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Service and Maintenance Manual

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1. 3 1 SLAM AUR few o rto vox a e etd with oh dea Se wT ea Re he anta 3 1 3 2 ped capui uei LE pu ao ae ud 3 2 setting Wheel Bearing End 3 2 SPCCIICALONS EC n 3 2 Quale duo 2 55 IP TIME 3 2 careasimna BedulFermienis i bc qampa baada aa 3 2 3 3 Drive Hub Part No 27802363 4 orion pie tek nent 3 4 Disassenibly Ol COVER sus Od 3 5 Disassembly of 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 3 5 Firial ASSOImD IWs ovs D pd 3 6 Initial Start up and After Repairs 3 6 dei udine nate Soc oaa ave eh Ae Rah ace dL 3 6 Oil Change Interval Gear Drive 3 6 Setting of Tapered Roller 5 3 6 Securing of the Shaft Nut 5 can
2. 9 8 el ecje B 0 960 55 Bes A 5 29 ef or HOLOIN zi 7 lol D T3NVd AH311V8 g AOA LP C 8 8 3 14 SECTION 3 CHASSIS amp TURNTABLE S429u2 9 2 on 7 YOLOW f eos 9 GOLON LSA A 00 S 2 Las lt ere uodo aut UIM SION Ge pue eui SHM MOUS pinous 5 eur uedo Joreloo upu sy pue dn sauye SU umm peuuioped eq pinous SS u L S usruq Jo dund eui J nou dung uedo 7 7 epoo PINOYS SHON SYA Z 0 pee PINCUS 3 15 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE Speed Sensor Installation Verification The motor controller averages the readings from the right
3. 3 64 Engine Oil Temperature Sensor 3 64 Alternator Output Current Sensor 3 65 Engine Speed Sensor 3 65 RBS Engine Generator 3 65 Warnings and Safety 5 3 66 oVstem e xem EE daa 3 66 System Status and Performance Monitoring 3 66 SVStelr acad ded de dob dd dre td utl eee reae edi deis doe 3 66 RBS Ola Copt aed a 3 67 FAD SUG lis UE Y Q 3 67 RBSAlarms and Flash 200652 1 40 pages 3 68 Resetting the RBS 3 68 Maintenance Schedule 3 68 uarie conderet ptores wi Roe A 3 69 APU Engine Start Battery 3 70 3121829 JLG Lift lii 5 3 14 Supplementary 1USC TOR ADU 3 71
4. 7 27 HD30 FDP20 Series ASSOImbly 3 5 25 aa ox Packed Sec Yr eR 7 28 HD30 HDP20 Series 7 28 vi JLG Lift 3121829 LIST FIGURES FIGURE NO TITLE 1 1 Seral Number Locations uyapi 1 5 1 2 Operator Maintenance amp Lubrication 1 6 1 3 Torque Chart SAE Fasteners Sheet 1 7 1 10 1 4 Torque Chart SAE Fasteners Sheet 2 7 1 11 1 5 Torque Chart SAE Fasteners Sheet 3 7 1 12 1 6 Torque Chart SAE Fasteners Sheet 4 7 1 13 1 7 Torque Chart METRIC Fasteners Sheet 5 7 1 14 1 8 Torque Chart METRIC Fasteners Sheet 6 1 15 1 9 Torque Chart METRIC Fasteners Sheet 7 017 1 16 2 1 Engine Operating Temperature Specifications Kubota 2 9 3 3 spindle ASSOmblIV zu sd na i pb n 3 3 3 1 Drive HUD CUTAWAY mta aO 3 7 3 2 Drive Brake eset don eund Vd olm o xpo Doi hak ale f dore 3 9 3 3 Sp
5. 5 4 5 4 Repar 223 235 0 ect ae UP apama NUS RE ae doa i de grs 5 4 eC Lr 5 4 Cleaning and Inspectioh i s L ee Reik Rex GER EX Baw 5 5 ASSSImDlV te Wee 5 6 5 5 Pressure Setting Procedures 23 ic Lata bad oe pc SiGe So REOR baw ud Boi eos 5 20 Maitt Helle iu bs EC uuu ed vata aud Q iaa one 5 20 Upper gt DOW Relefi 35555 t 5 20 Lower Lift Down 5 20 TelescoDedelilel aus y dea ve wel Soe aig Oe qo odia Soe e dca wach 5 20 Plattorm Level Up Relief uo e DH SOY Pen Ic y TEUER ia euh 5 20 Platform Level Down 5 21 Sieger Helle 25555 ec af suysu gt 5 21 Jib Lift Up Down 5 21 Releveling Valve 5 21 SECTION 6 JLG CONTROL SYSTEM 6 1 JLG Control System Analyzer Kit Instructions 6 1 6 1 Connect the JLG Control System Analyzer 6 2 JS ICM De
6. FJ Ex gt jJ 00 2 Adjust Platform Level Down Relief to value given 3121829 Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present SECTION 5 HYDRAULICS Steer Relief 1 With pressure gauge at G port on steer brake valve activate and bottom out Steer Left or Right Adjust Steer Relief to value given in Table 5 4 Pres sure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Shut down hydraulic system and remove pressure gauge Jib Lift Up and Down Relief 1 Install the pressure gauge at the at the port on the Main Control valve activate and bottom out jib up or down Adjust the Jib pressure to the value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Releveling Valve Relief 1 JLG Lift Install a pressure gauge at port G on the main valve Adjust the lower lift down pressure relief to the value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present With the lower boom lowe
7. et 6 2 Changing the Access Level of the Hand Held 6 3 Adjusting Parameters Using the Hand Held Analyzer 6 4 Machine SOU DS a E nad t E 6 5 Machine Personality Settings 6 6 Machine Configuration Programming 6 9 Level Vehicle 6 10 Help Descriptions and Fault Flash 5 6 10 Analyzer Diagnostics Menu 6 20 a eR dac deba d er a o ey morc doe Sobre oed 6 22 3121829 JLG Lift V 5 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION SCHEMATICS 7 1 General ue act aient haces 7 1 7 2 TEOUDIGSDOOLFIC 7 1 7 3 M llirieler eorr x ______ ias 7 19 3 neice T qs ian 7 19 49 6 ea 7 19 MME te 7 19
8. 4 26 MRO UDIESMOOUING Sead a depot Roda TOR aL Dee P ux ap x 4 27 4 13 Powertrack 4 28 Hermoviric d EK bua Edd se 4 28 Installing a New GNK za soto dots ev oe aut uo eso voe aeneo D d s 4 31 Replacing Fixed End Brackets s amp s so ates dep Ges dts qos hw paite wauu s SR o e adhe 4 36 Replacing Moving End dba nant Senes 4 38 iv JLG Lift 3121829 5 SECTION 5 HYDRAULICS 5 1 Lubricating O Rings the Hydraulic 5 1 CUD ANC BROS arie 5 1 DIO MeMO a uci 5 2 Spray ET dias cd A A e 5 2 EC 5 2 5 2 Gylinders Theory or Operati 52 dup in acea Pest IRE BRUCH Qe HAS BR Een x 5 3 Double Acting we Rede a 5 3 5 3 Cylinder Checking Procedures qui deut d aute bue OL RC Ir RUNS ied p m edd 6 5 3 Cylinder Without Counterbalance Valves 5 3 Cylinders With Single Counterbalance 5 3 Cylinders With Dual Counterbalance
9. LEFT SPEED SENSOR 1 T RED BLACK x m YEL RED 2 3 Sog BARE c 2 RIGHT SPEED SENSOR 8 CH Q E SPEED SENSOR CONNECTIONS ES 6 lt O 5 GROUND BLACK BRAKE PRESSURE S gt 2 SPEED WHITE SWITCH OPENS n DIRECTION GREEN 2 ON RISING 51 PRESSURE gt 0 V V x lt 8 X g ORN RED 49 10 C s NG lt o lt J ORN RED 49 9 e gt Sir SANUS ge WHT BLK 58 7 N N at 2 SOCKET YELLOW 55 1 es YELLOW 9 1 jm PROP e 1 YEL RED 2 7 4 lt 15 PIN Ll E POWER MODULE gt RED 1 5 12 Y N C 25 x 2E NEGATIVE nis gaa Z NS 4 PIN gt N C 77145 52 J2 ANALZER gt iz POSITIVE n 6 SOCKET CONNECTION 3 HORN l ES MAIN WHITE G CONTACTOR s THIS FUSE IS FOR x UL OPTION ONLY PLUGGING DIODE gt E E
10. NO OPERATION BELOW THIS AMBIENT TEMPERATURE 180 F 82 C HYD OIL TANK TEMP AMBIENT AIR TEMPERATURE C 12 18 5 40 23 C uj 20 F 29 C 30 F 34 C 40 F 40 EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 82 C OR ABOVE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF AHYDRAULIC OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS 410 F 43 C AMBIENT TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES 100 38 OF 100 F 38 C OR ABOVE 90 F 32 C 80 F 27 C 70 F 21 C 5 60 F 16 C 8 5 50 F 10 C HYDRAULIC 40 F 4 C SPECIFICATIONS 30 F 1 C 2 20 F 7 C 1 10 F 12 C 0 18 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE 0 DO NOT START UP HYDRAULIC SYSTEM 30 84 C WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2
11. 3 71 POC OCLC deos a dr aa hid 3 71 SECTION 4 amp PLATFORM 4 1 Boom Eben pice 4 1 REMOVA a ees dva UC Ad dr ua 4 1 Disassembly Boom 5 4 1 4 2 3 tons es Gogh cata aah net dotes ve ve DIES rd efe 4 2 dicic TRRC rT 4 3 4 2 Upper Main Boom Lift Cylinder Y Je RR SG bate eels 4 4 PVG MOM AM ra se i ca pw Sc STE CRIT 4 4 E mcr Ades Me ge teat dos ed cO EM E M dM aM 4 4 4 3 Mic BOO ETE GV det s 72 3 023 RR WAG aa Eco oen bieten a nd 4 4 pelo v suy sa quam iQ Boda Gu bus eu hawapas Crea i peti he SERI 4 4 oett casus ot eere M a 4 5 4 4 Lower Boom Lit CvlIDCer xe 4 5 gie ata 4 5 incus pM 4 5 4 5 Upper Boom Telescope Cylinder 4 6 Bid 4 6
12. peeds peo OQ SHOA 1ndino OU 1591 O JezAJpuv SUI JOJO ul JSnul e goua JOLOJOUSD eu pub eg Jsnuu SIN 5 PUNOIH SU ALON 99999 N S 3 57 JLG Lift 3121829 3 58 SECTION 3 CHASSIS amp TURNTABLE Overspeed If the engine speed exceeds the overspeed limit the engine will stop immediately and an overspeed alarm will be indicated 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 signal 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 cause
13. 7 28 7 15 HD HDP Locking Contacts Into Position 7 28 7916 HD HDP Gontact Removal serr 3 408 ed v er sss 7 28 7 17 HD HDP Unlocking Contacts 7 28 viii JLG Lift 3121829 LIST FIGURES FIGURE NO TITLE PAGE NO 7 18 Electrical Components Installation Sheet 1 7 30 7 19 Electrical Components Installation Sheet 2 7 31 7 20 Electrical Schematic Sheet 1016 7 32 7 21 Electrical Schematic Sheet 2016 7 33 22 Electrical Sehematic Sheet 3 OF 6 ek ex e ua 7 34 7 23 Electrical Schematic Sheet 4016 7 35 7 24 Electrical Schematic Sheet 016 7 96 7 25 Electrical Schematic Sheet6 6 7 37 7 26 Hydraulic Schematic M450A E450A Sheet 1 of 2 7 38 7 27 Hydraulic Schematic M450A E450A Sheet 2of 2 7 99 7 28 Hydraulic Schematic M450A E450A Sheet 1 2 7 40 7 29 Hydraulic Schematic M450A E
14. 4 15 4 14 Rotator Counterbalance Valve 4 25 3121829 JLG Lift PAGE NO LIST FIGURES FIGURE NO TITLE PAGE NO 5 1 Cylinder Barrel SUDDO rte dr EN Re OSE EES das 5 4 5 2 Cabpscrew PEIMOVAl dedo sensu S Mod a diae web ale dene 5 5 5 3 Cylinder Bod SUDDO s d acide qp dedos aba ede d 5 5 5 4 Tapered Bushing 5 5 5 5 Gar Max Bearing 5 6 5 6 ROG Seal IMSTANAU ON 2 suy copa o RR UR RR Xu dcn o a de Esa asa 5 6 5 7 Wiper Seal installations Exc YS xd END RR xA de eg us 5 7 5 8 installation ot Head Seal u ay u y ole eee oe e ate ara 5 7 5 9 Piston Seal Kit Installation o 5 7 5 10 Tapered B shing a OS hasa 5 8 5 11 Seating the Tapered Bearing 5 8 5 12 Poly Pak Piston Seal 5 8 5 13 HOG Assembly Installation d eae t wale we at aaa 5 9 5 14 Jib GylinGer aus oae tih ex n EI
15. 3 49 3 20 Generator Components 3 54 3 21 Generator System Analyzer Flow 3 57 MEE rs uc whe 1 3 61 4 1 Location of Components Boom 4 1 4 2 Upper Boom Lift Cylinder 4 4 4 3 Mid Boom Lift Cylinder 4 4 4 4 Lower Boom Lift Cylinder 4 5 4 5 Upper Telescope Cylinder 4 6 4 6 Wear Fad TAICRKNES S oos de et E 4 7 4 7 Platform Support Torque Values 2 23 he Aa ee ds 4 8 4 8 Boomibimit 4 ort ub s ve ies 4 9 4 9 Platform Components and Attaching Hardware M450A amp 4504 4 10 4 10 Location of Components Articulating Jib 4 11 4 11 Toad SENSING a i atu a diete doin de Nae saus one a ea c 4 12 4 12 Rotary Actuator Exploded View 4 14 4 13 Rotary Actuator Cutaway
16. 7 19 edis duc oix RAP che d Mace o Bat dd 7 19 Voltage 7 19 Resistance Measurement 7 20 Continuity Measurement 7 20 Current Measurement 7 21 7 4 CHECKING SWIIGIIGS tated ale lee alae Bae uq 7 21 Basic te ee eae ee 7 21 7 21 7 22 Switch Wiring Low Side High 7 22 7 5 Applying Silicone Dielectric Compound to Electrical 5 7 22 7 6 AMP Connector a md rae odes rete dede de B Gd 7 23 Applying Silicone Dielectric Compound to AMP 7 23 ASSEDI cca ta acutius fune awaqa ua a 7 23 added ird Rond orden id aaa 7 25 Wedge LOCKS xt der Od api Des dS e qr gu ao 7 25 service Voltage 7 25 7 7 Deutsch CohnectOEs sa ce 7 27 DIDIP 3SerlesASSOmbly esto votos hoan y ed velo ks 7 27 DT DTP Series
17. 304 1 Sc E 22 421 1 lt Ad ZA am Ef 2 103 1 Optional Valve Manifold Counterbalance Item 401 Motion Control Item 403 SECTION 4 BOOM amp PLATFORM 1 Housing 200 T Seal 304 Thrust Washer 2 Shaft 202 T Seal 304 1 Wiper Seal 3 PistonSleeve 204 O Ring 400 Stop Tube Optional 4 EndCap 205 Cup Seal 401 Counterbalance Valve 109 Lock Pin 207 Back Up 113 Cap Screw 302 Wear Guide 3121829 Figure 4 13 Rotary Actuator Cutaway View JLG Lift 4 15 SECTION 4 amp PLATFORM Disassembly 4 Install the end cap 4 removal tools provided with 1 Remove the cap screws 113 over end cap lock pins 109 5 Using a metal bar or something similar un screw the end cap 4 by turning it counter clock wise 2 Using a 1 8 3 18mm drill bit drill hole in the cen ter of each lock pin to a depth of approximately 3 16 4 76mm 6 Remove the end 4 and set aside for later inspection 3 Remove the lock pins using an Easy Out a size 2 15 shown If the pin will not come out with the Easy Out use 5 16 drill bit to a depth of 1 2 12 7mm todrill out the entire pin a 4 16 JLG Lift 3121829 SECTION 4 amp PLATFORM 7 Remove the stop tube if included The stop tube is 9 Prior to removing the shaft 2 use a felt marker to an available option to limit the rotation of th
18. 3 39 Turntable Bearing Mounting Bolt Condition 3 39 Wear oler ee sued x achete auto we datar be tva ace v ana 3 40 Replacement of Swing 3 41 owing Bearing Torque 3 43 Checking Worm Gear End 3 43 Asin lay une goose atit ug S OC e tts oo e 3 43 3 9 Battery Maintenance and Charging 3 45 Battery Maintenance 3 45 Optional On Board 3 45 Battery Charging On Board Charger 9 47 3 10 Battery Charger S N 0300059350 to 3 48 Operating Inst OFIS vob cg e ter a e es 3 48 Maintenance Instructions Ca odo E 3 48 Battery Charger Fault 3 48 Excessive Battery Watering Requirements or Strong Sulphur Rotten Egg Smell 3 51 Checking Changing the Battery Charger 3 52 3 12 Generator Prior 10 S N 88599 55 3 ua ak e aee are i AUR QR ua e c
