oil pressure the generator 1 2 High Engine Tem Shutdown due to high engine perature oil temperature 1 3 Engine Overspeed Shutdown due to high engine speed 1 4 Engine Under Shutdown due to engine speed Overcrank overcrank or underspeed 1 5 No Speed Signal Shutdown due to loss of speed signal 2 1 Overvoltage Shutdown due to high output v
182. irected to the output terminator The output rating is 58 volts DC at 45 amps Voltage regu lation and current limiting is provided by the Engine Gen erator Controller The rectifier diodes and output current sensor are located in the alternator end Dynamo and Dynamo Voltage Regulator The engine is equipped with a 12 Volt 15 Amp DC output dynamo Dynamo Output Fuse The dynamo output fuse is used to protect the output of the dynamo This fuse is rated at 20 Amps DC slow blow and is located on the left side of the engine Control Fuse This fuse provides power to the engine generator and the relays for start control fuel control and pre heater This fuse is rated at 15 Amps DC and is located on the right side of the engine Start Battery A 12 volt lead acid battery is utilized to provide starting power for the generator and power for the generator con trols This battery is charged by the engine dynamo and dynamo regulator when the engine is running Engine Starter The engine is equipped with a 12 Volt DC starter This starter provides mechanical power to crank the engine Electrical power for the starter is provided by the start bat tery The starter is energized by the start control relay 3 52 JLG Lift Start Control Relay The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid The start control relay is located on the fuel sol
183. l the RBS will shut down and an engine no speed signal alarm will be indi cated This shutdown is delayed by a factory set period to ensure the fault was not momentary Overvoltage If the voltage measured at the alternator output exceeds the high voltage setting the RBS will stop immediately and an RBS high output alarm will be indicated This shut down is delayed by a factory set period to ensure the fault was not caused by a transient condition This feature pro tects the batteries and load from high DC voltages Engine Starting System Fault Indicates a problem with either the engine start battery engine magneto or magneto voltage regulator Loss Of Voltage Sense If the voltage measured at the alternator output is less than half of the system nominal voltage the RBS will stop immediately and an RBS loss of voltage sense alarm will be indicated This feature protects the batteries and load from high DC voltages due to a loss of output control Run Inhibited The RBS unit is disabled by the run inhibited input Output Current and Voltage Settings Normal Extended Output Voltage The normal extended output voltage setting is the voltage at which the alternator changes under normal operating conditions Current Limit The current limit setting determines the maximum alterna tor output current High Voltage Shutdown Level This setting determines the alternator output voltage at which the high voltage
184. lace one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise c Ifthe switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Induc tive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows 1 Remove prox switch from its mount 2 Reconnect harness if it was disconnected for step a and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using t
185. left speed MAX LEFT Displays adjusts maximum jib left speed MIN RIGHT Displays adjusts minimum jib right speed MAXRIGHT Displays adjusts maximum jib right speed STEER MIN SPEED Displays adjusts minimum steer speed which applies when vehicle speed is at maximum MAXSPEED Displays adjusts maximum steer speed which applies when vehicle speed is at minimum GROUND MODE LIFTUP Displays adjusts fixed lift up speed LIFT DOWN Displays adjusts fixed lift down speed SWING Displays adjusts fixed swing speed Displays adjusts fixed telescope speed BASKETLEVEL Displays adjusts fixed basket level speed BASKETROTATE Displays adjusts fixed basket rotate speed JIB U D Displays adjusts jib lift speed Not displayed if JIB NO JIB L R Displays adjusts jib swing speed Not displayed if JIB NO 6 24 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM 3121813 Table 6 7 Diagnostic Menu Descriptions DRIVE DRIVE Displays drive joystick direction amp demand SPEED Displays vehicle direction amp speed 4WD Displays 4WD status NOTE Not Displayed when 4WD ASSIST NO POSITRAC Displays positrac status STEER Displays steer switch direction amp demand NOTE steer demand is inversely proportional to vehicle speed BRAKES Displays brake control system status CREEP Displays pump po
186. 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 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 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 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 NOTE This information is based on 6 drops per minute cyl inder leakage 3121813 JLG Lift 2 5 SECTION 2 GENERAL 2 6 WELDING ON JLG EQUIPMENT NOTE This instruction applies to repairs or modifications to the machine and to welding performed from the machine on an external structure or component Do the Following When Welding on JLG Equipment 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 turn
187. llation of the shaft nut 4 requires a special tool and a torque of 626 ft Ibs 876 Nm for proper reas sembly These components Will Fail if not properly reassembled Inspect the planetary stage assemblies as complete units Thoroughly clean and check both the gearing and the bearings for damage and apply new oil If the gears or bearings need replacing they must be replaced as complete sets The first stage planetary gears 2 must be changed in sets of three pieces The first stage planetary gears 2 must be changed as a complete set of three and JLG recommends changing the sun gear shaft 43 along with this set of planets The second stage planetary bearings 11 must be replaced in sets of four pieces The second stage planetary gears 1 must be changed as a complete set of four and JLG recom mends changing the sun gear 3 along with this set of planets Disassembly of Cover 1 2 3 Loosen and remove hex head bolts 53 to remove cover 51 Remove shaft rod 56 and o ring 54 Remove sleeve 52 Disassembly of the first stage planetary assembly 7 1 2 3 4 6 Push sun gear shaft 43 out of the first stage Remove snap rings 14 Press planet pins 5 out of the planet gears 2 Pull cylindrical roller bearing 10 out of the planet gears 2 Remove snap ring 16 from sun gear 3 and Remove planet carrier 7 from sun gear 3 Remove thrust washer 49 Disas
188. ller responds by shutting down drive and reporting flash code 5 5 Vehicle Runaway Check Speed Encoders If either speed sensor is disconnected or faulty the con troller will recognize this condition and immediately report flash code 5 5 Left or Right speed Encoder Faulty Verification w Analyzer Procedure Below is a procedure using the Analyzer that will verify that the speed sensors are installed correctly NOTICE THIS PROCEDURE REQUIRES A LARGE SPACE CLEAR OF OBSTRUCTIONS THE OPERATOR SHOULD BE FAMILIAR WITH JLG EQUIPMENT AND BE PREPARED TO USE THE FOOTSWITCH TO STOP THE MACHINE READ AND UNDERSTAND THIS ENTIRE PROCEDURE PRIOR TO BEGINNING 1 JLG Lift Before beginning this procedure insure that there is at least 10 ft 3m in front and back of machine Be sure that all other personnel stand clear of the machine during this procedure Unplug the left speed sensor from the posi trac tilt module Power up the machine in platform mode and plug in the Analyzer in the platform Use the right and left cursor keys on the analyzer to highlight DIAGNOSTICS and press enter Use the right and left cursor keys on the analyzer to highlight DRIVE and press enter 3 27 SECTION 3 CHASSIS amp TURNTABLE 10 11 12 13 14 15 3 28 Use the right and left cursor keys to display SPEED 096 on the analyzer While watching the analyzer display select drive for ward Be ready to remov
189. ls 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 JLG Lift 2 3 SECTION 2 GENERAL 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 NOTE The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty 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 fied intervals required in the Lubr
190. m upper lift or swing was selected before and during footswitch closure PUMP POT FAULTY The pump potis open circuit all platform boom functions except upper lift amp swing will run at creep PUMP SWITCHES FAULTY CHECK DIAGNOSTICS BOOM Aboom function telescope basket level basket rotate jib has both directions selected together PUMP SWITCHES LOCKED SELECTED BEFORE EMS FSW Aboom function telescope basket level basket rotate jib was selected before keyswitch or footswitch closure PUMP SWITCHED LOCKED SELECTED BEFORE EMS A ground boom function telescope basket level basket rotate jib was selected before keyswitch SWING LIFT JOYSTICK FAULTY The swing joystick center tap is out of valid range or the wiper is wire off 6 16 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 2 5 Flash code 2 5 indicates that a function is prevented due to a cutout BOOM PREVENTED DRIVE SELECTED Aboom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive amp boom operation BOOM PREVENTED FUNCTION CUTOUT ACTIVE Aboom function is selected while function cutout is active and configured to cutout boom functions DRIVE amp BOOM PREVENTED FUNCTION CUTOUT ACTIVE Drive or aboom function is selected while function cutout is active and configured to cuto