19. NOTE CAUTION THE OUTER BEARING 19 IS LUBRICATED THE SYS TEM S HYDRAULIC FLUID BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE NOTE The coupling shaft 12 will be flush or just below the housing wear surface when properly seated while 10 the coupling shaft 12 The coupling shaft must rotate smoothly on the thrust bearing package NOTE 3121829 JLG Lift SECTION 3 CHASSIS amp TURNTABLE Apply a small amount of clean grease to a new seal ring 4 and insert it into the housing 18 seal ring groove One or two alignment studs screwed finger tight into housing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of components as required in the following procedures The studs can be made by cutting off the heads of either 3 8 24 UNF 2A or 5 16 24 UNF 2A bolts as required that are over 0 5 inch 12 7 mm longer than the bolts 1 used in the motor Install drive link 10 the long splined end down into the coupling shaft 12 and engage the drive link Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the arive link splines in their original position in the mat ing coupling shaft splines 3 33 SECTION 3 CHASSIS amp TURNTABLE 11 Assemble wear plate 9 over the drive link 10 and NOTE alignment studs onto the housing 18 NOTE NOTE 4 4 f I I
20. SNG See 4 6 4 6 emite nasus eb gam Solos 9 ai 4 7 4 7 4 7 4 8 ATticulatingslb DOOM 4 11 signo MI P 4 11 ISAS SOMO 4 11 jeje edo pe RM 4 11 PASSE VOY corta ie ME Bede oe 4 11 4 9 Sensing SYSIOM io wid dU 4 12 AMDT NS lt 2 Sco oh E OE TET R 4 12 4 10 Boom 5ynchronizing 2 ret ox lui 4 12 4 11 FOOISWIIGIIAOIUSUDODL utet a 0 4 12 4 12 Hela Rotary i d verre ERATES 4 13 Theory OT OPerallOn ebur 4 13 Tools Required for Assembly Disassembly 4 13 DSas RP rr MER RTT 4 16 Cp D M 4 19 295 6 tor ee ee Dae Ease ous eec d 4 20 Installing Counterbalance Valve 4 24 SSAC ne ACIUSIDE qa 4 24 Installation and
21. 5 2 3 55555 2 3 SySlerk 2 usus y aw Molten hearer ehhh 2 3 ae ee Sd 2 4 changing Hydrate Oll reia e aa edad 2 4 gt 422 5 ang ine dne OP d Ya SU wane ae 2 4 2 4 m VMS DIE CSU acces ve eer nah so net 2 4 urn 2 4 cylinder IT toe T usphata panaka lu akuy Bp Db 2 4 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Welding JLG 2 5 Do the Following When Welding JLG 2 5 Do NOT Do the Following When Welding on JLG 2 5 SECTION 3 CHASSIS amp TURNTABLE 3 1 TINGS cc Wheels s uictum tt dicte lana cata 3 1 MTS MAT ACO Sn Gras ut e D ete UC 3 1 pr MP C aod Anat i 3 1 Tire TRE DIACGINGN Us 2 ae 3 1 Wheel
22. NIN 1411 NIYIN 260 ddduo NIYIN 2608 XVIN 1411 NIYIN 1411 NIYIN 567014240 1411 NIYIN 50 L 1399Y NIYIN NIVIA uodn eq jou sueaJos jeu oseoJ qd suaoJos Jez AJeue ejqissod 5 8 XVIN SAILNVNOSYAd V0ZLI 9VullSOd 501 OVYLISOd 0 XVIN d33u2 01 Q31V 3 13 96 NIN SG 0 19080 SG 1 1399V 53 1 00000 409 1 41 559499 OS3 0N H31N3 S3A S1S31 H1VALLOV 19945 OL L 13431 55499 51591 ALVAILOV 199 5 3121829 JLG Lift 6 18 SECTION 6 CONTROL SYSTEM JO 19996 uoisJoA 9 09 STWO ANIA 0 STWO ANTH uodn eq jou SuaaJos WOS jeu Ld 5 sueaoJos JazAjeue ojqissod 5 jno e 941 3L1ON STVO
23. ee cmd Race arcte Ene aree 3 6 3 4 Drive Brakes MiGO adque tats one SOM oto ed drm st 3 8 DiSassermDlys 3 8 ASSG TID yz Saa c 3 8 ss 3 8 3 5 Speed Sensor Adjustment 3 11 Adjustment 3 11 Speed Sensor Installation 3 16 Verification w Analyzer Procedure 3 16 3 6 aao rM 3 19 3 7 Swing Motor S N 0300135649 to 3 21 Preparation Before 3 24 Disdssermblyssncd INSDECUON aca der sd eod eer tack ibd ar 3 24 PSSCIMOIY Ek ote PL S DUC d uM 3 30 One Piece Stator Construction 3 37 Two Piece Stator Construction 3 38 Final Checks a vado ache te td dtp HIER M DUE tee Arg ah eee haar aaa 3 38 JLG Lift 3121829 5 3 8 SWIG d Bh i ides ai
24. 5 AZL Q31SIM1 4731 5 q31IHS 55 NYO 3151 n18 13A 2 01 55 Q31SIML n18 134 ig Ssna NWO 118 134 014 WORKLIGHT B SUPPLY COLOR DICTATED BY WORKL GHT VENDOR SOQN3A 1 91 WHO4IV d 1S NYOH 18 NM8 A8 831 1210 gt 5 8 LHD gt S1H9 TAHOM 304 N30138 BOOM CABLE AND 14 PASS CABLE CONNECTORS O 1 8 E NAO 66 r S os 9 5 Li 8 2 Q33 13A gt gt gt HARRA coo 8E E 11 2 Q38 13A gt gt a WERE Figure 7 20 Electrical Schematic Sheet 1 of 6 3121829 JLG Lift 7 32 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS WHT BLK 58 5 BLACK 16 3 CABLE PUMP SPEED CREEP MODE SWITCH ASSEMBLY BLU ORG 52 1 SOFT TOUCH 1 SVERRIDE SWITCH BLACK NC NC WHT RED 57 6 SOFT TOUCH Q Q SWING UPPER LIFT JOYSTICK ASSEMBLY UPPER LIFT BLU YEL 4 5 2 z WHITE gt Z x 5 gt 5 m O m e TA AAAA 3X1X6X4 J2 3 PIN 3
25. Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement n JLG Lift gt 2 T ee Figure 7 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing continuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity 3121829 3121829 SECTION 7 BASIC TROUBLESHOOTING 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 4 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
26. O Ring Ring Seal Screw Plug Seal Ring Bolt Ball Expander thru 28 Not Used Washer Ring Gear thru 32 Not Used ORing Spring thru 42 Not Used eun Gear Shaft Input Shaft thru 48 Not Used Washer Not Used Cover Disc Bolt O Ring Pressure Spring Figure 3 1 Drive Hub Cutaway JLG Lift Shaft Rod thru 58 Not Used Rotor Disc opindle Not Used Coupler thru 65 Used Retaining Ring thru 80 Not Used Ball Bearing Retaining Ring Retaining Ring thru 87 Not Used Wheel Stud SECTION 3 CHASSIS amp TURNTABLE 3 4 DRIVE BRAKE 0 Disassembly 1 Remove pressure plate 3 from cover 21 by removing the capscrews 1 and washers 2 A CAUTION 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 Remove case seal 4 from cover 21 Remove piston 7 from pressure plate 3 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9 from piston 7 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 HRemove stack
27. 40 40 C Flash Point Min 330 F 166 C Viscosity at 40 C 15 cst iis at 100 F 80 SUS at 210 F 43 SUS cp at 30 F 3 200 a Table 1 15 Mobil EAL 224H Specs Type Biodegradable Vegetable Oil ISO Viscosity Grade 32 46 Specific Gravity 922 Pour Point Max 25 F 32 C Flash Point Min 428 F 220 C Operating Temp 0 to 180 F 17 to 162 C Weight 7 64 b per gal 0 9 kg per liter Viscosity at 40 C 37 cst at 100 C 8 4651 Viscosity Index 213 NOTE Must be stored above 32 F 0 C 1 13 CRITICAL STABILITY WEIGHTS Table 1 16 Critical Stability Weights Component LB KG Counterweight 3850 1746 Tire amp Wheel foam filled 207 94 Platform 4ft 1 2 m 90 41 Platform 5 ft 1 5 m 100 45 Battery each 120 54 A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES PLATFORM DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY 3121829 1 14 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent millimeters mm given in parenthe Ses Table 1 17 Cylinder Specifications Cylinder Bore Stroke Rod Dia Upper Lift 3 00 20 3125 1 50 Cylinder 76 2 719 1 38 1 Mid Lift Cylinder 3 00 21 25 1 50 76 2 539 7 38 1 LowerLift Cylinder 4
28. lt 12V SUPPLY FOR PLATFORM MODULE 13 BLU RED lt RETURN FOR 12V PLATFORM SUPPLY lt 12 BLK RED 48V CONTROL 6 BRN 48V ACCESSORY B 5 YEL FOOTSWITCH SIGNAL TO POWER MODULE 4 ORN 48V RETURN FROM PLATFORM EMS 3 BLU BOOM CABLE AND 14 ES PASS CABLE CONNECTORS n V V V V V V V V V m 5 5 a CAN 18 AWG STP YEL RED 2 6 ORN RED 49 3 HORS 2 7 4 02 55 5 v T XEL RED 2 4 ECCE 5 BLACK _ _ OPTIONAL GENERATOR m er WHT BLK 58 5 WHT RED 57 1 CONTROL BOX WHT RED 57 4 WHT RED 57 2 J2 281 25 be P J2 1 136 lt 5 lt YEL RED 2 7 2 42 5 127 lt QKYEL RED 48 2 O x em WHITE 59 2 7 4 V go YEL RED 2 8 YEL RED 2 7 1 BLACK BLACK u 5 lt P rut qoa J2 13 13343 8LAck e BLACK arg ud WHITE 60 2 RIGHT O 55 vero 2 2 amp ENGINE FAULT LED 2 14 135 ORN RED 49 13 e RED lt lt Euer VV ww m WE gt WHITE 16 2 CABLE 22058 J1 1 4 48V amp 85 579 5 9 SOCKET NEGATIVE x O 4 SOCKET 4 SOCKET 50220 ud J3 BL
29. 1 10 JLG Lift Using suitable lifting equipment position boom assembly on upright so that boom pivot holes in both boom and upright are aligned Install boom pivot pin ensuring that location of the hole in pivot pin aligns with attach point on upright Using all applicable safety precautions operate lift ing equipment in order to position boom lift and master cylinders so that holes in cylinder rod ends and boom structure are aligned Insert cylinder pins If necessary gently tap pins into position with a soft headed mallet ensuring that attach holes in pins are aligned with attach holes in boom structure Secure with hardware Connect all hosing and wiring Install the slave leveling cylinder to the boom assembly Install the platform to the boom assembly Connect all hosing and wiring at platform control station Using all safety precautions operate machine sys tems and extend and retract boom for four or five cycles Shut down machine systems and check for leakage 4 3 SECTION 4 amp PLATFORM 4 2 UPPER MAIN LIFT CYLINDER Removal 1 Place the machine on a flat and level surface Place the Upper Boom in a horizontal position Place Lower and Mid Booms 5 degree above horizontal Shut down machine and prop boom Tag disconnect and cap the upper boom lift cylinder hydraulic lines and ports Remove the hardware securing the cylinder rod attach pin 1 to the bo
30. Dynamo 12 volt 15 amp DC 0 32 mph 0 5 kph nee Drive above Fwd amp Rev E450A M450A 67 71 Control Fuse 15 amps DC 5018 0 48 mph 0 8 kph Swing Leftto Swing Right should be within 1096 of each other Swing Left to Swing Right should be within 15 of each other Drive Forward to Drive Reverse should be within 1096 of each other 1 2 4150273N JLG Lift 3121829 1 10 PRESSURE SETTINGS Table 1 10 Pressure Settings Prior to S N 0300062642 EN Brake Steer Valve Releveling Valve Releveling Relief 1200 3121829 SECTION 1 SPECIFICATIONS Table 1 11 Pressure Settings S N 0300062642 to Present Main Control Valve Tower Lift Down Relief E M450AJ 1700 117 Priorto S N 86022 Tower Lift Down Relief E M450AJ 2600 179 S N 86022 to Present Tower Lift Down Relief E M450A 1700 117 Priorto S N 91053 Tower Lift Down Relief E M450A 2600 179 S N 91053 to Present Telescope Relief A 3000 Telescope Relief AJ amp AJP 3100 Platform Level Up Relief 3000 Platform Level Down Relief 1200 Brake Steer Valve Steer Relief 2300 Main Relief E450A M450A 3200 Main Relief E450AJ M450AJ 3400 Jib Valve 2200 152 Releveling Valve Jib Relief Up and Down Releveling Relief 1200 83 Priorto S N 86022 Releveling Relief E M450Au 2200 152 S N 86022 to Present Releveling Relief E M450A 1200 03 Priorto S N 91
31. E f hc Va Z N 77 NN NI jf NK ES 7 PRA Z NN Ns KS NN NN x X 2 NN N 7 V NN TA IN X NI A S AN 2 2 NI Qiii ud s 2620 2 3 44 3 9 BATTERY MAINTENANCE AND CHARGING Battery Maintenance Quarterly 1 Open battery compartment cover to allow access to battery terminals and vent caps 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 with wire brush then re connect cable to post Coat non contact surfaces with
32. 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 The traction motor has been operating in current limit at a low percentage on for a period of time greater than 10 seconds 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 mea surement shunt and the power module TRACTION POINT A HIGH CHECK POWER CIRCUITS Traction point A is near battery supply when neither direction contactor is energized and the traction MOS FETs are off This could be due to a welded direction contactor or a power wiring error TRACTION POINT A LOW CHECK POWER CIRCUITS Traction point is near OV when neither direction contactor is energized and the traction MOSFETs are off This could be due to a power wiring error JLG Lift 6 15 SECTION 6 JLG CONTROL SYSTEM 9 9 6 16 Table 6 4 Help Descriptions and Fault Flash Codes 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 failsafe tests
33. 14 12 Apply a small amount of clean grease to a new seal ring 4 and assemble it into the seal ring groove on the wear plate side of the rotor set stator 13 Install the assembled rotor set 8 onto wear plate 9 with rotor counterbore and seal ring side down and the splines into mesh with the drive link splines _ Ins 3 34 JLG Lift It may be necessary to turn one alignment stud out of the housing 18 temporarily to assemble rotor set 8 or manifold 7 over the drive link If necessary go to the appropriate Hotor Set Com ponent Assembly Procedure The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor drive link spline contact A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent to determine which side was down The rotor set seal ring groove faces toward the wear plate 9 Apply clean grease to a new seal ring 4 and assemble it in the seal ring groove in the rotor set contact side of manifold 7 The manifold 7 is made up of several plates bonded together permanently to form an integral component The manifold surface that must contact the rotor set has it s series of irregular shaped cavi ties on the largest circumference or circle around the inside diameter The polished
34. 22 23 24 JLG Lift SECTION 3 CHASSIS amp TURNTABLE 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 SECTION 3 CHASSIS amp TURNTABLE 49302 deo JAN lISEO ouo Duueeg so puids pue sjueuodujio5 BuueoelS 4 Buueeg INN qnH pnis Buueeg Jeuu El ouo Duueeg OL leas dr 6 1 15714 79 INN 91 9 2909 749 yul 19915 M9JOS J pul O 3121829 JLG Lift 3 18 SECTION 3 CHASSIS amp TURNTABLE NOTE Torque Wheel Lugs to 170 ft Ibs 230 Nm DRIVE HUB Apply Loctite 242 Torque to 165 foot pounds 224 Nm TIRE AND WHEEL ASSEMBLY Figure 3 8 Drive Components 3 6 POSITRAC TILT MODULE 5 Use the right arrow key to curse over to LEVEL VEHICLE Depress Enter Depress Enter again When