191. mbly bubbles If a leak is detected in a seal o ring or gasket the part must be replaced and the unit rechecked 1 Leak test at 10 psi for 20 minutes Tightening and Torquing Bolts 2 If an air impact wrench is used to tighten bolts extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque 4 The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle 1 Tighten but do not torque bolt A until snug 2 Goto the opposite side of the bolt circle and tighten 5 bolt B until equally snug 3 Crisscross around the bolt circle and tighten remain ing bolts 4 Now use a torque wrench to apply the specified 6 torque to bolt A NOTE 5 Using the same sequence crisscross around the bolt circle and apply an equal torque to the remain ing bolts BOLT A 7 NOTE 10 11 12 13 3121813 JLG Lift Perform Roll Check and Leak Check if applicable prior to disassembling the unit Drain oil from unit Note the condition and volume of the oil Remove Coupling 7 from Spindle End first Remove Retaining Ring 6G by prying the open end of Retaining Ring out of the groove in the Ring Gear 1F with a screwdriver then grasp the loose end with pliers and pull the Retaining Ring completely out of the groove Remove the Cover Subassembly 6 from the unit The unit can be carefully pressurized with
192. module but not the ground module This should not be possible CANbus FAILURE PLATFORM MODULE The power module is receiving from the ground module but not the platform module This is probably due to wiring problems between the platform and ground modules CANbus FAILURE POWER MODULE The power module is not receiving acknowledgments from the platform ground or positilt modules to transmitted data This is prob ably due to wiring problems between the power and positilt modules GROUND MODULE FAILURE OBSOLETE ON THIS VEHICLE The ground module is an old design which is incompatible with the E600 vehicle it must be replaced it can be used on E300 M45 E45 vehicles 3121813 JLG Lift 6 19 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 1 1 Flash code 7 7 indicates problems with a motor CAPACITOR BANK FAULT CHECK POWER MOTOR WIRING The capacitor bank is not charging This is probably due to a motor or power wiring error causing illegal current drain it could also be due to a very low battery supply OPEN CIRCUIT PUMP MOTOR Pump point A is collapsing when the pump MOSFETs are pulsed This is probably due to an open circuit pump motor or a power wiring error WARNING If the power wiring between the power module amp contactor panel is wrong this fault can occur any attempt operate the vehicle could damage the power module OPEN CIRCUIT DIRE
193. mount of wear in the spline teeth will have little effect on the actuator strength New spline sets are manufactured with a backlash of about 0 005 0 127 mm per mating set After long service a backlash of about 0 015 0 381 mm per set may still be acceptable in most cases depending on the required accuracy of the application Item 1 is the integral housing and ring gear Check the ring gear for wear and weld damage to the pins Inspect the cylinder bore for wear and scratches The surface fin ish should be 32 RMS or better re hone if necessary The radial bearings 18 and 1 9 and the piston bearings 17 should have a maximum radial clearance of 0 006 0 152 mm A clearance in excess of 0 008 0 203 mm requires replacement of the bearings Rough and grooved shaft journals require shaft replacement 4 10 Assembly and Testing Wash all parts thoroughly in cleaning solvent and blow dry Coat all sealing and working surfaces with a good grade hydraulic oil Install seals and bearings in the piston sleeve piston shaft and end cap The lips of the exclu sion seals 16 face outward and the lips of the high pres sure seals face inward Place the actuator in a vertical position install the piston sleeve 3 in timed relation to the housing applying firm pressure as the new seals and bearings enter the housing and become compressed by the housing chamber A CAUTION DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE
194. n Oshkosh Corporation Company Service and Maintenance Manual Model E600 E600J E600JP M600 M600J M600JP P N 3121813 December 18 2012 INTRODUCTION A SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS GENERAL 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 PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER 1 IN 3121813 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 CON TROL
195. nd Leak Testing Torque Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit s gears bearings and seals are working properly The following information briefly outlines what to look for when performing these tests THE ROLL TEST The purpose of the roll test is to determine if the unit s gears are rotating freely and properly You should be able to rotate the gears in your unit by applying con stant force to the roll checker If you feel more drag in the gears only at certain points then the gears are not rolling freely and should be examined for improper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency THE LEAK TEST MAIN UNIT The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o rings or gaskets JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE meet on the exterior of the unit then checking for air Main Disasse
196. ning through center of turntable and frame Use a suitable con tainer to retain any residual hydraulic fluid Cap lines and ports Attach suitable overhead lifting equipment to the base of turntable weldment Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable This will aid in aligning the bearing upon installation Remove bolts nuts and washers which attach the turntable to the bearing inner race Dis card nuts and bolts Use the lifting equipment to carefully lift the com plete turntable assembly from the bearing Ensure that no damage occurs to the turntable bearing or frame mounted components Carefully place the turntable on a suitably supported trestle The bearing weighs approximately 100 Ibs 45 kg Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame This line will aid in aligning the bearing upon installation Remove the bolts and washers which attach the outer race of the bearing to the frame Discard the bolts Use suitable lifting equipment to remove the bearing from the frame move to a clean suitably supported work area Installation of the swing bearing is as follows 1 3121813 Install bearing to turntable with two capscrews so the grease hose is on the forward side of the frame as close to the centerline of the turntable as the bolt pattern will allow Do not tighten capscrews Line up high spo
197. nly 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 from 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 JLG Lift 3121813 SECTION 2 GENERAL 2 4 CYLINDER DRIFT TEST Maximum acceptable
198. nsert the first stage planetary assembly 7 into drive Install ring 33 in groove of ring gear 30 Install end the cover unit 8 on shoulder ring gear 30 and fix with snap ring 34 Install seal rings 21 and screw plugs 22 Before installation of motor CHECK THAT THERE IS 1 2mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER 62 Install the motor and reconnect hydraulic lines Roll motor so that one fill plug is at 12 o clock posi tion and the other is at 3 o clock Fill to bottom of 3 clock plug with gear oil reinstall plugs Initial Start Up and After Repairs Before operating the machine make sure that the drive is filled with clean oil approximately 0 2 us gallons 0 8 L An accurate oil level is determined by the oil level plug which should be removed before oil fill With the gear case filled to their proper levels start the machine and allow sufficient time for run in at moderate pressure and speed before running at full speed After 4 hours of operation recheck oil level Maintenance Daily Check for oil leakage Weekly Check oil level Monthly Check mounting bolt torque Oil Change Interval Gear Drive 1 Perform the first oil change after approximately 150 hours 2 Subsequent changes every 1500 hours or annually whichever occurs first NOTE Flush the drive before filling with new oil 3 3 DRIVE HUB S N 115723 TO PRESENT Roll a
199. o align roll pin holes on Carrier 4A i and Planet Shaft 4E 4 Be sure not to hit the Planet Gears 4F when driving in Roll Pins 4G 5 Drive Roll Pin 4G down into the aligned roll pin holes Pin should be flush with OD of Carrier 4A Repeat Steps 1 5 for the installation of the two 6 remaining Planet Gears 4F T 8 9 NOTE JLG Lift Spray a light film of oil on all component parts during assembly Place Hub 1G into pressing base Press nine Studs 1H into Hub Use enough pressure to press in studs Don t use excessively high pressure to press in studs or hub may crack Spray a generous amount of oil on bearings during installation Press Bearing Cup 1D position A into Hub 1G using appropriate pressing tool Turn hub over and press Bearing Cup 1D position B into hub using appropriate pressing tool Place Bearing Cone 1E into Bearing Cup 1D position B Grease Seal 1B lip and press seal into Hub 1G using appropriate tool until seal is flush with end of hub Press Seal Boot 1Q onto Hub 1G if required Turn Hub 1G over and lower onto Spindle 1A Install Bearing Cone 1C into Bearing Cup 1D position A Place Bearing Spacer 1N on top of Bearing Cone 1C Using appropriate tool install Retaining Ring 1J into Spindle 1 groove Make sure ring is com pletely seated in groove Extra bearing pre load caused by using tool in Step 9 must be removed
200. oil temperature 9 Speed sensing input 10 RS 232 12V 11 RXD 12 TXD 13 LED Driver GND 14 LED Driver 48V 15 Speed sensor GND 16 Not used 17 Not used 18 Output voltage 19 Engine oil temperature ambient temp 8V 20 Speed Sensing 8V 21 Output current sensor GND 22 Not used 23 RS 232 GND 24 Field drive 25 Start battery 26 Start battery 27 Pre heat 28 Inhibit run 29 Engine temp switch 30 Output voltage 31 Speed sensing 5V 32 Output current sense 33 Not used 34 Not used 35 Field Drive 3121813 SECTION 3 CHASSIS amp TURNTABLE Warnings and Safety Precautions System Settings CALL TO START SETTINGS WARNING THE RBS MAY START WITHOUT WARNING Low battery voltage call to start level 48 0 VDC Low battery voltage remove call to start level 54 0 VDC WARNING Low temperature call to start level 5 MORE THAN ONE LIVE CIRCUIT IS USED INSIDE THE RBS coN _ LOW temperature remove callto start level TROL PANEL EXERCISE CAUTION WHEN THE CONTROL PANEL Low start battery voltage call to start level 12 2V IS OPEN EVEN WHEN THE RBS IS NOT RUNNING Low start battery voltage remove to start level 12 9V System Controls CURRENT AND VOLTAGE SETTINGS INHIBIT RUN INPUT Normal output voltage level 58 0 VDC The inhibit run input prevents the RBS from starting clears Extend o
201. oltage 2 2 Engine Starting Alarm not a shutdown Indi System fault cates problem with the engine starting system 2 3 Not Used Not Used 2 4 Loss of Voltage Shutdown due to loss of volt NOTE The cable has a four pin connector at each end of Sense age sensing the cable the cable cannot be connected back Contin Unit Disabled No Faults RBS enabled and wards no can respond to any CTS Off Unit Disabled RBS off or disabled Will not 2 Power up the Analyzer by pulling out the ground sta respond to any CTS tion EMS and positioning the Generator Enable switch on the platform control box to the on posi Low Oil Pressure tion Refer to Figure 3 34 Generator System Ana lyzer Flow Chart Enabled once TDBP time delay bypass period has elapsed after engine startup If the low engine oil pressure switch closes the engine will stop immediately and a low oil pressure alarm will be indicated High Engine Temperature If the engine oil temperature exceeds the high engine tem perature setting the engine will stop immediately and a low oil pressure alarm will be indicated Overspeed If the engine speed exceeds the overspeed limit the engine will stop immediately and an overspeed alarm will be indicated 3121813 JLG Lift 3 55 SECTION 3 CHASSIS amp TURNTABLE Heya Moly Jez jeuy eu sei o1 SUI JO
202. ontacts Wedge Lock The wedge lock has slotted openings in the forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading A CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ INGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands This nullifies the effectiveness of the con nector seals and could result in system failure 3121813 JLG Lift 7 7 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA X CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 7 11 Connector Installation 7 8 JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS 7 11 DEUTSCH CONNECTORS DT DTP Series Assembly NOTE 3121813 C D Figure 7 12 DT DTP Contact Installation
203. operation manual Use firm contact with meter leads JLG Lift 3121813 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS Current Measurement Figure 7 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected f meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads 7 8 CHECKING SWITCHES Basic Check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 De energize the circuit 2 Isolate the switch from the rest of the circuit if possi ble If not possible keep in mind it may affect read ings 3 Access the terminals to the switch 4 Ifthe switch has two terminals a Measure resistance across the terminals b Change the switch position 3121813 c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 5 f the switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a P
204. or System Flash 3 55 3 7 Controller Interface Pin 3 64 3 8 RBS Alarms and Flash 3 67 3 9 Troubleshooting i eee cR dtd due PR ERU cbe gi en 3 68 4 1 Troubleshooting Rte Ten t e e Pigeon pase Feo et pk Fave rds 4 33 5 1 Cylinder Head and Tapered Bushing Torque 5 16 5 2 Holding Valve Torque Specifications 5 16 6 1 Machine Setup 6 8 6 2 Personality Ranges Defaults isses 6 9 6 3 Machine Configuration Programming Information 6 12 6 4 JLG Control System Flash 6 14 6 5 Help Descriptions and Fault Flash Codes 6 15 6 6 ADJUSTMENTS Personality Descriptions 6 22 6 7 Diagnostic Menu Descriptions 6 25 6 8 Calibration Descriptions 2 Re ee ep et eta LR ur ug 6 27 6 9 Calibration 4 6 28 6 10 System Test
205. ort goes to the Ground or negative side of the sig nal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 1200 Example 50 mA 0 05 Voltage Measurement Figure 7 1 Voltage Measurement DC f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads JLG Lift 74 SECTION 7 BASIC ELECTRICAL INFORMATION amp SCHEMATICS Resistance Measurement Continuity Measurement Figure 7 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing Figure 7 2 Resistance Measurement continuity Disconnect component from circuit before testing First test meter and leads by touching leads together Resistance should read a short circuit 5 Use firm contact with meter leads very low resistance eres First test t i Circuit power must be turned OFF before testing meter ana leads Dy touching leads together Meter should produce an audible alarm resistance ns indicating continuity Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s
206. ounter bore in Brake Housing 6 Assemble Test Cover See Tools at back of manual for drawing to Brake Housing 6 using four Bolts 15 evenly tightening Bolts 15 to 80 100 ft lbs Check the brake for release Apply pressure to brake port in side of Brake Housing 6 while trying to rotate Sun Gear 9 by hand The brake should release between 200 255psi Remove Test Cover Assuming that Brake passed the Brake Test place Motor 10 into Brake Housing 6 with splines of Motor 10 meshing with splines of Sun Gear 9 Attach Motor 10 to Brake Housing 6 with four Bolts 15 and torque to Bolts 15 to 80 100 ft lbs 13 Install O Ring Plug 13 and torque to 13 15 ft Ibs Motor Brake Assembly See Figure 3 19 Motor and Brake Disassembly 1 JLG Lift Grease Thrust Washer 11 and install into counter bore of Carrier Subassembly which should already be installed into the Main Subassembly Grease O Ring 5A and install into counter bore of the Brake Housing 6 in the Motor Brake Subas sembly Install Motor Brake Subassembly onto Main Assem bly using twelve Bolts 12 Torque bolts to 23 27 ft Ibs 3121813 SECTION 3 CHASSIS amp TURNTABLE Motor Control Valve Assembly See Figure 3 18 Motor Control Valve Disassembly 1 NOTE Lay assembly down with motor ports facing up Remove the two plastic plugs in the motor ports on new motors being careful not to loose the O ring in
207. oved and that no adjacent parts are interfering 3121813 SECTION 2 GENERAL 3121813 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 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 g
208. peed of all platform functions to creep when tilted and 1 above elevation Reduces drive speed to creep when tilted Domestic Japan 2 4 degree reduces the maximum speed of all platform functions to creep when tilted and above elevation Reduces drive speed to creep when tilted European Australian 3 4 degree cuts out drive and reduces boom functions to creep speed when tilted and above ele vation Reduces drive speed to creep when tilted only Option 4 3 degree reduces the maximum speed of all boom functions to creep when tilted and above elevation Reduces drive speed to creep when tilted CE and Australian E6 00JP M600JP NOTE Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is tilted and above elevation 3 0 Battery Charger Cutout cuts out drive when the battery charger is plugged 0 DRIVE CUTOUT 1 Battery Charger Cutout and Simultaneous Drive and Boom functions disabled above elevation European Australian 2 Battery Charger Cutout and Drive Cutout above elevation Option 4 0 0 No Function Cutout 0 FUNCTION CUTOUT LIMIT 1 1 Cuts out all boom functions when switch opens Option SWITCH 2 2 Cuts outall functions whenthe switch opens Option 5 0 No jib installed 0 JIB 1 Jib installed which has up and down movements only Option 2 Jib installed which has up and down movements and side to side movements Option 6 0 No ground alarm installed
209. per and safe operation FORWARD Figure 3 28 Swing Bearing Torque Sequence Swing Bearing Torque Value Install with Loctite 190 ft Ibs 260 Nm 3 46 Swing Drive Installation 1 Coat the threads of the socket head bolts securing the swing drive to the mounting plate with Loctite 271 and torque to 120 ft lbs 168 Nm Position swing drive to location of bearing gear max eccentric tooth High spot is marked with yellow paint in tooth With the mounting plate pivoting about the shoulder bolt adjust backlash between the pinion and bear ing gear teeth to 0 008 to 0 012 inch backlash 0 20mm to 0 30mm Tighten the adjusting bolt jam nut and shoulder bolt to prevent the swing drive from moving Coat the threads of the shoulder bolt with Loctite 271 and torque to 420 ft lbs 588 Nm Coat the threads of the mounting plate bolts with Loctite 271 and torque to 420 1 165 588 Nm Setting Backlash 1 JLG Lift Place a shim JLG P N 4071009 between pinion and bearing on high spot of bearing After applying Loctite 271 to the shoulder bolt torque to 420 foot pounds 588 Nm Remove the lock pin on the turntable After applying Loctite 271 torque the four 3 4 socket head bolts to 120 foot pounds 168 Nm Tighten the setscrew until the pinion is snug against the shim and bearing Torque the setscrew to 50 foot pounds 70 Nm Tighten the jam nut Torque the four
210. piston sleeve 03 Helical spline teeth machined on the shaft engage matching splines on the in side diameter of the piston The outside diameter of the piston carries a second set of splines of opposite hand which engage with matching splines in the housing As hydraulic pressure is applied the piston is displaced axially within the housing similar to the operation of a hydraulic cylin der while the splines cause the shaft to rotate When the control valve is closed oil is trapped inside the actuator 4 12 JLG Lift preventing piston movement and locking the shaft in posi tion Bars indicate starting posi fluid pressure is applied tions of piston and shaft the piston is displaced axially Arrows indicate direction they while the helical gearing will rotate The housing with causes the piston and shaft to integral ring gear remains sta rotate simultaneously The tionary double helix design com pounds rotation shaft rota tion is about twice that of the piston The shaft is supported radially by the large upper radial bearing and the lower radial bearing Axially the shaft is separated from the housing by the upper and lower thrust washers The end cap is adjusted for axial clearance and locked in position by set screws or pins 3121813 SECTION 4 BOOM amp PLATFORM Required Tools 6 Pry bar removal of end cap and manual rotation of shaft Upon assembly and disassembly of the actuator