35. SPEED Displays vehicle direction amp speed 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 pot creep switch status BOOM Displays lower lift switch direction amp demand NOTE demand is controlled by the pump pot Displays upper 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 2 NO JIB L R Displays jib swing switch direction amp demand NOTE demand is controlled by the pump pot Not displayed if JIB NO Displays pump pot demand 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 hourmeter but not for any la
36. Service and Maintenance Manual Model E450A E450AJ M450A M450AJ P N 3121829 March 20 2014 INTRODUCTION SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A 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 WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER 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 SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA
37. b Noise originating from the joint during operation Filament wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface Pins should be replaced if any of the following is observed pin should be properly cleaned prior to inspection a Detectable wear in the bearing area b Flaking pealing scoring or scratches on the pin surface c Rusting of the pin in the bearing area 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 unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and opera tion 2 6 WELDING 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 Ground only to structure being welded Do N
38. sion from coupling shaft Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines Remove the motor from system drain it of fluid and take it to a clean work surface Clean and dry the motor before you start to disassem ble the unit As you disassemble the motor clean all parts except seals in clean petroleum based solvent and blow them dry A WARNING PETROLEUM BASE SOLVENTS ARE FLAMMABLE BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLO SION OR FIRE COULD CAUSE INJURY OR DEATH A WARNING WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS A CAUTION NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPO NENTS DO NOT FORCE OR ABUSE CLOSELY FITTED PARTS Keep parts separate to avoid nicks and burrs Discard all seals and seal rings as they are removed from the motor Replace all seals seal rings and any damaged or worn parts with OEM approved service parts Disassembly and Inspection 1 Place the motor in a soft jawed vice with coupling shaft 12 pointed down and the vise jaws clamping firmly on the sides of the housing 18 mounting flange or port bosses Remove manifold port O Rings if applicable A WARNING IF THE MOTOR IS NOT FIRMLY HELD IN THE VISE IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES CAUSING INJURY 2 Scribe an alignment mark down and across the motor components fr
39. 96 3131 GNNOYD 06 ONIMS AGOW GNNOYS 49 AGOW GNNOYS SS NMC AGOW GNNOYD 6 dN LAN AGOW GNNOYD ACOW ealLrIVNOSHad 001 d33dS 83315 4 49895 83315 88415 ealLrIVNOSg3d JO Z 1394S uoisJoA sazAjeuy 9 SalLLIVNOSH3d LHOIH c1a1v1Ou WYOsLV 1d NIN clalvloy WHOd V ld 1441 15357 SG 0 19080 WHOdZ V ld 59 0 1399Y eclaivlou WHOZ V ld 31V 1OH SAILNVNOSY3d sseooy Ajuo 2 XVIN 13431 WeOsLV Id NMOC NIA 3Ad3 1 260 dN 4 13431 WeOslV ld 0 1 1309430 13431 WeOsLV Id 50 1 1399V 3Ad 1 HO4AlV ld 13441 WHOALV Id SAILNVNOSYAd 0 LNO XVIN 3191 9 LNO 3191 09 XV 3191 ce NI NIIN 2 3131 0 19080 Alda 50 L THOOV 3191 3131 SAILNVNOSYsd 07 LHOIY d3dHO 5 06 LHDIY SNIMS ONIMS 0 1 41 44 ONIMS 06 1451 9 14971 SNIMS SG L 18080 ONIMS 50 lt 1399 ONIMS ONIMS SHILNVNOSYAd SS NMOG NIYIN 69 NMOC XVI 1411 06
40. HWFS CODE 17 The hardware failsafe tests failed because the contactor drive failsafe tripped too quickly POWER MODULE FAILURE HWFS TEST STALLED The hardware failsafe tests did not complete but no reason can be determined POWER MODULE FAILURE BAD TEMPERATURE SENSOR The temperature sensor measurement is 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 foot switch was closed 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 wirings JLG Lift 3121829 SECTION 6 CONTROL SYSTEM JO uoisJoA sazAjeuy 2 9 sseooy ul ejqejreAy CE WHHZA IVNV SNOIS SHHA X X L IILISOd gt SNOITSHHA X X X X X X 5 5 5 LLSONOVIG dS Vud DO IVLVG UXXUXXX IVINS BO TL UXXUXXX ATL SOT Vw UXXUXXX ONIMS gt DO IVLVG UXXUXXX 1417 JUI Lvu UXXUXXX OIL VG UXXUXXX HATAC OO TY LV UXXUXXX NO DO IVIVG 9 99
41. LEFT BRAKE I SS GROUND CONTROL BOX GENERATOR MODULE Figure 7 19 Electrical Components Installation Sheet 2 3121829 JLG Lift 7 31 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Y Lv LHM N38 133208 6 6 LHM N38 1 47 LHM N38 6 4 LHM N38 Lv LHM NS8 9 19 LHM NY8 Wav Id ORN RED 49 5 DRIVE ORIENT 9 86 we 9 86 f WHT BLK 58 6 CAN 18 AWG STP 9 88 pu 3 86 A on 1671H 2 91 3NVd dAV1 I O FOOTSWI TCH WHITE 16 3 CABLE 9 2 034 734 8 SW gt gt PLATFORM STATION EMS u S Z Q33 13A 01 2 034 134 O 8 AMOSS3OOV ABP gt gt N 10 1 0397 134 2 034 734 O TOXINOO A8v x 5 86 e S 4G Q38 1HM 9 a m HORN HORN 6 03Y NY0 gt gt SW3 W3O4lV1d 3 vj TWNOIS 211 61004 13A 5 9 AMOSS39 V 9 9 10 1 02 8 qau 18 21 WYO4LV1d AZL MO3 qau n18 1 3710n00W W3O4lVld M04
42. Q 5 59 Q0 Q0 CQ SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOLD MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP ENGINE OIL TEMP SPEED SENSING INPUT 85232 2 RXD TXD LED DRIVER GND LED DRIVER 48 SPEED SENSOR GRD AUTO SPARE FUEL SWITCH SPARE OUTPUT VOLTAGE ENGINE OIL TEMP AMBIENT TEMP SPEED SENSING 8V OUTPUT CURRENT SENSOR GRD NC RS232 GND s FIELD DRIVE START BATTERY START BATTERY PRE HEAT INHIBIT RUN ENGINE TEMP SWITCH SPARE OUTPUT VOLTAGE OUTPUT CURRENT 8V OUTPUT CURRENT SENSE CHOKE NC FIELD DRIVE 8V 1870227 E Figure 7 25 Electrical Schematic Sheet 6 of 6 3121829 JLG Lift 7 37 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS E450A E400A NARROW PLATFORM R 785 SQ IN ANNULUS 2 35 SQ IN ROTATOR r MAIN VALVE ASSY M IF AIF 450 E400A NARROW MASTER CYLINDER RE 2 2 D 1 785 SQ IN ANNULUS 2 35 SQ IN GENERAT I VE SWING MOTOR SIEER BRAKE ELECTRIC RELEASE VALVE MOTOR BRAKES Figure 7 26 Hydraulic Schematic M450A E450A Sheet 1 of 2 7 38 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING
43. Replace seals JLG Lift 7 5 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Function Speed and Drive Speed does not operate below horizontal Ifthe boom assembly does not fully lower No responseto telescope control Boom will not extend 7 6 Damaged wiring on level limit switch Creep Switch Open Machine Tilted Speed Sensor Failure LOWER LIFT FUNCTION Table 7 2 Boom Assembly Troubleshooting PROBABLE CAUSE REMEDY Repair or replace wiring Run System Test Replace switch Run System Test Level machine Replace Sensor The Mid and Lower Booms outof synchroni Refer to synchronize procedure zation MAIN TELESCOPE SYSTEM Telescope function not activated within 7 sec onds after footswitch was depressed Telescope control switch inoperative Hydraulic system oil low Damaged wiring on control switch or solenoid valve Directional valve not functioning properly Restricted or broken supply line on valve bank or hydraulic pump Proportional Flow Regulator Not Powered Telescope cylinder not functioning properly Hydraulic pump not functioning properly Telescope function not activated within 7 sec onds after footswitch was depressed Directional valve not functioning properly Restricted or broken hydraulic line or fitting Pressure setting incorrect Telescope cylinder not functioning properly Personality Setting
44. SECTION 4 amp PLATFORM 3 Install radius pins into their original locations and NOTE When installing snap rings make sure they are install snap rings Repeat with other moving end if replacing as well i A L e CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY 4 When complete make sure that both brackets rotate correctly EC 3121829 JLG Lift 4 39 SECTION 4 amp PLATFORM 27 NOTES 4 40 JLG Lift 3121829 SECTION 5 HYDRAULICS SECTION 5 HYDRAULICS 5 1 LUBRICATING O RINGS IN THE 2 Holding the fitting over the hydraulic oil container brush an even film of oil around the entire o ring in HYDRAULIC SYSTEM the fitting making sure the entire o ring is com When assembling connectors in the hydraulic that use o pletely saturated ring fittings it is necessary to lubricate all fittings with hydraulic oil prior to assembly To lubricate the fittings use one of the following procedures NOTE All O ring fittings must be pre lubricated with 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 3 Turn the o ring on the other side of the fitting and repeat the previous step ensuring the entire o ring is coated with hydraulic oil 1 Hold the fitting in one hand while using the brush with the other hand to dip
45. apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If 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 SECTION 2 GENERAL 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
46. dNWZ4lL NINW dWalL XVW SOLLSONSVIQ 67667 6766 1111 dO NVNW 5444 MOT S4WNVHd WAILSAS AAO 509 5 dO LOOLDnO WAILSAS dO LOOLDnO CMS 5 TMS4 940 04 Add LLIVa WHISAS 7070 dATVA WAILSAS VO VO NOILOVAL WAILSAS WHISAS SOILSONDOVIG QWXMOO I SHNVHg 0 FIAL WOOd SAISVG N T uogeunDijuoo uodn Buipuedep jou suaaJos Jeu BJOU SP d suoaJos ejqissod sapnjoul uwous jno e 991 ILON AAIILOV 44445 NOOd 0 LOd NOOd 0 dO MS sod NOOd 0 dir dO MS SOd NOOd AIYA i 50 ALLOY 44445 J NOOd AIYA ar 440 OVALISOd 0 50 44445 6 19945 WOOS HAIA WOOd SOLLSONSVIGQ SOILSONOVICG SOILSONOVIG ANNAN XXXXXXXXXXXXX XX XXX 501 MO WHLSAS T00 THH ANEN 3121829 SECTION 6 JLG CONTROL SYSTEM 5 H 1 05 alr 00 3lVlOd AGOW GNNOYS 1341 aNnoH9
47. inder pin 1 Using a suitable brass drift and ham mer remove the cylinder pin from articulating jib boom ARTICULATING SLAVE BOOM LEVELING CYLINDER 2 ROTATOR SUPPORT ARTICULATING JIB BOOM PIVOT CYLINDER Figure 4 10 Location of Components Articulating Jib Boom 4 Remove mounting hardware from articulating jib boom pivot pin 2 Using a suitable brass drift and hammer remove the pivot pin from boom assembly Disassembly 1 Remove mounting hardware from articulating jib boom pivot pins 3 and 4 Using a suitable brass drift and hammer remove the pins from articulating jib boom pivot weldment 2 Remove mounting hardware from rotator support pins 5 and 6 Using a suitable brass drift and hammer remove the pins from rotator support 3 Remove mounting hardware from lift cylinder pin 7 Using a suitable brass drift and hammer remove the cylinder pin from articulating jib boom 3121829 JLG Lift 2 Pins and Composite Bearing Repair Guidelines Inspect articulating fly boom pivot pin for wear scor ing tapering and ovality or other damage Replace pins as necessary Inspect articulating fly boom pivot attach points for scoring tapering and ovality or other damage Replace pins as necessary Inspect inner diameter of articulating fly boom pivot bearings for scoring distortion wear or other dam age Replace bearings as necessary See Sectio
48. means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit The reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Parts Manual for hydraulic diagrams of the various circuits JL G Lift 7 1 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 1 Platform Assembly Troubleshooting TROUBLE Automatic leveling inoperative Platform will not maintain level attitude Noresponse to platform leveling controls Platform will not adjust up or down to level PROBABLE CAUSE Hydraulic system oil low Dual check valves dirty inoperative Restricted or bro
49. shaft 7T Rubber mallet removal and installation of shaft and piston sleeve assembly 8 Nylon drift installation of piston sleeve 9 cap dowel pins removal and installation of end cap sold with Helac seal kit NOTE Bars indicate starting positions of piston and shaft Arrows indicate direction they will rotate The hous ing with integral ring gear remains stationary As fluid pressure is applied the piston is displaced axially while the helical gearing causes the piston and shaft to rotate simultaneously The double helix design compounds rotation shaft rotation is about twice that of the piston 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 JLG Lift 4 13 SECTION 4 amp PLATFORM 1 Housing 200 2 Shaft 202 3 PistonSleeve 204 4 EndCap 205 109 Lock Pin 207 113 Cap Screw 302 T Seal 304 Thrust Washer T Seal 304 1 Wiper Seal O Ring 400 Stop Tube Optional Cup Seal 401 Counterbalance Valve Back Up Wear Guide Figure 4 12 Rotary Actuator Exploded View JLG Lift 3121829 x a
50. 100 Ibs 108 11 Table 5 3 Holding Valve Torque Specifications 21 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior SUN 7 BHEXMDOXISTHDS 7 8 HEXM20 X 1 5 THDS 303505 to the reinstallation of any holding valve or valves 41 48 Nm 22 If applicable install the cartridge type holding valve SUN 1 1 8 HEX 1 14 UNS THDS 45 50 ft Ibs and fittings in the rod port block using new o rings 61 68 Nm licable Table 5 3 Holding Valve T E Kd ES SUN 1 1 4 HEXM36X2 THDS 150 160 ft Ibs 204 217 Nm NOTICE RACINE 1 1 8 HEX 1 1 16 12 THDS 50 55 ft Ibs IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON 68 75 Nm THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE RACINE 1 3 8 HEX 1 3 16 12 THDS 75 80 ft Ibs THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER 102 109 Nim A TRAVELING OVERHEAD HOIST FORK LIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING RACINE 1 7 8 HEX 1 5 8 12 THDS 100 110 Ibs ROD 136 149 Nm CYLINDER BARREL PISTON ASSY WASHER lt RING Figure 5 13 Rod Assembly Installation 3121829 JLG Lift 5 9 SECTION 5 HYDRAULICS Prior to S N 0300106518 1683779 E 1 Loctite 242 7 Bearing 13 O ring Plug 19 WearRing 25 Seal 2 Loctite 222 8 Bushing 14 Piston 20 WearRing 26 Bolt 3 Primer 7471 9 CylinderHead 15