211. piston sleeve 3 upwards The left handed spline of the piston sleeve 3 will combine with the right handed spline of the shaft 2A and cause rapid counter clockwise rotation of the shaft and flange 2B looking down Fluid entering Port P1 will reverse this rotation Displacement and torque are identical for clockwise and counterclockwise rotation The shaft 2A is integral with the shaft flange 2B and bearing tube 2C The shaft is supported radially by the large upper radial bearing 19 and the lower radial bear ing 18 Axially the shaft is separated from the housing by the upper and lower thrust rings 20 The end cap 5 is adjusted for axial clearance and locked in position by cap screws 7 Disassembly and Inspection Place on a clean workbench with room to place the inter nal parts as they are removed Remove all hydraulic fit tings Loosen cap screws 7 and unscrew locknut 6 and end cap 5 The shaft is now free to move up and out of engagement with the piston sleeve 3 Note the orienta tion between the spline teeth see Figure Il as this will greatly simplify actuator timing upon reassembly After removing the shaft the piston sleeve and the piston assembly can now be moved down and out of the hous ing Remove all seals and bearings from their grooves except static piston seals 9 and 11 These seals gener ally do not require replacement Clean all parts thoroughly and inspect for wear A small a
212. r 9 5 15 Lanyard Anchorage Point 2 1 2 10 1 2 10 Turntable Assembly 9 Swing Bearing 1 2 14 1 2 3 13 14 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 Wheel Bearings 14 24 Oscillating Axle Lockout Cylinder Systems 5 8 Steer Components Drive Motors Drive Hubs 11 11 Functions Controls 9 Platform Controls 5 5 6 6 Ground Controls 5 5 6 6 Function Control Locks Guards or Detents 1 5 1 5 5 5 Footswitch 1 5 5 5 3121813 JLG Lift 2 7 SECTION 2 GENERAL Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Deli 2 4 m pesat mee Pene cae See Maintenance Maintenance Inspection Inspection Emergency Stop Switches Ground amp Platform 5 5 5 Function Limitor Cutout Switch Systems 5 5 5 Capacity Indicator 5 Drive Brakes 5 Swing Brakes 5 Boom Synchronization Sequencing Systems 5 Manual Descent or Auxiliary Power 5 5 Power System 9 Engine Idle Throttle and RPM 3 3 Engine Fluids Oil 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
213. rac contactors are energized and de energized checks are made for short circuit and open circuit coils Problems which can be reported include CANT TEST CONTS There is a wiring problem which prevents the contactor test from functioning correctly Check power wiring Check contactor wiring BAD CONT WIRING There is a wiring problem which caused the capacitor bankto be charged when a direction contactor was energized probably the wiring to the contactor coils is incorrect Check contactor wiring Check power wiring contname WELDED The named contactor appears to have not opened Check named contactor Check power wiring contname COIL O C The named contactor coil did not load its driver circuit so is presumed to be open circuit Check contactor wiring contname COIL S C The named contactor coil overloaded its driver circuit so is presumed to be short circuit Check contactor wiring contname DIDNT CLOSE The named contactor appears to have not closed Check contactor wiring Check power wiring CONT TEST DONE Indicates that contactor test is complete with or without faults 3121813 JLG Lift 6 31 SECTION 6 JLG CONTROL SYSTEM Table 6 11 System Test Messages CHECKING INPUTS INPUTS DONE Indicates thatthe inputs test is beginning Every is checked to ensure that it is in its normal position function switches should be open cutout switches should be closed joysticks should
214. raction motor open circuit or a power wir ing error 3 2 Flash code 3 2 indicates that a contactor did not open when deenergized WELDED LINE CONTACTOR The capacitor bank charge did not decrease from battery supply when line contactor was deenergized this could be due to a power wiring error WARNING If the line contactor is welded the controller will not switch off when EMS or keyswitch is turned off 3121813 JLG Lift 6 17 SECTION 6 JLG CONTROL SYSTEM Table 6 5 Help Descriptions and Fault Flash Codes 3 3 Flash code 3 3 indicates that a contactor coil is short circuit OVERLOADED VALVE SUPPLY CHECK WIRING There is ahigh current draw fromthe valve supply when no valve is energized this is probably due to a wiring error atthe ground module SHORT CIRCUIT FORWARD CONTACTOR COIL The forward contactor was not energized when required due to coil overcurrent protection SHORT CIRCUIT LINE CONTACTOR COIL The line contactor was not energized when required due to coil overcurrent protection SHORT CIRCUIT REVERSE CONTACTOR COIL The reverse contactor was not energized when required due to coil overcurrent protection 3 5 Flash code 3 5 indicates that there is a brake pressure problem BRAKES DID NOT LOCK Brake pressure did not clear when the brake valve was deenergized BRAKES DID NOT RELEASE No brake pressure was detected when running the pump motor and energizing the brake valve
215. ransient con dition Preheat delay if engine temperature is below 32 F 0 Cranktime RBS will crank and rest until Resttime engine starts or Overcrank fault is indicated after 3 failed crank cycles Time delay bypass RBS waits until normal engine Operating conditions are reached before Low oil pressure and Underspeed faults are moni tored 3 66 rent below 30ADC 2 Engine temperature above 8 C 3 Startbattery voltage above 12 9V and finish charging cur rent below 30ADC Engine run time delay This period ensures that no fur ther callto start conditions occur priorto cool down period Cool down period Alternator output is reducedto a minimal level to allow the engine to cool down JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE RBS Alarms and Flash Codes In the event of an RBS alarm a flash code will be issued and an alarm indicated on the analyzer Table 3 8 RBS Alarms and Flash Codes Flash Code Problem RBS Condition 1 1 Low Oil Pressure Below 7psi Shutdown 1 2 High Engine Temp Over248 F 120 C Shutdown 1 3 Overspeed Over 3800 RPM Shutdown 1 4 Underspeed 1 Below 2000 RPM Shutdown Overcrank failed crank cyclesCallto startremoved Call to start removed 1 5 No Speed Signal Shutdown 2 1 Overvoltage 3 Over 63VDC Shutdown 2 2 Engine Starting System fault 4 Alarm
216. rd until platform sits at a 45 degree angle 3 After completing the above shut down hydraulic system and allow machine to sit for 10 15 minutes This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appro priate cylinder port block 4 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 the following cylinder repairs must be made If the retract port is leaking the piston is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterbalance is defective and must be replaced 5 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 6 no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 7 Remove boom prop overhead crane activate hydraulic system and run cylinder through complete cycle to check for leaks and operation 5 4 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a
217. re removing the shaft from the housing Do not remove the O ring from the stop tube It performs no sealing functions and should be reused when the actuator is reassembled 3121813 SECTION 4 BOOM amp PLATFORM eH 1 Housing 111 Grease Fitting 205 Bearing Seal 2 Shaft 112 Grease Relief Valve 206 Exclusion Seal 3 PistonSleeve 400 Stop Tube 301 Piston Bearing 4 EndCap 200 Rod Seal 302 Shaft Bearing 5 Lockring 201 Rod Seal 303 Shaft Bearing 102 Socket Head 202 Piston Seal 304 Thrust Washer 106 PortPlug 204 Seal Figure 4 12 Jib Rotator Assembly 3121813 JLG Lift 4 27 SECTION 4 BOOM amp PLATFORM DRILL 17 64 DIAMETER THRU BREAK EDGE H SIDES BOT 4 PLACES EQUALLY SPACED 050 x 45 TYPICAL ON A 2 780 BOLT CIRCLE DRILL amp TAP 3 8 16 UNC THRU 2 PLACES EQUALLY SPACED ON A 2 780 BOLT CIRCLE Figure 4 13 Tool for Removing End Cap 6 With the shaft removed note the orientation of the timing marks on the piston sleeve and ring gear in the housing as below The adjacent weld can make the ring gear timing marks difficult to locate using a light can help Again mark the teeth with a felt tip marker to make the marks easier to see and to simplify timing during reassembly Drive the piston sleeve out of the hous 4 28 Lift ing using the handle of a rubber mallet as s
218. rease if the DOWN arrow is pressed and the value is at the minimum value for any particular per sonality If the value does not change when pressing the up and won arrows check the access level to ensure you are at access level 1 6 6 MACHINE SETUP When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example ME GROUND ALARM 2 DRIVE A J GROUND ALARM 2 DRIVE The effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving There are certain set tings allowed to install optional features or select the machine model When selection the machine model to match the size of the machine the personality settings will all default to the factory recommended setting NOTE Refer to Table 6 2 Personality Ranges Defaults and Table 6 1 Machine Setup Descriptions in this Ser vice Manual for the recommended factory settings NOTE Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings 3121813 JLG Lift 6 7 SECTION 6 JLG CONTROL SYSTEM There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK WARNING CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PE
219. rformance 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 model Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires JLG Lift 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc PHA seule Reference yp 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 Servi
220. ring gear and hub Torque them to 15 20 ft Ibs Place Output Carrier Sub Assembly 4 into mesh with Spindle 1A splines Place External Retaining Ring 5 over 13T spline to the retaining groove on Input Shaft 9 For ratio 48 1 assemble Output Sun Gear 11 over Input Shaft 9 first then install External Retaining Ring 5 Using appropriate tool to install Retaining Ring 20 into groove on Output Sun 11 Place Input Shaft 9 spline end into mesh with Inter nal Coupling 7 splines With the modified spline end facing up place the Output Sun Gear 11 into mesh with the output planet gears Place Input Carrier Sub Assembly 3 onto Output Sun Gear 11 splines Drop Input Sun 10 into mesh with planet gears for specific ratios if required No timing required Grease O Ring 17 and insert into groove in Cover Sub Assembly 6 Install Cover Sub Assembly 6 into Ring Gear 1F counterbore and install Retaining Ring 6G into groove in Ring Gear 1F Attach ID Tag 15 onto unit using Drive Screws 16 Check disconnect roll and air check unit leak check brake and record release pressure 14 Insert Plas tic Plug 12 into place if applicable SECTION 3 CHASSIS amp TURNTABLE 5 n S XS 5 TIIKAN sill AY N 2 S Figure 3 9 Hub Assembly Sheet
221. rking properly The following information briefly outlines what to look for when performing these tests NOTE The brake must be released and hydraulic lines to motor removed before performing the roll test ROLL TEST The purpose of the roll test is to determine if the unit s gears are rotating freely and properly You should be able to rotate the gears in your unit by applying constant force to the roll checker If you feel more drag in the gears only at certain points then the gears are not rolling freely and should be examined for improper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency LEAK TEST MAIN UNIT The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge reading on your air checker starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or gaskets are located The exact loca tion of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o rings or gaskets meet on the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes BRAKE TEST T
222. roblem Solution 2 2 Engine Starting System fault Check engine start battery charging system for current output Check for failed engine start battery 2 4 Loss Of Voltage Sense APU Engine Start Battery Boosting Always connect the POSITIVE of the booster battery to the POSITIVE of the APU start battery and the NEGATIVE of the booster battery to the ground of the engine block WARNINGS A WARNING ALWAYS SHIELD YOUR EYES AND AVOID LEANING OVER THE BATTERY WHENEVER POSSIBLE A WARNING DO NOT ALLOW BATTERY ACID TO CONTACT EYES OR SKIN FLUSH ANY CONTACTED AREA WITH WATER IMMEDIATELY SEEK MEDICAL ATTENTION IF IRRITATION PERSISTS A WARNING STARTING BATTERIES GENERATE EXPLOSIVE GASES KEEP SPARKS FLAME AND LIGHTED CIGARETTES AWAY FROM BAT TERIES A WARNING IMPROPER USE OF A BOOSTER BATTERY TO START AN APU MAY CAUSE AN EXPLOSION 3121813 A WARNING DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID LEVEL IN THE BATTERY A WARNING THE VOLTAGE OF THE BOOSTER BATTERY MUST BE RATED AT 12V THE AMP HOUR CAPACITY OF THE BOOSTER BATTERY MUST NOT BE LOWER OR SUBSTANTIALLY HIGHER THAN THAT OF THE DISCHARGED BATTERY USE OF BATTERIES OF DIFFER ENT VOLTAGE OR SUBSTANTIALLY DIFFERENT AMP HOUR RAT ING MAY CAUSE AN EXPLOSION OR PERSONAL INJURY APPLYING A HIGHER VOLTAGE WHILE BOOSTING WILL ALSO CAUSE DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS A WARNING A CHARGING SYSTEM BATTERY CHARGER OR BATTERY
223. rom the valve ports b Remove the plug andthe housing s valve ports Operate the actuator through the housing ports Conductthe internal leakage testas described in the Testing section on page 24 of this manual c Purge air from actuator See bleeding proce dures 3121813 JLG Lift 4 33 SECTION 4 BOOM amp PLATFORM LB NOTES 4 34 JLG Lift 3121813 SECTION 5 HYDRAULICS SECTION 5 HYDRAULICS 5 1 LUBRICATING O RINGS IN THE HYDRAULIC SYSTEM When assembling connectors in the hydraulic that use o ring fittings it is necessary to lubricate all fittings with hydraulic oil prior to assembly To lubricate the fittings use one of the following procedures NOTE O ring fittings must be pre lubricated with hydrau lic oil prior to assembly Cup and Brush The following is needed to correctly oil the o ring in this manner Asmall container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush with the other hand to dip into the container Remove excess hydraulic oil from the brush so an even film of oil is applied on the o ring 3121813 JLG Lift 2 Holding the fitting over the hydraulic oil container brush an even film of oil around the entire o ring in the fitting making sure the entire o ring is com pletely saturated 3 Turn t
224. rse and drive machine off of block and ramp Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed posi tion lockout cylinders should release and allow wheel to rest on ground it may be necessary to acti vate Drive to release cylinders Place the 6 inches 15 2 cm high block with ascen sion ramp in front of right front wheel Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block With boom over left side of machine place Drive control lever to Reverse and drive machine off of block and ramp Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed posi tion lockout cylinders should release and allow wheel to rest on ground it may be necessary acti vate Drive to release cylinders 13 If lockout cylinders do not function properly have qualified personnel correct the malfunction prior to any further operation 3 7 OSCILLATION CYLINDER BLEEDING NOTE The oscillating axle must be checked daily for proper operation Bleeding Procedure 1 NOTE R
225. s adjusts minimum telescope in speed MAXIN Displays adjusts maximum telescope in speed MIN OUT Displays adjusts minimum telescope out speed MAXOUT Displays adjusts maximum telescope out speed BASKET LEVEL ACCEL Displays adjusts basket level acceleration DECEL Displays adjusts basket level deceleration MIN UP Displays adjusts minimum basket level up speed MAXUP Displays adjusts maximum basket level up speed MIN DOWN Displays adjusts minimum basket level down speed MAXDOWN Displays adjusts maximum basket level down speed BASKET ROTATE ACCEL Displays adjusts basket rotate acceleration DECEL Displays adjusts basket rotate deceleration MIN LEFT Displays adjusts minimum basket rotate left speed MAXLEFT Displays adjusts maximum basket rotate left speed MIN RIGHT Displays adjusts minimum basket rotate right speed MAXRIGHT Displays adjusts maximum basket rotate right speed JIB Not displayed if JIB NO ACCEL Displays adjusts jib acceleration DECEL Displays adjusts jib deceleration MIN UP Displays adjusts minimum jib up speed MAXUP Displays adjusts maximum jib up speed MIN DOWN Displays adjusts minimum jib down speed 3121813 JLG Lift 6 23 SECTION 6 JLG CONTROL SYSTEM Table 6 6 ADJUSTMENTS Personality Descriptions MAXDOWN Displays adjusts maximum jib down speed MIN LEFT Displays adjusts minimum jib
226. s applied the piston is displaced axially while simultaneously the helical gearing forces the rotation of the shaft Note how the double helix design compounds rotation shaft rotation is about twice that of the piston Figure 4 12 Operating Principle Jib Rotator JLG Lift 4 25 SECTION 4 BOOM amp PLATFORM turning in a counterclockwise direction as shown below and the root of a spline tooth on the shaft gearing indicate timing as seen below A considerable amount of torque may be required to loosen the end cap Com pletely filling the length of the screws with a stack of washers or a bushing as seen in the illustration to the right will per mit more force to be applied to the screws and prevent them from bending be sure to thread the screws completely into the endcap If the end cap is difficult to break loose spe cial tooling may be fabricated according to the drawing below 5 Remove the shaft from the housing assembly by driving it out with a plastic hammer as seen below Before the shaft and piston gearing are completely disengaged note the orientation between the spline teeth small punch marks on the face or the piston 4 26 Lift Marking the teeth at this time with a permanent felt tip marker will make the marks easier to see and greatly simplify actuator timing during reassembly For 120 rotation actuators remove the stop tube from the shaft befo
227. s follows 1 JLG Lift Elevate the fully retracted boom to full elevation and rotate the platform 90 Swing the turntable over the side At turntable rear try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position 3121813 SECTION 3 CHASSIS amp TURNTABLE 4 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 0015 Feeler Gauge Figure 3 25 Swing Bearing Feeler Gauge Check 7 Lower the boom to horizontal and fully extend the boom 8 At turntable front try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position 9 Assure that the 0 0015 feeler gauge will not pene trate under the bolt head to the bolt shank 10 Swing the turntable 90 degrees and check some selected bolts at the new position 11 Continue rotating the turntable at 90 degrees inter vals until a sampling of bolts have been checked in all quadrants 3121813 Wear Tolerance 1 With the boom positioned over the side of the machine the Boom horizontal with telescope fully extended using a magnetic base dial indicator measure and record the distance b