51. 14 Inspect for wear brinelling corrosion and a full com plement of retained rollers S Jj 16 Remove seal 16 and back up ring 17 from hous ing 18 and backup washer 25 Discard both 4 17 Remove housing 18 from vise invert it and remove and discard seal 20 A blind hole bearing or seal puller is required N N 2 N 3121829 18 19 JLG Lift SECTION 3 CHASSIS amp TURNTABLE Inspect housing 18 assembly for cracks the machined surfaces for nicks burrs brinelling or cor rosion Remove burrs that can be removed without changing dimensional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas discard the housing assem bly If the housing 18 assembly has passed inspection to this point inspect the housing bearings bushings 19 and 13 and if they are captured in the housing cavity the two thrust washers 14 and thrust bearing 15 The bearing rollers must be firmly retained in the bearing cages but must rotate and orbit freely All rollers and thrust washers must be free of brinel ling and corrosion The bushing 19 or 13 to cou pling shaft diameter clearance must not exceed 0 010 inch 0 025 mm A bearing bushing or thrust washer that does not pass inspection must be 3 29 SECTION 3 CHASSIS amp TURNTABLE replaced If the housing has passed this inspect
52. 15 207 16 0700 0 3730 23800 300 47 220 298 330 49 28 363 78 9 0870 0 4620 29400 40 583 320 44 45 66 386 523 14 0 8750 0 5090 32400 470 67 350 475 50 707 45 56 1 8 1000 0 6060 38600 60 868 40 61 675 98 59 7865 12 1 0000 0 6630 42200 70 949 50 719 7355 100 633 858 11 8 7 1420 0 7630 42300 800 1085 600 813 840 1142 74 98 12 1420 08560 47500 80 1193 60 85 95 1258 802 1087 12 1 2500 10730 59600 140 1681 920 1247 1300 1768 1118 156 13 8 6 13750 1 1550 64100 140 1979 1100 1491 1525 2074 1322 1792 12 13750 13150 73000 1680 2278 1260 1708 1750 2380 156 202 11 2 6 1500 1400 7800 1940 2630 140 1979 205 2754 1755 299 112 1 5000 1 5800 87700 2200 2983 1640 2224 2300 3128 194 266 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100011 242 Vibra TITE 121 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium Hig
53. 15 Mobil EAL 224H SPECS EE Een Be 1 4 1 16 C iiliealSatabililyyaVeghiSru y u caca B pac Se doe 1 4 1 17 s m oic edad ee den RO gt 1 5 1 18 Major Component Weights hh hrs 1 5 1 19 uses are oo PE Ge IE eter 1 7 2 1 Inspection and 2 2 2 2 CyliiderDrillba u crm 2 4 2 3 Inspection and Preventive Maintenance Schedule 2 6 3 1 Wheel Tol dude Ghan n UR qa p e AR 3 2 3 2 Drive Brake 2 3 10 3 3 swing Motor Troubleshooting pur s b huk kuku 3 22 3 11 Battery Charger Fault Codes 3 48 3 4 Battery sx xe oe ee 3 52 3 5 ABS Preslia cs suuni dca qui do dco Ade ted FE d dedos Du Oe dca aur Trace ES eos 3 55 3 6 ABS Startup SEQUENCE s 244 220 ids ta icd eas aal d 3 55 3 7 ABS Shutdown all ced Yace d soe d 3 55 3 8 Generator System Flash Codes 3 56 3 9 Controller Interface
54. 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 Stallation of the shaft nut 4 requires a special tool and a torque of 626 ft lbs 876 Nm for proper reas sembly These components Will Fail if not properly reassembled 15 16 17 18 19 JLG Lift 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 3121829 Disassembly of Cover 1 Loosen and remove hex head bolts 53 to remove cover 51 Remove shaft rod 56 and o ring 54 Remove sleeve 52 Disassembly of First Stage Planetary Assembly 7 1 Push sun gear shaft 48 out of the first stage 2 Remove snap rings 14 3 Press planet pins 5 out of the p
55. 2 1 2 0 1 2 0 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 2 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 3121829 JLG Lift 2 7 2 Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Deliverv 4 tege en Maintenance Maintenance nspection Inspection Walk Around Inspection Performed 21 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 1 2 Grease and Lubricate to Specifications 22 22 Function Test of 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 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 m
56. 3 Analyzer Flow Chart Software Version 3 x Sheet 2013 6 18 6 4 Analyzer Flow Chart Software Version 3 x Sheet 30713 6 19 7 1 Voltage Measurement 7 19 7 2 Resistance 7 20 7 3 dic dae tie CUERO 7 20 7 4 Current Measurement 2pm ute arc Regem 7 21 7 5 Connector Assembly Figure 1 7 23 7 6 COMIMCCIOR 7 23 7 7 Connector Assembly Figure2 7 24 7 8 Connector Assembly Figure 3 7 24 7 9 Connector Assembly Figure 4 7 24 7 10 Connector 4 7 25 fel onHecioPInstallalloni SD obe eo tete cte dn dedo eoi dde 7 26 7 12 DT DTP Contact Installation vito acuario te zr ena eme SERERE 7 27 7543 c eu eue 7 27 7 14 HD FIDP
57. 3121829 the cylinder head retainer cap screws and remove 10 cap screws from cylinder barrel CAPSCREWS Figure 5 2 Capscrew Removal NOTE Steps 6 applies only to the lower lift and telescope cylinders 6 Using a spanner wrench loosen the end cap or head retainer and remove from cylinder barrel T Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND 14 CYLINDER BARREL SURFACES 15 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the 16 complete rod assembly from the cylinder barrel URN ROD SUPPORT 1 wd SUPPORT TABLE gt 3 4 Figure 5 3 Cylinder Rod Support 9 9 Using suitable protection clamp the cylinder rod in 6 a vise or similar holding fixture as close to the piston as possible 3121829 JL G Lift 11 12 SECTION 5 HYDRAULICS 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 Remove the bushing from the piston TAPERED BUSHI
58. 3121829 JLG Lift 7 23 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 24 c PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 7 7 Connector Assembly Figure 2 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 8 SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 7 8 Connector Assembly Figure 3 JLG Lift 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 9 WEDGE LOCK FLUSH WITH HOUSING ESS SSS SEY GSS IEEE SS lt lt CAS EX V emm Figure 7 9 Connector Assembly Figure 4 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Figure 7 10 Connector Disassembly Disassembly 1 Insert 4 8 mm 3 16 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 2 Pry open the wedge lock to the open position 3 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed NOTE The wedge lock should never be removed from the housing for insertion or removal of the contacts Wedge Lock The wedge lock has slotted openings in the forward or mating end These slots accommodate circuit testing in the field by
59. A did not go HIGH when reverse contactor was energized This maybe due to an open circuit traction motor or power wiring error 33370 33 FORWARD CONTACTOR COIL SHORT CIRCUIT The forward contactor was not energized when required due to over current protection 33371 33 REVERSE CONTACTOR COIL SHORT CIRCUIT The reverse contactor was not energized when required due to over current protection 33411 33 VALVE SUPPLY OVERLOADED There is a high current draw from the valve supply when no valve is energized this maybe due to a wiring error at the ground mod ule 421 42 POWER MODULE TOO HOT PLEASE WAIT Controller heat sink temperature reached 75 C the controller is shut down until it cools to below 70 C 441 44 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN Battery voltage is below 33 volts EMS recycle is required 442 44 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN Battery voltage is above 62 volts EMS recycle is required 445 44 BATTERY VOLTAGE LOW Battery voltage is below 40 volts this is only a warning the con troller does not shut down 469 46 VEHICLE OVERSPEED opeed in the wrong direction was measured with the traction motor full ON This maybe due to a faulty speed sensor being installed incorrectly it could also be dueto a speed sensorfaultor faults for NO VEHICLE MOVEMENT DETECTED with the vehicle ona grade 4610 46 RIGHT SPEED SENSOR NOT RESPONDING PROPERLY The right speed sensor is indicating an impossible number of pulses
60. ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 4150548 E Figure 2 1 Engine Operating Temperature Specifications Kubota 3121829 JLG Lift 2 9 SECTION 2 GENERAL 27 NOTES 2 10 JLG Lift 3121829 3121829 SECTION 3 CHASSIS amp TURNTABLE 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 product or rim decal for safe and proper operational characteristics 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 cr
61. B o b gt gt gt LEE HERR LE ji N CB1 15 300 oy 4 ARMATURE gt ARMATURE E lt gB EFT m to a X 5 RED 1 AWG BLACK 1 BLACK 4 AWG GENERATOR POSITIVE N P SEE SHEET 2 OF 2 SK MKS d BLACK 4 AWG GENERATOR NEGATIVE J LOCATION H 8 RED 2YEL LD LED BLACK 1 BLACK GRD 4 2 5 2 WHITE 2 YEL LED L RED 1 5 3 GREEN 1 GRN LED 10 awc POS BATTERY L BLACK 10 AWG NEG CHARGER ACTUAL BATTERY P2 CHARGER DETERMINED pie COUNTRY OF USE 1870227E OUT AJP AJP OPTION OPTION OPTION JIB LEFT JIB RIGHT MOTOR l Figure 7 23 Electrical Schematic Sheet 4 of 6 3121829 JLG Lift 7 35 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 96 5 2 BLACK 4 AWG GENERATOR POSITIVE LOCATION 1 BLACK 4 AWG GENERATOR NEGATIVE 134 i io 116 116 115 114 GENERATOR ENGINE SCHEMATIC VOLTAGE REGULATOR 250 WATT STARTER MOTOR SOL 8113
62. BRIEF TIME PERIODS TO AVOID HEAVY SATURATION JLG Lift 6 5 SECTION 6 JLG CONTROL SYSTEM Machine Personality Settings NOTE Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance Table 6 1 Personality Ranges Defaults seem mmn _ _ MAXimum speed MAXimum speed 10 100 ELEVATED MAXimum speed m to 25 10 for CE om E450AJ _ 6 6 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 1 Personality Ranges Defaults ANE E _ 0 5 3121829 JLG Lift 6 7 SECTION 6 JLG CONTROL SYSTEM Table 6 1 Personality Ranges Defaults en _ Dwmeewser oe _ 6 6 8 JLG Lift 3121829 2 Table 6 2 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 pres ence function PLATFORM ALARM Displays adjusts platform alarm pres ence function NOTE BATTERY MONITOR Di
63. Check for correct operation and hydraulic leaks Secure as necessary Check fluid level of hydraulic tank and add as neces sary 3121829 4 6 WEAR PADS 1 Shim up wear pads until snug to adjacent surface 2 Replace wear pads when worn to thickness shown below Ji 5 LLLI e gt 5 3 4 NBC OPERE wr 1 Cd sii a a 5 Table 4 1 Pad Thickness Thickness of New Replace When Worn to 0 375 0 3125 0 3125 Figure 4 6 Wear Pad Thickness 3 Adjust wear pads as follows a Loosen jam nut on adjustment bolt turn bolt CW until wear pad is snug to adjacent surface b After adjustments have been made tighten the jam nuts on wear pad bolts 3121829 SECTION 4 BOOM amp PLATFORM 4 7 BOOM LIMIT SWITCHES Refer to Figure 4 8 Boom Limit Switches for adjustments to be made to the two Boom Limit Switches which bolt in place on the upright JLG Lift 4 7 SECTION 4 amp PLATFORM NOTE If any rotator bolts are replaced all bolts on the rotator should be retorqued Torque to 50 1 105 68 Nm Loctite 242 Torque 250 270 ft Ibs 339 366 Nm Checktorque every 150 hours of operatio
64. ELECTRICAL INFORMATION 8 SCHEMATICS E400A NARROW UPPER LIFT CYL 3 7 065 SQ IN ROD 1 75 2 405 SQ IN ANNULUS 4 660 SQ IN E450A UPPER LIFT CYL 5 7 065 SQ IN ROD 1 5 1 76 50 IN ANNULUS 5 305 SQ IN LC LR n LOWER LIFT DOWN LU gt L i _ e LOWER CYL MID CYL BLEEDER FITTING FOR PURGING AIR FROM CIR SIEER CYL BORE 2 5 14 SQ IN ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN 2792505 Figure 7 27 Hydraulic Schematic M450A E450A Sheet 2 of 2 3121829 JLG Lift 7 39 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS E450A E400A NARROW PLATFORM R 785 SQ IN ANNULUS 2 35 SQ IN ROTATOR r MAIN VALVE ASSY M IF PO 450 E400A NARROW MASTER CYLINDER RE 2 2 D 1 785 SQ IN ANNULUS 2 35 SQ IN GENERAT I VE SWING MOTOR SIEER BRAKE ELECTRIC RELEASE VALVE MOTOR BRAKES Figure 7 28 Hydraulic Schematic M450A E450A Sheet 1 of 2 7 40 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS E400A
65. 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 3 60 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE 2 IK B z 7 VS _ i e 1 1 S 8 SS Jp 1 g EJ L A 1 Glow Plug Relay 8 Temperature Sensor 2 Fuel Control Relay 9 Voltage Regulator 3 Start Control Relay 10 Alternator 4 FuelSolenoid 11 Starter 5 FuelPump 12 Starter Solenoid 6 LowOilPressure Switch 13 Oil Filter 7 Glow Plug 14 Fuel Filter Figure 3 22 Generator 3121829 JLG Lift 3 61 SECTION 3 CHASSIS amp TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead acid start battery not sup 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 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 me