228. sembly of second stage planet gears 1 Press cylindrical roller bearings out of planet gears 1 Assembly of first stage planetary assembly 7 1 JLG Lift Pre freeze planet pins 5 and install into planet car rier 7 Install planet carrier 7 together with planet pins 5 on sun gear 3 and install snap ring 16 Pre heat thrust washer 49 and Install onto sun gear shaft 43 Put sun gear shaft 43 into sun gear 3 Pre heat stay rings 17 and install onto planet pins 5 Pre heat cylindrical roller bearings 10 and install onto planet pins 5 and fix bearings with snap rings 14 3 5 SECTION 3 CHASSIS amp TURNTABLE Assembly of end cover unit 8 1 gt Press sleeve 52 into cover 8 Install o ring 54 into groove of cover 8 Install shift rod 56 into cover 8 Install the cover 51 into cover 8 and fix cover 51 with hex bolts 53 Tighten bolts with torque wrench to 6 3 ft Ibs 8 5 Nm Final Assembly 11 12 3 6 Install thrust washer 29 in spindle 60 Install o ring 19 into groove of support ring 6 Install planet gears 1 onto planet pins which are part of spindle 60 Install snap rings 15 on planet pins of spindle 60 in order to fix the planet gears 1 Put ring gear 30 onto support ring 6 and fix ring gear 30 with hex head bolts 23 Tighten bolts with torque wrench to 15 5 ft 16 21 1 Nm I
229. shaft clockwise until it is bottomed out against the piston sleeve Using a rubber mallet drive the shaft into the housing until the thrust 4 29 SECTION 4 BOOM amp PLATFORM 8 4 30 washer comes to a stop against the housing thrust surface Remove the masking tape and apply anti seize to the shaft threads Install the stop tube if applicable Apply a thin film of grease to the seals then thread the end cap onto the shaft to a net fit where the end cap just begins to damp against the thrust washer Tighten the end cap to approximately 120 FT LB 163 N m 11 12 JLG Lift Apply a generous amount of anti seize to the splines at the end of the shaft Locate the correct position of the locknut to align its bolt circle with that of the end cap If the bolt circles do not align unthread the end cap no more than a half a pitch of the shaft splines Insert the cap screws and torque to 108 IN LB 147 N m Grease the thrust washers Pump a high quality NLGI 2 lithium based grease into the grease fittings at both ends of the housing until it begins to ooze from the grease reliefs If possible rotate the shaft during greasing to ensure even distribution on the thrust surfaces 3121813 SECTION 4 BOOM amp PLATFORM Installing Counterbalance Valve Refer to Figure 4 14 Rotator Counterbalance Valve 1 Make sure the surface of the actuator is clean free of any contamination and foreign debris
230. t switch if the machine lunges forward The analyzer display should read the following if the left speed sensor is adjusted properly SPEED 2096 FWD If the left speed sensor is adjusted improperly the analyzer will display SPEED 20 REV and the machine will lunge forward Adjust the left speed sensor using the preceding Adjustment Procedure until the analyzer displays SPEED 20 FWD when forward is selected in the platform The percentage displayed is not critical just the direction After obtaining the display in step 10 operate the machine in both the forward and reverse directions The machine should be controllable in both direc tions and will only drive at a maximum of creep speed The display on the analyzer should match the direction selected Plug in the right sensor to the power module Test the machine The machine should now have maximum drive speed available in both directions and should be controllable in both directions The analyzer display should match the direction selected 3121813 SECTION 3 CHASSIS amp TURNTABLE AXLE OSCILLATION VALVES DRIVE ASSIST VALVE OSCILLATION CYLINDER KING PIN STEER CYLINDER COVER PLATE STEER CYLINDER p 44 5 MM REF ADJUST TOE WITH STEER CYLINDER ROD CENTERED IN STEER CYLINDER ASSEMBLY TOLERANCE 3 175 MM 1 8
231. t marked with yellow paint of bear ing with center tooth of bull gear Set backlash to 0 008 0 012 inch 0 20 0 30 mm Refer to Swing Drive Installation Tighten capscrews as shown in Figure 3 28 Swing Bearing Torque Sequence Grease bearing with Mobilith SHC Bearing Grease Grease fitting is on inside wall of inner race of bear ing JLG Lift NOTE If Mobiltac 375NC is not available Tribol Molub Alloy 936 Open Gear Compound or Mobilith SHC Bearing Grease or Multi Purpose Grease MPG can be sub stituted however the service interval will be shorter 4 Using suitable lifting equipment install bearing assembly to frame with soft spot red 90 degree rel ative to load axis If reusing old bearing ensure that scribed line of outer race of the bearing aligns with the scribed mark on the frame A CAUTION JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8 BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW GRADE 8 NUTS AND BOLTS SINCE THE SWING BEAR ING 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 1 HIGHLY RECOMMENDED 5b Apply a light coating of Loctite 271 to the new bear ing bolts and loosely install the bolts and washers through the frame and outer race of bearing A CAUTION IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BO
232. t creep switch status BOOM Displays lift joystick direction amp demand SWING Displays swing joystick direction amp demand LEVEL Displays basket level switch direction amp demand NOTE demand is controlled by the pump pot TELE Displays telescope switch direction amp demand NOTE demand is controlled by the pump pot ROTATE Displays basket rotate switch direction amp demand NOTE demand is controlled by the pump pot JIB U D Displays jib lift switch direction amp demand NOTE demand is controlled by the pump pot Not displayed if JIB NO JIB L R Displays jib swing switch direction amp demand NOTE demand is controlled by the pump pot Not displayed if JIB NO PUMP POT Displays pump pot demand CREEP Displays pump pot creep switch status SYSTEM TRACTION Displays measured traction motor current PUMP Displays measured pump motor current VALVE Displays measured valve 12V supply current NOTE this includes current for the ground alarm amp hourmeter but not for any lamps BATTERY Displays measured battery voltage TEMPERATURE Displays measured heatsink temperature JLG Lift 6 25 SECTION 6 JLG CONTROL SYSTEM 6 26 Table 6 7 Diagnostic Menu Descriptions FSW1 Displays footswitch status NOTE FSW1 is wired to the power module FSW2 Displays footswitch status NOTE FSW2 is wired to the platform module DRIVE
233. t down LLD If the switch is faulty or the wiring is faulty the controller will not move on to the next input The controller will continue to wait for the closure of the input If the operator knows the switch is faulty and wants to continue the tests he must simply press the enter key on the analyzer to con tinue After the controller has conducted the tests from the chosen operator station it will display TESTS COM PLETE This indicates that the controller has checked all inputs and outputs for that station NOTICE 2 In order to test the inputs on the machine the con ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF troller will ask the service technician to perform vari TEST IS COMPLETE POWER MUST BE RECYCLED USING THE ous tasks at the appropriate operator control station EMS OR THE KEYSWITCH An example of this is Close LLU Switch The con troller expects the operator to close the lower lift up switch When the controller sees that the lower lift up Table 6 10 System Test Descriptions ACTIVATE TESTS Not available once tests are activated YES ENTER NO ESC ENTER activates system tests NOTE cannot be done while controller is in use footswitch closed and for a short afterwards RUN SYSTEM TEST ENTER starts system test Not available until tests are activated Displays messages while system test runs test Some messages are prompts requiring user intervention ENTER can be pressed if
234. table 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 CAUTION FAILURE COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COMPONENT DAMAGE I E ELECTRONIC MODULES SWING BEARING COLLECTOR RING WIRE ROPES ETC 2 6 JLG Lift 2 7 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS Silicone Dielectric Compound must be used on all electri cal connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors This procedure applies to all plug connections not enclosed in a box Sili cone grease should not be applied to connectors with external seals 1 To prevent oxidation silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly This is most easily achieved by using a syringe NOTE Over a period of time oxidation increases electrical resistance at the connection eventually causing cir cuit failure
235. tection if it is not present at the controller the unit will fault with a loss of speed sig nal indication The engine speed sensor is located inside the recoil starter cover at the front of the engine Engine Low Oil Pressure Switch The engine is equipped with a low oil pressure switch The switch is closed when the oil pressure is below 14 2 psi 1 Bar 3121813 SECTION 3 CHASSIS amp TURNTABLE _ FUEL SOLENOID FUEL FILTER CONTROL FUSE naga ENGINE LOW BE OIL PRESSURE SWITCH START CONTROL FUEL CONTROL RELAY RELAY ALTERNATOR DYNAMO OUTPUT FUSE E 3 7 38 ENGINE STARTER DYNAMO ENGINE OIL VOLTAGE REGULATOR SENSOR Figure 3 33 Generator Components 3121813 JLG Lift 3 53 SECTION 3 CHASSIS amp TURNTABLE Timing Sequences RBS Prestart Sequence 1 Time Delay Engine Start TDES TDES is the period which the RBS waits to verify that the CTS is valid rather than a transient condition Time Delay Pre Heat TDPH TDPH if enabled occurs after TDES has elapsed and the engine temperature is below the factory set engine preheat temperature setting The engine pre heater will be energized for the factory set preheat delay period Table 3 3 RBS Prestart Sequence CTS Callto Start TDES Engine Start Preheat Delay RBS Startup Sequence RBS Startup Sequence 3