66. Input was CLOSED during startup SELECTED 2246 22 FUNCTION PROBLEM SWING RIGHT PERMANENTLY Input was CLOSED during startup SELECTED 2247 22 FUNCTION PROBLEM PLATFORM ROTATE LEFT Input was CLOSED during startup NENTLY SELECTED 2240 22 FUNCTION PROBLEM PLATFORM ROTATE RIGHT PERMA Input was CLOSED during startup NENTLY SELECTED 2249 22 FUNCTION PROBLEM JIB LIFT UP PERMANENTLY SELECTED Input was CLOSED during startup 2250 22 FUNCTION PROBLEM LIFT DOWN PERMANENTLY Input was CLOSED during startup SELECTED 2251 22 FUNCTION PROBLEM TELESCOPE IN PERMANENTLY Input was CLOSED during startup SELECTED 3121829 JLG Lift 6 27 SECTION 6 JLG CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash DTC Code Fault Message Description 2252 22 FUNCTION PROBLEM TELESCOPE OUT PERMANENTLY Input was CLOSED during startup SELECTED 2253 22 FUNCTION PROBLEM SWING LEFT PERMANENTLY SELECTED Input was CLOSED during startup 2254 22 FUNCTION PROBLEM SWING RIGHT PERMANENTLY Input was CLOSED during startup SELECTED 2255 22 FUNCTION PROBLEM MAIN LIFT UP PERMANENTLY Input was CLOSED during startup SELECTED 2256 22 FUNCTION PROBLEM MAIN LIFT DOWN PERMANENTLY Input was CLOSED during startup SELECTED 2251 22 FUNCTION PROBLEM TOWER LIFT UP PERMANENTL Y Input was CLOSED during startup SELECTED 2258 22 FUNCTION PROBLEM TO
67. Inspection and Frequent 2 1 Annual Machine lt 2 1 ss y ya esa God era Stas 2 1 2 2 Service and 2 2 General Sto ered au smua k EATS bia 2 2 Safety and Workmanship 2 2 ua Qeon a doa 2 2 Components Removal and 1 5 2 2 Component Disassembly and Reassembly 2 3 Pressure TE uo suae peo dp b bead d plat vida eo idol ea me 2 3 Bears sue aii ea Ber ee 2 3 Gaskel td eeu ud Loos tolo ioa sy eu 2 3 Bolt Usage and Torque Application 2 3 Hydraulic Lines and Electrical Wiring 2 3 riyqdraulie SySIGN RE ERE STO LL has kasuk LL TI IM 2 3 utra itd Seta DU DE bd ed 2 3 Palle I 2 3 Lubrication and ServIiGlIiQ 64225 ede uo os doa pad a Si Su 2 3 3121829 JLG Lift
68. NARROW UPPER LIFT CYL 3 7 065 SQ IN ROD 1 75 2 405 SQ IN ANNULUS 4 660 SQ IN E450A UPPER LIFT CYL 5 7 065 SQ IN ROD 1 5 1 76 50 IN ANNULUS 5 305 SQ IN LC LR n LOWER LIFT DOWN LU gt L i _ e LOWER CYL MID CYL BLEEDER FITTING FOR PURGING AIR FROM CIR SIEER CYL BORE 2 5 14 SQ IN ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN 2792505 Figure 7 29 Hydraulic Schematic M450A E450A Sheet 2 of 2 3121829 JLG Lift 7 41 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS E450A E400A NARROW PLATFORM R 785 SQ IN ANNULUS 2 35 SQ IN ROTATOR o MAIN VALVE ASSY e E450A E400A NARROW MASTER CYLINDER BORE 2 3 14 SQ IN ROD 1 4 85 SQ IN ANNULUS 2 55 SQ IN E450A E400A NARROW NO CYL TELESCOPE CIR 15 A REGENERATIVE ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN SWING MOTOR SIEER BRAKE RELEASE VALVE BRAKES Figure 7 30 Hydraulic Schematic M450AJ E450AJ Sheet 1 of 2 7 42 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL
69. NotUsed 21 O ring 27 Valve 4 Loctite RC 609 10 Barrel 16 Backup Ring 22 O ring tridge 9 Bolt 11 Cylinder Rod 17 Backup Ring 23 Seal 6 TaperedBushing 12 Washer Ring 18 Seal Ring 24 Wiper Figure 5 14 Jib Cylinder 5 10 JLG Lift 3121829 SECTION 5 HYDRAULICS 1685285 1883833 D 1 Barrel 7 Tube Spacer 13 O ring 19 Loctite 242 2 Cylinder Rod 8 Holding Valve 14 O ring 20 Loctite 222 3 Retainer 9 Setscrew 15 Wear Ring 21 Pipe Sealant 4 Piston 10 Pipe Plug 16 Rod Seal 22 Holding Valve 5 Cylinder Head 11 T Seal 17 Wiper 23 Plug 6 Hex Nut 12 Wear Ring 18 Locking Primer Figure 5 15 Level Cylinder A Models 3121829 JLG Lift 5 11 SECTION 5 HYDRAULICS 5 12 Loctite 242 7 Cylinder Rod 13 Wear Ring Primer 7471 8 Barrel 14 Backup Ring socketHead Bolt 9 Washer Ring 15 O ring TaperedBushing 10 Piston 16 O ring Bushing 11 NotUsed 17 Wiper Cylinder Head 12 Lock Ring 18 Seal 1683760 B 1683924 D 19 Backup Ring 20 Seal 21 Valve Cartridge 22 Valve Cartridge 23 Bolt Figure 5 16 Level Cylinder AJ amp AJP Models JLG Lift 3121829 SECTION 5 HYDRAULICS 450AJ 450 1683711 1683826 1683939 1 Barrel 7 TubeSpacer 13 Wear Ring 19 Not Used 2 Cylinder Rod 8 Holding Valve 14 O ring 20 Loctite 242 3 Retainer 9 Holding Va
70. PREVENT ANY DEBRIS FROM GETTING ON THEM 3121829 2 Parts used Bracket Center Pin and Center Pin Snap Ring gt W 4 i M 4 EE A 5 B TW 2 aT i KT ANC M gt lt 2 E 4 E 3 Take the new bracket and install bracket center pin and snap ring Repeat on the other bracket if replac ing it as well 3121829 SECTION 4 BOOM amp PLATFORM NOTE When installing snap rings make sure they are seated in pin groove and closed properly d j 1 E La EY P E 7 z Ts Hus i gt i oe 4 QUON d ws 1 Ov CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY JLG Lift 4 37 SECTION 4 amp PLATFORM Replacing Moving End Brackets 1 Remove existing pins and center rivet Remove the rivet the same way as shown in the link removal instructions Repeat on other bracket if replacing it as well LAT N E MOVE THE CABLES HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM 2 Take new bracket and install center pin with snap ring CENTER PIN 4 38 JLG Lift 3121829
71. Place the Mid Boom in a 10 degree elevated position Support Upper Boom with a prop Support upright with an overhead crane Using slings restrain the lower lift cylinder Remove the hardware securing the cylinder rod attach 3 to the boom Using an appropriate brass drift drive out the cylinder rod attach pin 3 Figure 4 3 Mid Boom Lift Cylinder Removal Tag disconnect and cap the lift cylinder hydraulic lines and ports Remove the hardware securing the barrel end attach pin 4 to the boom Using an appropriate brass drift drive out the cylinder barrel pin 4 Carefully remove cylinder from boom Place in a suitable work area 3121829 Installation NOTE Coat of bushings with specified lubricant prior to installing pins With the booms positioned and supported place cylinder in position and secure in place using slings Install the cylinder barrel 4 being sure to align the hole in the cylinder barrel pin with the retaining pin screw hole When holes align install hardware Correctly install hydraulic lines to cylinder as previ ously tagged Extend cylinder rod slowly until attach pin hole aligns with those in boom Using a suitable brass drift drive the cylinder rod attach pin 3 through the aligned holes Secure the pin in place using retaining hardware Remove boom prop and overhead crane Take the lift cylinder through one complete cycle to assure correct functioning Place boo
72. RESPONSIBILITY OF THE OWNER OPER ATOR B 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 C MAINTENANCE WARNING 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 15 MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP 15 CLOSED AND SECURE AT ALL OTHER TIMES e REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND 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 COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS
73. a ik 9 PIN ji PLATFORM CAN BUSS RS 232 4 SOCKET 4 PIN 6 SOCKET OOOO BER ANALZER CONNECT I ON WHT ZR BARE ORN 55 50 DRIVE ORIENTATION PUSHBUTTON CONTROL MODULE JQ J8 6 SOCKET POS TRACK PINK 26 3 PINK 25 3 24 3 GRAY 23 3 LEVEL PLATFORM ROTATE LEFT 5 RIGHT p BROWN 14 5 BROWN 13 3 TELESCOPE ORN RED 49 11 TAN 6 3 LOWER LIFT WHT RED 5 5 234500900 J7 15 PIN ED 57 WHT RED 57 6 BLUE 28 5 WHT YEL WHT GRN LEFT RIGHT REV T DRIVE STEER JOYSTICK ASSEMBLY DOWN UP RIGHT LEFT OPTION JIB BLUE 27 3 WHT RED 57 9 WHITE 60 5 WING JIB WHITE 59 5 3121829 Figure 7 21 Electrical Schematic Sheet 2 of 6 JLG Lift 1870227E AJP OPTION SIDE 5 7 33 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS z at x x xo m a zu LES GE uj ea eS gt mr lt 0 2 c o 2 amp a a e o 49 FE 00 Woe S T 10 YEL BLK lt TN Aaa amp oi iJ ve J lt lt lt nme upa Lia Dy Moe 270 pan lt lt OE 25 Sav gt
74. 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 m EN 19 Remove the piston O D seal 202 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 20 Remove the piston 1 0 seal 200 You may now pro ceed to the inspection process 3 Inspect the wear guide condition and measure thick ness not less than 0 123 or 3 12 mm 3121829 JLG Lift 4 19 SECTION 4 amp PLATFORM Assemhly 4 Using seal tool install the main pressure seal 205 onto shaft 2 and end cap 4 Use the seal tool in a 1 Gather all the components and tools into one loca circular motion tion prior to re assembly Use the cut away drawing E to reference the seal orientations 5 Install the wear guide 302 on the end cap 4 and shaft 2 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 4 20 JLG Lift 3121829 6 Install the inner T seal 200 into the piston 3 using 8 a circular motion Install the outer T seal 2
75. 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 controller 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 THI
76. 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 2 n order to test the inputs the machine the IN 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 Table 6 6 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 time afterwards RUN SYSTEM TEST ENTER starts system test Not available until tests are activated Displays messages while system test runs Some messages are prompts requiring user intervention ENTER can be pressed if a fault is found to confirm that the fault has been noted and to continue the system test NOTE a flashing message is critical and prevents the system test running 6 22 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 7 System Test Messages RUNNIN
77. as necessary Assemhly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used to install a new rod seal into the applicable cylinder head gland groove ROD SEAL SEAL TOOL SMOOTH SIDE CYLINDER HEAD Figure 5 6 Rod Seal Installation WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION FOR CORRECT 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 JLG Lift 3121829 SECTION 5 HYDRAULICS wear ring into the applicable cylinder head gland backup rings are to be positioned so as not to be in groove alignment with each other WIPER SEAL CYLINDER MALLET HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head BACKUP SPLIT SEAL RINGS Figure 5 7 Wiper Seal Installation 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD SPLIT SEAL SPLIT BACKUP RING Figure 5 9 Piston Seal K
78. 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 Remove retaining ring 17 from cover 21 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 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 shaft 10 4 Install shaft assembly and retaining ring 17 in cover 21 3 8 JLG Lift NOTE Be sure to use the same number of springs and spring pattern as recorded during disassembly This should be five red springs evenly spaced 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 Place a new rotor disc 13 including speed sensor ring 12 on the shaft 10 until it contacts the plate 14 Install stator disc 11 8
79. bear ing upon installation Remove bolts nuts and washers which attach the turntable to the bear ing inner race Discard nuts and bolts e 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 f Carefully place the turntable on a suitably sup ported trestle g 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 installa tion 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 and rotation box assem bly from the frame move to a clean suitably supported work area h Remove the two capscrews securing the bear ing to the rotation box to separate the two for inspection SECTION 3 CHASSIS amp TURNTABLE 2 Installation a Install bearing to rotation box with two cap screws so that fill plug of bearing is as close to gear as bolt pattern will allow Do not tighten capscrews b Line up high spot blue of bearing with center tooth of worm gear Set backlash to 0 008 0 010 inch 0 20 0 25 mm Tighten capscrews as shown in Figure 3 15 Swing Bearing Torqu ing Sequence c Apply Tribol Molub Alloy 936 Open Gear Com pound to bearing and worm gear teeth d Grease bearing with Mobilith SHC B
80. bottle so the brush end is in the downward position 3 Brush hydraulic oil on the entire o ring applying an even coat of oil 3121829 5 2 CYLINDERS THEORY OF OPERATION Double Acting Cylinder Upper Boom Lift Mid Boom Lift Lower Boom Lift Tele scope Slave Master Rotator 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 Master and Rotate Cylinders 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
81. did not complete because traction point A is not safe or the hardware failsafe is permanently tripped POWER MODULE FAILURE HWFS CODE 3 The hardware failsafe tests did not complete because a contactor was energized when all should be turned off POWER MODULE FAILURE HWFS CODE 4 The hardware failsafe tests did not complete because the hardware failsafe tripped immediately when the traction MOSFETs were turned on POWER MODULE FAILURE HWFS CODE 10 The hardware failsafe tests failed because the hardware failsafe did not trip within the allowed test time POWER MODULE FAILURE HWFS CODE 11 The hardware failsafe tests failed because the hardware failsafe tripped too slowly POWER MODULE FAILURE HWFS CODE 12 The hardware failsafe tests failed because the hardware failsafe tripped too quickly POWER MODULE FAILURE HWFS CODE 13 The hardware failsafe tests failed because the hardware failsafe remained tripped when the traction MOS FETs were turned off POWER MODULE FAILURE HWFS CODE 14 The hardware failsafe 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 failsafe tests failed because the contactor drive failsafe did not trip within the allowed test time POWER MODULE FAILURE HWFS CODE 16 The hardware failsafe tests failed because the contactor drive failsafe tripped too slowly POWER MODULE FAILURE