236. tform level and centered with the boom Start with the Jib down Jib Up Record Time Jib Down Record Time 1 2 Test Notes 1 Stop watch should be started with the function not with the controller or switch 2 Drive test results reflect 36 14LL 22 5 tires 3 speed tests are run from the platform These speeds do not reflect the ground control operation 4 The platform speed knob control must be at full speed turned clockwise completely 5 Function speeds may vary due to cold thick hydrau lic oil Test should be run with the oil temperature above 100 F 38 C 6 Some flow control functions may not work with the speed knob clicked into the creep position 1 8 PRESSURE SETTINGS Table 1 8 Pressure Settings SETTING PSI BAR Proportional Main Relief 3200 220 Bang Bang Main Relief 3000 207 Lift Up 2500 172 LiftDown 1100 76 Swing 2500 172 Swing Brake 320 22 Steer 1800 124 Platform Level Up 2500 172 Platform Level Down 1500 103 Jib Up 2300 158 5 Jib Down 2300 158 5 JLG Lift 3121813 SECTION 1 SPECIFICATIONS 1 9 TORQUE REQUIREMENTS Table 1 9 Torque Requirements Description Torque Value Dry Interval Hours Wheel Lugs 1701 lbs 238 Nm 150 T T Counterweight 400 ft lbs 560 Nm A R Bolts Swing Bearing Bolts 190ft lbs 260 Nm 50 600 Check swing bearing bolts for security after first 50 hours of opera tion an
237. the Harness label to the harness Next remove the Wire Ties so that the cable sleeve can be moved exposing the 3 70 JLG Lift 3121813 SECTION 3 CHASSIS amp TURNTABLE conductors of the harness 6 Re install the harness with the new fuse in place 7 Reconnect the lift and APU start battery The APU is now ready for use 5 Cut wire 106 going to the Engine Generator Control ler after the existing connection point and install the conductors that lead to the new inline fuse holder Use insulated butt splice connectors for these con ductors 3121813 JLG Lift 3 71 SECTION 3 CHASSIS amp TURNTABLE LB NOTES 3 72 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM SECTION 4 BOOM 4 1 BOOM Removal 1 Raise the boom to horizontal and make sure that it is adequately supported with a lifting device or block ing 2 Tag and disconnect the electrical leads at the plat form and the platform valve 3 Tag and disconnect all hydraulic lines on the plat form valve and rotator Cap or plug all openings 4 Remove the hardware attaching the platform and platform support and remove the platform NOTE Steps 5 and 6 are only applicable if the machine is equipped with a jib 5 If equipped with jib place the jib in a horizontal position and support it with blocking Tag and dis connect the hydraulic lines
238. to continue the test NOTE the platform alarm is only tested in platform mode NOTE the ground alarm is not tested if GROUND ALARM NO Problems which can be reported include alarmname S C A short circuit condition appeared while the named alarm was being tested presumably because it is short circuit Indicates that the alarms testis complete 6 32 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 11 System Test Messages TESTALL INPUTS Prompts whetherto check every operator input If ESC is pressed the system test ends If ENTER is pressed each operator input is prompted for in turn In platform mode every platform switch and joystick is tested In ground mode every ground switch is tested NOTE the jib switches nottested if JIB NO NOTE left right jib switches are nottested unless SIDESWING Prompts displayed during the operator inputtest include CLOSE switchname The named switch should be closed OPEN switchname The named switch should be opened joystickname direction TO MAX The named joystick should be pushed to its full extent in the named direction joystickname direction TO MIN The named joystick should be returned to neutral from the named direction PUMP POT TO MAX The pump pot should be turned to maximum PUMP POT TO MIN The pump pot should be turned to minimum MULTIPLE CLOSURE More than one operator inputis closed if only one has been operated there could be
239. to50 22 MINimum DOWN speed 0to20 2 MAXimum DOWN speed 0to60 12 BASKET ROTATE ACCELeration 0 5t05 0 2 DECELeration 0 1 to 3 0 1 5 MINimum LEFT speed 01015 6 MAXimum LEFT speed 0to 100 10 MINimum RIGHT speed 04015 6 MAXimum RIGHT speed 0to 100 10 JIB Lift ACCELeration 0 5t05 0 1 5 Lift DECELeration 0 1103 0 0 5 MINimum UP speed 0to50 4 MAXimum UP speed 0to 100 23 MINimum DOWN speed 04025 3 MAXimum DOWN speed 0to 100 15 MINimum LEFT speed 0to50 17 MAXimum LEFT speed 0to 100 30 MINimum RIGHT speed 0to50 17 MAXimum RIGHT speed 0to 100 30 STEER MINimum speed 010100 20 MAXimum speed 0to 100 30 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 2 Personality Ranges Defaults FUNCTION PERSONALITY RANGE DEFAULTS GROUND MODE LIFT UP speed 040100 85 LIFT DOWN speed 010100 63 SWING speed Oto 100 4 TELEscope speed 010100 60 BASKET ROTATE speed 040100 10 BASKET LEVEL speed Oto 100 8 JIB LIFT speed 010100 15 JIB SWING speed Oto 100 20 4150341 B 3121813 JLG Lift 6 11 SECTION 6 JLG CONTROL SYSTEM 6 8 MACHINE CONFIGURATION PROGRAMMING INFORMATION Table 6 3 Machine Configuration Programming Information E Em Default Configuration Digit Number Description Number 1 1 E600 1 MODEL 2 M600 2 When tilted the tiltlightis lit continuously and drive speed is reduced to the creep speed setting TILT SENSOR 1 5 degree reduces the maximum s
240. ts of two planetary stages with an integrated disconnect mechanism Each stage incorpo rates a set of matched planetary gears which provide an equal load distribution All torque transmitting compo nents are made of forged quenched and tempered high alloy steels External gears are carburized Precision roller bearings support the sprocket or wheel loads A shaft seal protects the unit against contamination Disengaging for Towing NOTICE PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT I E VIA TOW BAR TO PULLING VEHICLE THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY 3 2 JLG Lift NOTICE ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL A CAUTION THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY NOTICE ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE 1 Remove the two hex head bolts from the cover _ BOLT 2 Remove the cover COVER 3121813 SECTION 3 CHASSIS amp TURNTABLE 3 Rotate the cover to show the inside diameter COVER ROTATED 4 Press t
241. uel line to the fuel injector pump Clean up any spilled fuel and try to start the genera tor engine If no fuel flows there are some possibilities a There is no fuel getting to the injector pump No fuel in tank or obstruction in fuel line or clogged inline fuel filter b The engine camshaft rotation is not opening the injection fuel pump Using the recoil starter rotate the engine 1 3 of a turn and fuel should spill from the fuel injector pump Engine might run rough for 20 seconds or so but it will clean out 3121813 SECTION 3 CHASSIS amp TURNTABLE 3 12 GENERATOR S N 88375 TO PRESENT NOTE Throughout the Generator section the abbreviation RBS is used RBS stands for Rotary Battery System which is the generator system The engine driven generator is designed to produce a DC output directly without the need of a separate rectifier Included in the RBS unit is the engine generator engine generator controller harness and related components Engine Peak rating Continuous rating 6 2 HP 0 6 HP at 3600 RPM Refer to the Engine Manual for a complete description of the engine Alternator The RBS is equipped with a brushless DC output alterna tor The 3 phase AC output of the alternator is full wave recti fied and presented to the output terminals Output rating 58 0V at 45A Voltage regulation and current limiting is provided by the RBS Engine Generator Controller The rectifier
242. un Gear Shaft 44 Input Shaft 4510 48 Not Used 49 Thrust Washer 50 NotUsed 51 Cover 52 Disk 53 Bolt 54 O ring 55 Pressure Spring 56 ShaftRod 57 amp 58 NotUsed 59 Disk Rotor Figure 3 1 Torque Hub JLG Lift 60 Spindle 61 NotUsed 62 Coupler 63to 65 Not Used 66 Snap Ring 671080 Not Used 81 Ball Bearing 82 Snap Ring 83 Snap Ring 84 to 87 NotUsed 88 Wheel Stud 3121813 SECTION 3 CHASSIS amp TURNTABLE Disassembly 1 1 10 11 12 13 14 15 16 17 18 19 3121813 Position drive so that one of the fill holes is at the bottom of the end cover and drain the oil Remove all bolts holding the motor and Remove motor from drive Compress the disc 59 using a simple fixture or other suitable device Remove snap ring 66 and release pressure on disc until loose Remove tool and disc Remove the spring 55 from the input shaft 44 Turn unit so that cover 8 is in the up position Remove the screw plugs 22 and seal rings 21 Remove snap rings 34 and remove the cover unit 8 from drive Remove o ring 33 Remove the first stage planetary assembly 7 Remove hex bolts 23 Remove ring gear 30 and o ring 19 Remove snap rings 15 Pull off planet gears 1 together with cylindrical roller bearings 11 from spindle 60 Further disassembly of the hub is discouraged rein sta
243. un one side wheel onto a ramp or block of wood On the other side the lockout cylinder should be extended Block the rear wheels and disconnect the drive hubs Step three is only for models with all wheel drive Next unplug the 4 wheel assist valve under the frame Have an assistant activate drive forward and tele scope in from the platform Open up the bleeder screws on the extended side lockout cylinder Let the hydraulic oil run out until all the air bubbles are out of the cylinder Then close the bleeder screws Checking Oscillation Cylinders After bleeding the lockout cylinders check to see that they are holding their position when oscillated 1 2 JLG Lift Reconnect the drive hubs and 4 wheel assist valve Run one wheel onto a ramp or a block of wood mark the retracted cylinder with a marker swing the turntable off of the cam valve Back the unit off of the ramp check the retracted cylinder for drive no more than 1 2 12 7 mm Repeat this procedure for the other side If the lock out cylinders do not hold repeat the bleeding proce dure or check for the following a Air in lockout system b Bad cylinder seals c Bad holding valves 3 31 SECTION 3 CHASSIS amp TURNTABLE 3 8 SWING DRIVE Roll Leak and Brake Testing Torque Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit s gears bearings and seals are wo
244. ut use 4 16 JLG Lift 3121813 SECTION 4 BOOM amp PLATFORM 6 Remove the end cap 4 and set aside for later 8 Every actuator has timing marks for proper engage inspection ment 7 Remove the stop tube if included The stop tube is an available option to limit the rotation of the actua tor 9 Prior to removing the shaft 2 use a felt marker to clearly indicate the timing marks between shaft and piston This will greatly simplify timing during assem bly 3121813 JLG Lift 4 17 SECTION 4 BOOM amp PLATFORM 10 Remove the shaft 2 It may be necessary to strike the threaded end of the shaft with a rubber mallet 11 Before removing the piston 3 mark the housing 1 ring gear in relation to the piston O D gear There should now be timing marks on the housing 1 ring gear the piston 3 and the shaft 2 12 To remove the piston 3 use a rubber mallet and plastic mandrel so the piston is not damaged 4 18 JLG Lift 13 Atthe point when the piston gear teeth come out of engagement with the housing gear teeth mark the piston and housing with a marker as shown 14 Remove the o ring 204 and backup ring 207 from end cap 4 and set aside for inspection 15 Remove the wear guides 302 from the end cap 4 and shaft 2 3121813 SECTION 4 BOOM amp PLATFORM 16 To remove the main pressure seals 205 it is easi est to cut t
245. ut Carrier Assembly cs Beatles Rees Reel aes ER RULES EG RC 3 16 Hub Spindle Assembly 0 2 3 16 Cover Subassembly x x e URS daa EPA eds E 3 17 Main Assembly pU VERTU o PEN COP a9 NE 3 17 Drive Brake seri as RR a 3 21 Disassembly Ji Sore ure ier I EL e d 3 21 AsSetmbly eot b eH ue deg pee We vau E tu DAC Aet s 3 21 Bleeding 5 3 su Ecce ere ELUCET se e ed 3 21 Speed Sensor 1 3 24 Adjustment Procedure cabal deed 3 24 Speed Sensor Installation 3 27 Verification w Analyzer 3 27 JLG Lift 3121813 TABLE OF CONTENTS SECTION NO TITLE PAGE NO 3 6 Oscillating Axle Lockout Test If Equipped 3 31 3 7 Oscillation Cylinder Bleeding 3 31 Bleeding Procedure RE ERR EP ERE ees 3 31 Checking Oscillation 3 31 3 8 SWING Drive baa ee EUROPEI pee 3 32 Roll Leak and Brake
246. ut all functions DRIVE PREVENTED ABOVE ELEVATION Drive is selected while above elevation and drive cutout is configured to prevent drive DRIVE PREVENTED MOVEMENT SELECTED Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous drive amp boom operation DRIVE PREVENTED CHARGER CONNECTED Drive is selected while the charger is on indicated by drive cutout being active and drive cutout is configured to prevent drive DRIVE PREVENTED TILTED amp ABOVE ELEVATION Drive is selected while tilted and above elevation and tilt is configured to cutout drive 3 1 Flash code 3 1 indicates that a contactor did not close when energized LINE amp DIRECTION CONTACTORS MISWIRED When the line contactor was closed traction point A went high and the capacitor bank charge did notincrease to battery supply this occurs if the line contactor coil wiring is swapped with that for a direction contactor coil OPEN CIRCUIT FORWARD CONTACTOR OR TRACTION MOTOR Traction point A did not go high when forward contactor was energized this could be due to traction motor open circuit or a power wir ing error OPEN CIRCUIT LINE CONTACTOR The capacitor bank charge did not increase to battery supply when line contactor was energized this could be due to a power wiring error OPEN CIRCUIT REVERSE CONTACTOR OR TRACTION MOTOR Traction point A did not go high when reverse contactor was energized this could be due to t
247. ut switches are limiting maximum speed LIFT ACCEL Displays adjusts upper lift acceleration DECEL Displays adjusts upper lift deceleration MIN UP Displays adjusts minimum upper lift up speed MAXUP Displays adjusts maximum upper lift up speed CREEP Displays adjusts maximum upper lift up speed NOTE used when creep switch on pump potis active MIN DOWN Displays adjusts minimum upper lift down speed MAXDOWN Displays adjusts maximum upper lift down speed CREEP DOWN Displays adjusts maximum upper lift down speed NOTE used when creep switch on pump potis active SWING ACCEL Displays adjusts swing acceleration DECEL Displays adjusts swing deceleration MIN LEFT Displays adjusts minimum swing left speed MAXLEFT Displays adjusts maximum swing left speed 6 22 JLG Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 6 ADJUSTMENTS Personality Descriptions CREEP LEFT Displays adjusts maximum swing left speed NOTE used when creep switch on pump potis active MIN RIGHT Displays adjusts minimum swing right speed MAXRIGHT Displays adjusts maximum swing right speed CREEP RIGHT Displays adjusts maximum swing right speed NOTE used when creep switch on pump potis active TELE ACCEL Displays adjusts telescope acceleration DECEL Displays adjusts telescope deceleration MIN IN Display
248. uted to the platform module Check footswitch amp wiring Lift 3121813 SECTION 6 JLG CONTROL SYSTEM Table 6 11 System Test Messages TESTING VALVES Indicates thatthe valve test is beginning Each valve is alternately energized and de energized checks are made for open and short circuit valve coils NOTE in platform mode the footswitch must be closed NOTE jib valves are not tested if NO NOTE left right jib valves are nottested unless SIDESWING Problems which can be reported include CANT TEST VALVES There is a wiring problem which prevents the valve test from functioning correctly Check valve wiring Check ground alarm amp hourmeter wiring valvename S C The named valve is drawing too much current so is presumed to be short circuit Check valve wiring valvename O C The named valve is drawing too little current so is presumed to be open circuit Check valve wiring VALVE TEST DONE Indicates that the valve test is complete with or without faults TESTING CONTS Indicates that the contactor testis beginning In platform mode the forward amp reverse direction contactors are energized and de energized checks are made that they close amp open correctly and for short circuit coils In platform and ground mode the line contactor is energized and de energized checks are made that it closed amp opened correctly and for a short circuit coil In platform mode the posit
249. utput voltage level 58 0 any existing calls to start and stops the engine immedi ately To return to normal operating mode the inhibit run Current limit level 45 ADC input must be removed High voltage shutdown level 63 ADC MANUAL CALL TO START Finish charging current level 30 ADC The manual call to start input initiates an automatic run of the RBS unit TIME DELAY SETTINGS RS232 PORT TD engine start 30s The RS232 allows the RBS to be monitored and controlled TD purge 0s using an analyzer TD bypass 10s System Status and Performance Monitoring TD engine run 18005 TD cool down 30s System status and performance can be monitored by the analyzer TD high volts 25 CRANK SETTINGS Cranktime 15s Resettime 15s Crank cycles 3 SPEED TIME AND GLOW PLUG SETTINGS TD no speed signal 5s TD DC sensing fault 10s Starter disconnect 1000 Hz Overspeed shutdown 3800 RPM Underspeed shutdown 2000 RPM Glow plug on temperature 5 Glow plug on time 15s 3121813 JLG Lift 3 65 SECTION 3 CHASSIS amp TURNTABLE RBS Start RBS shutdown Callto start Manual 48V DC applied to the input startremoved Manually Inhibitrun input applied Automatic 1 Low battery voltage below Automati 1 Battery voltage above 48VDC cally 54VDC and finish charging cur 2 Lowengine temperature below 5 C 3 Lowstart battery voltage below 12 2V Engine start delay RBS waits to verify that call to startis valid notat
250. ve 20 Bushing Figure 5 3 Axle Lockout Cylinder 3121813 JLG Lift 5 5 SECTION 5 HYDRAULICS 1 Loctite 242 NotShown 7 Head 13 Piston 19 O ring 25 T Seal 2 Locking Primer 8 Rod 14 Wear Ring 20 O ring 26 Spacer 3 Loctite 4RC609 NotShown 9 Barrel 15 WasherRing 21 Setscrew 27 Counterbalance Valve 4 Bolt 10 O ringPlug 16 BackupRing 22 Bolt 28 Counterbalance Valve 5 Tapered Bushing 11 O ringPlug 17 Wear Ring 23 Wiper 6 Bushing 12 NotUsed 18 BackupRing 24 Seal Figure 5 4 Level Cylinder 5 6 JLG Lift 3121813 SECTION 5 HYDRAULICS 1 Loctite 242 Not Shown 7 Bushing 13 O ringPlug 18 Seal 23 Seal 2 NotUsed 8 Bushing 14 Piston 19 WearRing 24 Wiper 3 LockingPrimer NotShown 9 Head 15 NotUsed 20 WearRing 25 T Seal 4 Loctite RC609 NotShown 10 Barrel 16 BackupRing 21 O ring 26 Bolt 5 Bolt 11 Rod 17 BackupRing 22 O ring 27 Counterbalance Valve 6 Tapered Bushing 12 Washer Ring Figure 5 5 Jib Lift Cylinder 3121813 JLG Lift 5 7 SECTION 5 HYDRAULICS 5 8 oom Loctite 242 NotShown 7 Barrel 12 Piston 17 WearRing 22 RodSeal Locking Primer NotShown 8 Rod 13 BackupRing 18 O ring 23 Wiper Loctite Not Shown 9 Head 14 BackupRing 19 O ring 24 Check Valve Bolt 10 O ringPlug 15 WasherRing 20 Capscrew 25 Counterbalance Valve Tapered Bushing 11 NotUsed 16 WearRing 21 Seal 26
251. ve 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 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
252. ve grooves Refer to the Assembly Drawing on page 2 to ensure the cor rect orientation of all seals Note that the O ring ener gizer should be removed from seal 201 on the inside diameter of the piston nearest the piston splines This prevents pressure from being trapped between seals 200 and 201 With the housing positioned horizontally and firmly secured to prevent movement insert the piston sleeve into the housing bore until the piston seal contacts the housing chamfer Look through the opposite side shaft flange side of the housing bore and rotate the piston sleeve as necessary to align the timing marks on the housing ring gear and pis ton sleeve While holding the piston sleeve steady to prevent damage to the cylinder bore drive the pis ton sleeve into the housing with a rubber mallet until the gear teeth engage This assembly step is difficult and might require several attempts to successfully engage the gear teeth Double check the timing marks and the engagement of the gear teeth to insure correct alignment then drive the piston sleeve as far as possible into the housing until it comes to a stop against the ring gear Install the shaft as seen below in timed relation to the piston sleeve by aligning the punched timing marks as shown below Temporarily taping the threaded portion of the shaft with masking tape will make it easier to clear the rod seals and prevent their damage Once the gear teeth are engaged rotate the

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