82. 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 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 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 For example MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow key
83. 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 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 3121829 18 19 20 21 3121829 while watching the analyzer display select drive for ward Be ready to remove your foot from the foot 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 soeed 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
84. e 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 3121829 JLG Lift A 1 INTRODUCTION REVISON LOG Original Issue August 15 1999 Revised April 5 2001 Revised May 25 2004 Revised July 31 2007 Revised January 25 2008 Revised January 26 2009 Revised November 27 2012 Revised April 26 2013 Revised October 24 2013 Revised March 20 2014 A 2 JLG Lift 3121829 5 SECTION INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A Crac A 1 B Hydraulic System Safety u u aceto ea ke Do Oa deo ace d e D A A 1 C Malritenariee tute re ur dius A 1 SECTION 1 SPECIFICATIONS 1 1 Operating spaecille arp s qs c de de Vn dear a a EE Apto 1 1 1 2 Tu C C ha 1 1 1 3 ILS asa Edu tud Aut UR Ote 1 1 1 4 zii 1 1 1 5 Dimensional x t acd bach sharin 1 1 1 6 DIVE M All sae Oca Rev
85. 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 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 Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise c If the switch has more than one common contact repeat the process for that circuit 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 a
86. example 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 1 Personality Ranges Defaults and Table 6 2 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 3121829 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 PER FORMANCE OF YOUR MACHINE ITS IS GOOD PRACTICE 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
87. i Dust Cap Cotter Pin opindle Nut opindle Washer Stud Nut Bearing Cone Hub Bearing Cone Seal 0 Spindle Figure 3 3 Spindle Assembly 3121829 JLG Lift 3 3 SECTION 3 CHASSIS amp TURNTABLE 3 3 DRIVE 2780236 The final drive consists 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 carbonized Precision roller bearings support the sprocket or wheel loads A shaft seal protects the unit against contamination Disassembly 1 On eg 10 11 12 13 14 NOTE 3 4 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 80 and o ring
88. incorrect JLG Lift Recycle footswitch Repair or replace control switch Run System Test Replenish oil as necessary Repair or replace wiring Run System Test Repair or replace valve Clean or replace line Checkwiring Run System Test Repair or replace cylinder Repair or replace pump Run System Test Recycle footswitch Repair or replace control valve Clean repair or replace line or fitting Check pressure re adjust as necessary Repair or replace cylinder set to Factory Default 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Boom extends and retracts erratically No response to swing control Boom will swing in one direction only 3121829 Hydraulic system oil low Wear pads worn Restricted or broken hydraulic line or fitting Directional valve not functioning properly Worn seals in telescope cylinder Cylinder not functioning properly Counterbalance valve not functioning properly BOOM SWING SYSTEM Swing function not activated within 7 seconds after footswitch was depressed Hydraulic system oil low Swing Joystick not functioning Restricted or broken supply line on valve bank or hydraulic pump Directional valve not functioning properly Swing motor not functioning properly Foreign objects s wedged between swing motor pinion and swing gear No electric power to valve Restricted or broken hydraulic
89. isn t excessive end play and the hubs turn freely 7 Insert the dust and check to make sure the cot ter pin is not going to interfere Cap must be pressed all the way down The unit should be checked again to assure it spins freely after the dust cap is installed Specifications The end play specification is 0 001 0 010 0 025 0 254 mm for all units Checking The end play is checked by clamping the spindle in a fix ture or vise and moving the hub parallel to the spindle centerline without rocking the hub If the end play is set properly the following should apply 1 Hub should rotate freely when spun by hand 2 The hub should not be noticeably loose when moved parallel with spindle centerline Greasing Requirements Hub assemblies shall have grease packed in the bearings via an appropriate greasing spindle or by hand In either method the bearing must be greased so the grease is forced thru the entire bearing cavity and thru the rollers of both inner and outer bearings Dust or grease caps used shall have grease applied to the inside of the cap The bearing cavity shall be filled 50 80 full of grease on all applications Dust or grease caps shall also be filled 10 20 full of grease on all applications prior to final assembly Visually verify that grease has flowed thru all rollers of the inner and outer bearings 3121829 SECTION 3 CHASSIS amp TURNTABLE 2 7 d
90. line or fitting Directional valve not functioning properly Foreign object s wedged between swing motor pinion and swing gear Swing Joystick not functioning properly JLG Lift Table 7 2 Boom Assembly Troubleshooting PROBABLE CAUSE REMEDY Replenish oil as necessary Replace pads as required Clean repair or replace line or fitting Repair or replace valve Replace seals Repair or replace cylinder Replace counterbalance valve Recycle footswitch Replenish oil as necessary Repair or replace swing joystick Run System Test Clean or replace line Repair or replace valve Repair or replace motor Remove objects check for damage and repair or replace component s as required See proper wiring diagram Run System Test Clean repair or replace line or fitting Repair or replace valve Remove object s check for damage and repair or replace component s as required Repair or replace swing joystick Run System Test 7 7 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 2 Boom Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction Hydraulic system oil low Replenish oil as necessary Lack of lubricanton swing gear or speed reducer Lubricate required See Lubrication Chart pinion Swing motor not functioning properly Repair or replace swing control switch Worn or broken teeth
91. 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 3121829 SECTION 3 CHASSIS amp TURNTABLE Optional On Board Generator A WARNING EXHAUST GAS HAZARD RUN THE GENERATOR WELL VEN TILATED AREA ONLY WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IS ON PULLED OUT THE GENERATOR WILL START AUTOMATICALLY WHEN THE BATTER IES REACH A LOW CHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES THE GENERATOR WILL ALSO AUTOMATICALLY START IF THE GENERATOR START BATTERY IS LOW JLG Lift 3 45 SECTION 3 CHASSIS amp TURNTABLE 3 46 ALTERNATOR BATTERY CABLES OIL DRAIN TEMPERATURE OIL FILTER THROTTLE SOLENOID FUEL FILTER PRESSURE GENERATOR START BATTERY JLG Lift Figure 3 17 On Board Generator 3121829 NOTE engine will automatically shut down under the following conditions High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage Batteries fully charged SECTION 3 CHASSIS amp TURNTABLE To charge the batteries connect the charger to a 115 volt source with a 15 amp minimum capacity The Char
92. mm Service Qualification Primary Responsibility Reference Pre Start Inspection Prior to use each day or User or Operator User or Operator Operator and Safety Manual At each Operator change Pre Delivery Prior to each sale lease or Owner Dealer or User Qualified JLG Service and Maintenance Inspection rental delivery Mechanic Manual and applicable JLG inspection form Frequent Inspection In service for 3 months 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 Trained service and Maintenance Inspection date of the prior inspection Service Technician Manual and applicable JLG Recommended inspection form Preventive 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 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings General and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to The following information is provided to assist you in the prevent entry of foreign matter use and application of servicing and maintenance proce dure
93. n L4 14 ELI ELLE START CONTROL RELAY FUEL CONTROL RELAY ENGINE LOW OIL PRESSURE SWITCH ALTERNATOR 1 DYNAMO OUTPUT FUSE ENGINE OIL 1 TEMPERATURE SENSOR REGULATOR Figure 3 20 Generator Components 3 54 JLG Lift 3121829 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 5 RBS Prestart Sequence CTS Callto Start TDES Engine Start Preheat Delay RBS Startup Sequence RBS Startup Sequence 3 Crank Time The RBS will crank for a period up to the crank time or until the engine starts 4 Rest Time If the engine does not successfully start the RBS will wait for the rest time before attempting to crank the engine again 5 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 3121829 SECTION 3 CHASSIS amp TURNTABLE Time Delay Bypass TDBP Once the engine starts TDBP must elapse before low oil
94. on swing gear or swing Replace gear s as required motor pinion Restrictor valves s plugged Clean or replace restrictor valve 7 8 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Valve Spool Sticking Valve leaking 3121829 CONTROL VALVE Dirt in oil causing excessive temperature built up Incorrect valve mounting causing warping of the unit Valve spool scored Return spring weak or broken Relief valve malfunctioning causing excessive pressure within valve Dirt or other foreign material under seal Valve spool scored Excessive back pressure caused by restricted return line to reservoir Damaged valve seals JLG Lift Table 7 3 Turntable Assembly Troubleshooting PROBABLE CAUSE REMEDY Change oil using recommended viscosity and flush system Loosen valve and check mounting Repair as necessary Remove valve and repair or replace as neces sary Remove valve and repair or replace as neces sary Check pressure delivery to and from valve and repair or replace as necessary Remove and replace valve as necessary Repair or replace valve Remove line and clear obstruction or replace line as necessary Repair or replace valve as necessary 7 9 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Engine will not start Engine will not start ignition OK Eng
95. 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 facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod barrel must be replaced c Lubricate inside of the steel bushing with WD40 prior to bearing installation 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 Figure 5 5 Gar Max Bearing Installation 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 17 If applicable inspect piston rings for cracks or other damage Replace
96. regarding stability Wheel Installation It is extremely 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 1 SECTION 3 CHASSIS amp TURNTABLE 2 Tighten nuts in the following sequence 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 Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal Check torque every 3 month
97. settings for smooth control of acceleration deceleration creep and max speed for all boom drive and steering NOTE The cable has a four pin connector at each end of functions the cable the cable cannot be connected back wards The upper lift swing and drive are controlled by individual joysticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following The motor controller will control current 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 JLG tion HELP PRESS ENTER 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 whe
98. the engine block WARNINGS A WARNING ALWAYS SHIELD YOUR EYES AND AVOID LEANING OVER THE BATTERY WHENEVER POSSIBLE WARNING DO NOT ALLOW BATTERY ACID TO CONTACT EYES OR SKIN FLUSH ANY CONTACTED AREA WITH WATER IMMEDIATELY SEEK MEDICAL ATTENTION IF IRRITATION PERSISTS WARNING STARTING BATTERIES GENERATE EXPLOSIVE GASES KEEP SPARKS FLAME AND LIGHTED CIGARETTES AWAY FROM BAT TERIES WARNING IMPROPER USE OF A BOOSTER BATTERY TO START AN APU MAY CAUSE AN EXPLOSION 3 70 JLG Lift 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 DIF FERENT VOLTAGE OR SUBSTANTIALLY DIFFERENT AMP HOUR RATING MAY CAUSE AN EXPLOSION OR PERSONAL INJURY APPLYING A HIGHER VOLTAGE WHILE BOOSTING WILL ALSO CAUSE DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS WARNING A CHARGING SYSTEM BATTERY CHARGER OR BATTERY CHARGING ALTERNATOR MUST NEVER BE ENERGIZED WHILE BOOSTING DAMAGE TO SENSITIVE ELECTRONIC COMPO NENTS WILL RESULT THE MAIN BATTERY OF THE LIFT MUST NEVER BE USED TO BOOST THE APU DAMAGE TO SENSITIVE ELECTRONIC COMPO NENTS WILL RESULT 3121829 SECTION 3 CHASSIS amp TURNTABLE 3 14 SUPPLEMENTARY FUSE FOR APU 2 Find where the harness attaches
99. the cable supplied with the analyzer to the connector behind the ground control module located on the left side of the machine next to the ground control station and con nect the remaining end of the cable to the analyzer The ground control module contains the settings for the generator ANALYZER CONNECTION NOTE The cable has a four connector at each end of the cable the cable cannot be connected back wards 2 Powerup the Analyzer by pulling out the ground sta tion EMS and positioning the Generator Enable switch on the platform control box to the on posi tion Refer to Figure 3 21 Generator System Ana lyzer Flow Chart 3 56 JLG Lift Alarms and Fault Flash Codes In the event of an RBS alarm a flash code will be issued and an alarm indicated on the analyzer NOTE Alarms must be reset once the fault has been cor rected Table 3 8 Generator System Flash Codes Code 1 1 Low Oil Pressure shutdown due to low engine oil pressure 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 Description 1 5 No Speed Signal Shutdown due to loss of speed signal 2 1 Overvoltage Shutdown due to high output voltage 2 2 Engine Starting System fault Alarm not a shutdown Indi cates problem with the engine starting sy
100. the operating problems which may develop If a problem should develop which is not pre sented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 7 2 TROUBLESHOOTING The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 7 1 through Table 7 6 As an aid to table use the aerial platform is divided into four major groups each covered separately within this section These groups are as follows elevation sys tem chassis assembly hydraulic system and electrical system Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the remedial action should where possi ble be checked in the order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more that one probable cause and remedy are included This
101. this maybe due to a faulty speed sensor 4611 46 LEFT SPEED SENSOR NOT RESPONDING PROPERL Y The left speed sensor is indicating an impossible number of pulses this maybe due to a faulty speed sensor 4615 46 SPEED SENSOR INVALID READING Both speed sensors are indicating impossible number of pulses this maybe due to a faulty speed sensor 4616 46 BRAKES DID NOT LOCK Brake pressure did not clear when the brake valve was de ener gized 4617 46 NOVEHICLE MOVEMENT DETECTED AT MAXIMUM POWER No speed was measured with the traction motor full ON This could be due to atraction motor fault a power wiring error a speed sensor fault the brakes not releasing though brake pres sure is OK or the vehicle being overloaded so that the motor can notturn the wheels 661 66 CANBUS FAILURE POWER MODULE Power Module CAN communication lost 662 66 CAN BUS FAILURE PLATFORM MODULE Platform Module CAN communication lost 6631 66 CAN BUS FAILURE GROUND MODULE Ground Module CAN communication lost 6636 66 CANBUS FAILURE TILT MODULE Tilt Module CAN communication lost 772 77 STALLED TRACTION MOTOR OR POWER WIRING ERROR The power module traction MOSFET protection circuit is active This is dueto a massive current drain and could be a stalledtrac tion motor or a power wiring error 773 77 CAPACITOR BANK FAULT CHECK POWER CIRCUITS The capacitor bank is not charging this maybe due to a power wiring error causing illegal current
102. through housing ports do not exceed OEM s operating pressure The valve mustbe replaced if 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 ble with seals and bearings 2 Operation is erratic or not responsive Airin actuator Shaft will not fully rotate a Twisted or chipped gear teeth b Portfittings are obstructing the piston a Purge air from actuator See bleeding proce dures a Check for gear binding Actuator may not be able to be re built and may need to be replaced Damage could be a result of overload or shock b Check thread length of port fittings Fittings should during stroke not reach inside the housing bore a Control or counterbalance valve has internal leak 4 Selected position cannot be maintained b Piston and or shaft seal leak c Airin actuator a Disconnecthydrauliclines and bypass valve Leave valve ports open and operate the actuator through housing ports do not exceed OEM s operating pressure The valve must be replaced if a steady flow of fluid is seen coming from the valve ports b Removethe plug and the hou
103. to creep when tilted and above elevation Reduces drive speed to creep when tilted European Australian 3 3 degree cuts out drive and reduces functions to creep speed when tilted and above elevation Reduces drive speed to creep when tilted only Option 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 DRIVE CUTOUT 0 Battery Charger Cutout cuts out drive when the battery charger is plugged in 1 Battery Charger Cutout and Simultaneous Drive and Boom functions disabled above elevation Euro pean Australian 2 Battery Charger Cutout and Drive Cutout above elevation Option FUNCTION CUTOUT LIMIT SWITCH 0 No Function Cutout 1 Cuts out all boom functions when switch opens Option 2 Cuts out all functions when the switch opens Option JIB 0 jib installed 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 GROUND ALARM 0 No ground alarm installed 1 Travel Alarm Sounds when the drive function is active Option 2 Descent Alarm Sounds when either lift down is active Option 6 9 SECTION 6 JLG CONTROL SYSTEM 3 Motion Alarm Sounds when any function is active Option 7 PLATFORM ALARM 0 Sounds continuously when above elevation and tilted only 1 2 Sounds contin
104. to the bolt shank d Swing the turntable 90 degrees and check some selected bolts at the new position e Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants 3121829 JLG Lift SECTION 3 CHASSIS amp TURNTABLE 2 Check the turntable to bearing Attach bolts as fol lows a Elevate the fully retracted boom to 70 degrees full elevation b At the positions indicated on Figure 3 12 try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indi cated position c Lower the boom to horizontal and fully extend the boom d At the position indicated on Figure 3 12 try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indi cated position 0015 Feeler Gauge Figure 3 12 Swing Bearing Feeler Gauge Check 3 39 SECTION 3 CHASSIS amp TURNTABLE Wear Tolerance 1 With the boom positioned over the side of the machine the Upper Boom horizontal with telescope fully extended and Mid Lower Boom stowed See UPPER BOOM HORIZONTAL AND FULLY TELESCOPED MID LOWER BOOM FULLY LOWERED MEASURING POINT Figure 3 13 using a magnetic base dial indicator measure and record the distance between the swing bearing and turntable See Figure 3 14 UPPER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED LOWER BOOM FULLY ELEVATED Figure 3 13 Swing Bearin
105. to the rear cover of the generator and the connection point for the new The purpose of this section is to describe the procedure to inline fuse 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 cm of 16 AWG wire JLG P N 4920019 2 X insulated butt splice connectors JLG P N 4460035 6 X medium length wire ties JLG P N 4240033 Wire Side cutters 5 32 Allen Key Crimping tool Procedure 3 Remove the socket head drive screw with a 5 32 Allen key Next remove the cable clamp from the WARNING harness BEFORE BEGINNING THIS PROCEDURE ENSURE THAT ALL T 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 JLG 450 lift 1 Locate the harness at the rear of the APU 4 Cut and remove the Wire Ties holding the Harness label to the harness Next remove the Wire Ties so 3121829 JLG Lift 3 71 SECTION 3 CHASSIS amp TURNTABLE that the cable sleeve be moved exposing the 6 Re install the harness with the new fuse in place conductors of the harness 7 the lift and APU start battery The APU is now ready for use 5 Cut wire 106 going to the Engine Generato
106. 0 5625 0200 18250 170 230 15 20 10 15 18 0 6250 0 2560 23000 20 325 25 20 10 245 16 0 7500 0 3730 33600 420 50 380 55 35 430 7 8 9 0870 0 4620 41600 65 825 545 740 45 620 _____ 14 0 8750 0 5090 45800 60 90 60 85 50 680 1 8 1000 0 6060 51500 860 1170 70 145 645 875 12 1 0000 06630 5970 95 1355 895 1215 745 1015 12 1420 0 8560 7700 145 1965 1300 170 105 1475 12 1250 1 0730 96600 2015 2740 1810 260 1510 205 13 8 6 13750 1 1550 104000 2385 3245 245 295 175 2430 12 13750 1 3150 118100 2705 3680 2435 3310 2030 2760 112 6 15000 1 4050 126500 3165 4305 2845 3870 2370 3225 1 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES 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 3121829 JLG Lift 1 11 SECTION 1 SPECIFICATIONS 1 12 SOCKET HEAD SCREWS Magni Coating Ref 4150701 Torque Torque Loctite 242 or 271 d MT Si TE Bolt Di Tensile Clamp Load Torque Loctite 262 01778 Stress Area See Not
107. 00 23 25 2 25 101 6 590 5 57 1 Telescope Cylinder 2 00 92 1 25 50 8 2337 31 8 Master Cylinder E M450A 2 00 9 375 1 00 50 8 238 1 25 4 Master Cylinder E M450AJ 3 00 11 5 1 25 75 292 32 slave Cylinder E M450A 2 00 9 375 1 00 50 8 238 1 25 4 slave Cylinder E M450AJ 3 00 11 6 1 25 75 295 5 32 Rotator Cylinder 1 875 15 250 1 00 47 6 387 3 25 4 Steer Cylinder 2 50 4 06 1 75 Double Rod 63 5 103 1 44 5 1 15 MAJOR COMPONENT WEIGHTS Table 1 18 Major Component Weights Platform and Support 215 97 5 Upper Boom Complete 810 367 Mid Boom Complete 550 249 Lower Boom Complete 550 249 Upper Lift Cylinder 89 40 Mid Lift Cylinder 95 43 Lower Lift Cylinder 110 50 Telescope Cylinder 85 38 5 Upper Upright 225 102 Lower Upright 97 44 Turntable 948 430 Battery Box incl batteries 600 272 Chassis w pneu tires 4 295 1948 Chassis w foam filled tires 4 695 2130 Counterweight 3850 1746 Machine Complete 11 800 5352 3121829 SECTION 1 SPECIFICATIONS A WARNING SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF SAFELY SUPPORTING WEIGHT 1 16 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the left rear of frame in front of left rear wheel If the serial number plate is damaged or miss ing the machine serial number is stamped on the top left side of the frame and the top left side of
108. 02 by stretching it around the groove in a circular motion Each T seal has 2 back up rings see drawing for ori entation 7 Beginning with the inner seal 200 insert one end of b u ring in the lower groove and feed the rest in using a circular motion Make sure the wedged ends overlap correctly Repeat this step for the outer seal 202 3121829 JLG Lift the housing bore SECTION 4 amp PLATFORM Insert the piston 3 into the housing 1 as shown until the outer piston seal 202 is touching inside Looking from the angle shown rotate the piston 3 until the marks you put on the piston and the hous ing 1 during disassembly line up as shown Using a rubber mallet tap the piston into the housing up to the point where the gear teeth meet Pw 4 21 SECTION 4 amp PLATFORM 10 11 12 4 22 Looking from the opposite end of the housing 1 you can see if your timing marks are lining up When they do tap the piston 3 in until the gear teeth mesh together Tap the piston into the housing the rest of the way until it bottoms out Install the shaft 2 into the piston 3 Be careful not to damage the seals Do not engage the piston gear teeth yet Looking from the view shown use the existing tim ing marks to line up the gear teeth on the shaft 2 with the gear teeth on the inside of the piston 3 Now tap th
109. 053 Releveling Relief E M450A 2200 152 S N 91053 to Present JLG Lift 1 3 SECTION 1 SPECIFICATIONS 1 11 TORQUE SPECIFICATIONS Table 1 12 Torque Requirements Description Torque Value Interval Hours Wheel Lugs 17011 Ibs 150 230 Nm Swing Bearing 190ft Ibs 50 600 Loctite 260 Nm Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter 1 12 LUBRICATION SPECIFICATIONS Refer to Section 1 17 Operator Maintenance amp Lubrica tion for specific lubrication procedures Hydraulic Oil NOTE Hydraulic oils must have anti wear qualities at least to Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice Aside from JLG recommendations it is not advis able to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobil DTE 11M is desired contact JLG Industries for proper recommendations Table 1 13 Hydraulic Hydraulic System S A E Viscosity Operating Grade Temperature Range 0 to 180 F 10W 18 to 83 C 0 to 210 F 10W 20 10W30 18 to 99 C 50 to 210 F 20W 20 10 to 99 G 1 4 JLG Lift Table 1 14 Mobil DTE 11M Specs 150 Viscosity Grade 15 Gravity 31 9 Pour Point
110. 1 D 27721 Ritterhude Ihlpohl Germany 2 49 0 421 69 350 20 49 0 421 69 350 45 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Z3 55 19 3295 0407 55 19 3295 1025 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 4 34 93 772 4700 34 93 771 1762 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2 England 44 0 161 654 1000 44 0 161 654 1001 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 www jlg com 3121829 JLG France SAS Z I de Baulieu 47400 Fauillet France Z 33 0 5 53 88 31 70 33 0 5 53 88 31 79 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 65 6591 9030 465 6591 9031
111. 121829 SECTION 5 HYDRAULICS 17 Position the cylinder barrel in a suitable holding fix Table 5 1 Cylinder Head and Tapered Bushing Torque ture Specifications Head Torque Value Tapered Bushing NOTICE Wet Torque Value Wet EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF Jib Cylinder 1 2 CENTER WHICH COULD CAUSE DAMAGE THE PISTON AND CYLINDER BARREL SURFACES Level Cylinder 30 ft Ibs 5ft Ibs M450AJ 41 Nm 7 Nm 18 With barrel clamped securely and while adequately Master Cylinder Ibs 9 ft Ibs supporting the rod insert the piston end into the M450AJ 41 Nm 7 Nm barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged Table 5 2 Cylinder Piston Nut Torque Specifications 19 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel Description Nut Torque Valve Setscrew Torque Value Pee inder 20 Secure the cylinder head gland using the washer 2001 5 IDs 100 6 ring and socket head bolts Lift Cylinder 2 0 Nm 11 Nm Mid 400 ft Ibs 100 in Ibs Lift Cylinder 542 Nm 11Nm SPACER HEAD ASSY Lower 400 ft Ibs 100 in Ibs Lift Cylinder 542 Nm 11 Nm Level Cylinder 80 ft Ibs 100 in Ibs M450 A 108 Nm 11 Nm Master Cylinder M450A 80 ft Ibs
112. 2 5 5 5 5 38 6 03750 oors 5 o 5 3 5 24 oso 0 0878 s 70 5 o 3 5 716 14 04375 0103 50 70 5 6 5 7 20 0437 10 10 70 95 a 12 13 0500 9449 305 4 95 13 89 no 20 05000 0 1599 140 120 6 no t 90 12 916 5 8 3 4 78 9 0 8750 0 4620 41600 65 825 55 740 45 620 14 0 8750 0500 450 60 90 60 85 50 680 __ 8 1000 0 6060 5150 860 1170 75 1055 65 8 5 12 1000 0650 590 95 1355 895 1215 75 1015 12 1420 0 8560 77000 1445 1965 1300 1770 1085 1475 12 1250 1 0730 960 X 2015 2740 1810 2460 1510 2055 138 6 13750 1 1550 10400 2385 3245 2145 215 1785 2430 12 13750 1 3150 1110 2705 3680 2435 330 2030 2760 11 72 6 1 5000 1 4050 126500 3165 4305 2845 3870 2370 3225 12 1500 1 5800 142200 3555 4835 3200 4350 2665 3625 5000059 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 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 CLAS
113. 4 Plate 20 Dowel Pin 3 PressurePlate 9 BackupRing 15 Spring 21 Cover 4 Case 10 Shaft 16 Spring Retainer 22 Rotary Oil Seal 5 O ring 11 Stator Disc 17 RetainingRing 23 Gasket 6 BackupRing 12 SensorRing 18 Bearing Figure 3 2 Drive Brake 3121829 JLG Lift 3 9 SECTION 3 CHASSIS amp TURNTABLE Problem Brake slips Brake drags or runs hot Brake will not release 3 10 Table 3 2 Drive Brake Diagnosis Cause Excessive pressure In hydraulic system Oil In brake if designed for dry use Springs broken or have taken a permanent set Low actuation pressure Explanation If there is back pressure in the actuation line of the brake holding torque will be reduced Wetlinings generate 67 of the dry torque rating If the brake has oil Init check the type of oil hydraulic or gearbox 1 Gearbox oil 2 Hydraulic oil Broken or set springs can cause reduced torque rare occurrence The brake should be pressurized to minimum of 1 38 bar 20 psi over the full release pressure under normal operating conditions Lower pressures will Bearing failure Stuck or clogged valve cause the brake to drag thus generating heat Ifthe bearing should fall a large amount of drag can be generated Brakes are designed to come on when system pres sure drops below stated release pressure If pres sure cannot getto brake the brake will not release Discs frozen Release p
114. 450A Sheet 2012 7 41 7 30 Hydraulic Schematic 450 450 Sheet 1 2 7 42 7 31 Hydraulic Schematic 450 450 Sheet 2012 7 43 7 32 Hydraulic Schematic Component List 3121829 JLG Lift LIST TABLES TABLE NO TITLE PAGE NO 1 1 Operating Speciiicallols uvis Soe ed Rx wd 1 1 1 2 C D Ce PME 1 1 1 3 gt RIT amara alee 1 1 1 4 au Ses ip aes 1 1 1 5 Di DOS L u yuku E a uu b Sua aS 1 1 1 6 DI Since Pad aan Bele e cob ba 1 2 1 7 Hydraulic Pump Electric 1 2 1 8 Geneon 5055 a T 1 2 1 9 5 2 vata qa e ua dte apt 1 2 1 10 Pressure Settings Prior to S N 0300062642 1 3 1 11 Pressure Settings S N 0300062642 to Present 1 3 1 12 Torcdue HedquirerielllS 5 E pes D en wi E 1 4 1 13 ila boite 1 4 1 14 MobILDTE TIM SBOCS E uuu Re beta eee He t oe e e Soie ds 1 4 1
115. ACK 16 2 CABLE BLACK 1672 CABLE 6 SOCKET CAP SPLICE rz INSIDE GROUND 4 CONTROL BOX g 8 OLON Bos GROUND CONIROL MODULE L Ho Ouz amp u P 5 JOT 9 24 WHITE 16 2 CABLE 2 PIN a CS J8 ORN RED 49 1 2 SOCKET WHT BLK 58 4 49 21 JS WHITE 60 1 gd S 9 PIN WHITE 59 1 A 49 20 2 SOCKET J7 J4 BLUE 27 1 15 DIN 15 SOCKET 7 34 DRIVE ORIENTATION SWITCH ENABLE ORN RED 49 4 ORN RED 49 5 WHT RED 57 11 WHT RED 57 11 HT RED 57 11 5 6 7 8 09 V V V qom DD ES I x x m m a UP DOWN LEFT LOWER UPPER SWING LIFT LIFT RIGHT LEFT LEVEL TELESCOPE ROTATE UP DOWN OPTION JIB GRAY 23 1 GRAY 24 1 1 WHT BLK 58 3 M m RED WHT 50 1 PROPORT I ONAL L FLOW RED WHT 50 24 L Edu Z Egan WHT BLK 58 3 TECE BUE SWING PRIORITY ROTATE BYPASS RIGHT z lt WHT BLK 58 3 UPPER n LIFT SWING SWING LEVEL LEVEL OPTION DOWN LEFT RIGHT UP DOWN JIB DOWN Figure 7 22 Electrical Schematic Sheet 3 of 6 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS POSI TRACK J4 TILT MODULE 45
116. ALED PILOT COUNTERBALANCE CARTRIDGE PILOT RATIO 7 1 HYDRAULIC TANK 3 5 4 WAY VALVE STEER SHUTTLE VALVE STEER RELIEF VALVE DIRECT ACTING STEER SET AT 1400 PSI SPRING RETURN PULL TO OPEN POPPET CARTRIDGE MANUAL COUNTERBALANCE CARTRIDGE PILOT RATIO 10 1 500 PSI HOLDING 1200 PSI THERMAL VENTED SPRING SEALED PILOT PRESSURE SWITCH CHECK V ALVE S WAY 2 POSITION DIRECTIONAL POPET VALVE RELIEF VALVE DIRECT ACTING SYSTEM RELIEF SET AT 3200 PSI CARTRIDGE PLUG PROPORTIONAL FLOW REGULATOR PRESSURE COMPENSATED DELETED DELETED DELETED DELETED DELETED DELETED DELETED 0 028 ORFICED PLUG 3 POS 4 WAY VALVE JIB RELIEF VALVE SET AT 1500 PSI COUNTERBALANCE CARTRIDGE 5 1 e 2500 PSI COUNTERBALANCE CARTRIDGE 10 1 e 700 PSI 1200 PSI THERMAL COUNTERBALANCE CARTRIDGE 7 1 e 2500 PSI COUNTERBALANCE CARTRIDGE 5 1 5000 PSI NON VENTED SPRING CHECK VALVE SET AT 60 PSI Figure 7 32 Hydraulic Schematic Component List JLG Lift 2500 PSI HOLDING 3300 PSI THERMAL NON VENTED SPRING SEALED PILOT 3121829 Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 61 2 65813058 JLG Deutschland GmbH Max Planck Str 2
117. ALVE COMPONENT LIST FLOW REGULATOR PRESSURE COMPENSATED POPPET VALVE NORMALLY OPEN BYPASS UNLOADING VALVE LOWER LIFT VALVE UPPER LIFT VALVE SWING SPOOL VALVE NORMALLY CLOSED VALVE TELESCOPE OUT VALVE TELESCOPE IN VALVE PLATFORM LEVEL VALVE ROTATOR DIRECT ACTING LOWER LIFT DOWN SET AT 2600 PSI DIRECT ACTING UPPER LIFT DOWN SET AT 800 PSI DIRECT ACTING TELESCOPE SET AT 3000 PSI DIRECT ACTING PLATFORM LEVEL BACKWARD ROD END SET 1200 PSI DIRECT ACTING PLATFORM LEVEL FORWARD PISTON END SET 3000 PSI SHUTTLE VALVE TELESCOPE PILOT OPERATED CHECK PLATFORM LEVEL ROD SIDE PILOT OPERATED CHECK PLATFORM LEVEL PISTON SIDE ROTARY 2 POS 3 WAY VALVE EMERGENCY DESCENT MANUAL HAND PUMP 0 47 1 3 0 031 ORIFICE PLUG FILTER HIGH PRESSURE 10u ABSOLUTE 61761 ELECTRIC MOTOR PUMP ASSEMBLY 48VDC MOTOR GEROTOR TYPE FIXED 3 2 CU IN SWING COUNTERBALANCE CARTRIDGE 10 1 e 5000 PSI NON VENTED SPRING COUNTERBALANCE CARTRIDGE 1 1 e 35500 PSI VENTED SPRING SEALED PILOT COUNTERBALANCE CARTRIDGE 1 1 5500 PSI VENTED SPRING SEALED PILOT COUNTERBALANCE CARTRIDGE 5 1 e 4000 PSI VENTED SPRING SEALED PILOT COUNTERBALANCE CARTRIDGE 5 1 e 4000 PSI VENTED SPRING SEALED PILOT RELIEF VALVE DIRECT ACTING LEVELING RELIEF VALVE SET AT 2200 PSI CRACKING PRESSURE COUNTERBALANCE CARTRIDGE 10 1 e 2500 PSI NON VENTED SPRING COUNTERBALANCE CARTRIDGE 5 1 e 2500 PSI VENTED SPRING SE
118. APPLY TO CADMIUM PLATED FASTENERS REN 2 ALL TORQUE VALUES 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 01 O1 POT O O O OIO Figure 1 5 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift 3121829 SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 TOM Torque Si TPI Bolt Di Tensile Clamp Load unos M Loctite amp 2621 i otaa Stress Area See 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 K 0 18 __ m Sem Im N N x pe 31 73 40 00018 L L LL LLL 0390 L T LL LL LLL 20 0250 4 TL 00994 164 148 17 Sim IB Nm Nm FTB Nm 03125 90580 5
119. AR OUT THE CONTROL SYSTEM CONTROLLER WILL NOT DRIVE THE MACHINE 3121829 SECTION 3 CHASSIS amp TURNTABLE 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 3 Speed Sensor Ori entation 4 Use a 1 2 wrench to hold the sensor and a 11 16 wrench to snug the lock nut to the brake JLG Lift 3 11 SECTION 3 CHASSIS amp TURNTABLE WIRE SENSOR IN LEFT MOTOR BRAKE SENSOR IN LEFT MOTOR BRAKE MOTOR B m NOTCH e BLACK WIRE WHITE GREEN WIRE WM WIRE NOTCH y RED WIRE WIRE WHITE WIRE SENSOR IN RIGHT MOTOR BRAKE SENSOR IN RIGHT MOTOR BRAKE MOTOR A Figure 3 3 Speed Sensor Orientation 3 12 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE CONTACTOR PLATE ASSEMBLY POWER CONTROLLER Q gt SOsy ANALYZER Figure 3 4 Frame Mounted Electrical Components Sheet 1 of 2 POSITRAC TILT CONTROLLER 3121829 JLG Lift 3 13 SECTION 3 CHASSIS amp TURNTABLE 3121829 Z JO Z 199uS sjueuoduio 514129153 S E SHTNI 08 OL SLAN SSVH8
120. ATION OF ACTUATOR 2 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 3 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 4 Repeat steps 2 amp 3 After the last 1 2 gallon is purged close both bleed nipples before rotating away from the end position 4 26 JLG Lift 3121829 Troubleshooting Table 4 1 Troubleshooting SECTION 4 BOOM amp PLATFORM Problem Cause 1 Shaftrotates slowly or not at all a Insufficienttorque 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 onthe 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 ofthe actuator b Inspect ports for obstructions and hydraulic lines for restrictions and leaks c Disconnect hydraulic lines and bypass valve Leave valve ports open and operate the actuator
121. CONTACTOR DRIVER The line contactor energized when the footswitch was CLOSED before it was ON this maybe due to a failed driver within the power module or a power wiring error 99138 99 POWER MODULE FAILURE TEMPERATURE SENSOR The temperature sensor measurementis invalid this maybe due to a disconnected wire within the power module 99139 09 POWER MODULE FAILURE CONTACTOR CODE 1 A contactor remained energized when turned OFF 99140 99 TILT MODULE FAILURE INTERNAL ERROR Startup test detected faulty tilt sensors or voltages on the tilt sen sor are bad could be caused if positiltis mounted upside down vertical 99141 99 GROUND MODULE OBSOLETE ON THIS VEHICLE The power module determined the hardware version of the Ground module was incompatible with the current software 90142 99 48VPROTECTION TRIPPED The power module is not receiving acknowledgements from the platform module or ground module to transmitted data and the protection circuit which supplies the platform and ground mod ules has tripped This maybe due to wiring problems atthe plat form or groundmodule 6 32 JLG Lift 3121829 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION SCHEMATICS SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION amp SCHEMATICS 7 1 GENERAL This section contains basic troubleshooting information and basic electrical information to be used for locating and correcting most of
122. E450 M450AJ E450AJ 8 5 in 0 22 m 8 in 0 20 m JLG Lift 1 1 SECTION 1 SPECIFICATIONS 1 6 DRIVE SYSTEM Table 1 6 Drive System 1 9 FUNCTION SPEEDS Table 1 9 Function Speeds Drive Motor 48 VDC 12 5 3200 rpm continuous Function Seconds rotation reversible Drive Brake opring applied hydraulically released uy 2 ee Main Lift Down 29 23 Turntable Swing Right amp Left 360 81 67 1 7 HYDRAULIC PUMP ELECTRIC MOTOR Telescope Out EASOAJ TEES ASSEMBLY Telescope Out E450A M450A 18 14 Table 1 7 Hydraulic Pump Electric Motor Telescope In EA50AJ 19 15 Motor 48 VDC 2 14 H P 2700 rpm Telescope In E450A M450A 28 23 Pump 0 098 in 3 rev 1 6 cm 3 rev Platform Rotate Right amp Left 180 450 M450AJ 20 24 Pump Output 2 96 11 2 Ipm 3200 psi 222 Bar Platform Rotate Right amp Left 180 E450A M450A 17 147 Jib Up 25 26 1 8 GENERATOR Lower Lift Up 33 27 Table 1 8 Generator 26 22 Alternator Output 58 volts 45 Amps High Drive Fwd amp Rev 42 44 RPM s under max load 3100 200 ft 3 2 mph 5 1 kph otart Battery 12 volts Drive above Horiz ANSI Fwd amp Rev 50 53 Engine 10W30 Referto 201 0 64 mph 1 kph Engine Manual Drive above Horiz CE Fwd amp Rev E450AJ 107 112
123. ER must be pressed to continue the test Alarms are tested in the order ALARM G ALARM 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 5 A short circuit condition appeared while the named alarm was being tested presumably because itis short circuit ALARM TEST DONE Indicates that the alarms testis complete 3121829 JLG Lift 6 25 SECTION 6 JLG CONTROL SYSTEM Table 6 7 System Test Messages TEST ALL INPUTS Prompts whether to check every operator input If ESC is pressed the system test ends If ENTERis pressed each operator input is prompted for in turn In platform mode operator inputs are tested in the order UL U UL D SWINGL SWING R LEVEL U LEVEL D PUMP POT CREEP ROTATE L LL U LL D JIB U JIB D TELE I TELE DRIVE FWD DRIVE REV STEERL STEERR POSITRAC In ground mode operator inputs are tested in the order ROTATEL ROTATE R LEVEL U LEVEL D JIB U JIB D TELE I TELE O UL U IJL D LL U LL D SWING L SWING R NOTE the jib switches are nottested if JIB NO Prompts displayed during the operator input test 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 joysti
124. FWAY FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD 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 f 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 Lower Lift Mid Lift Telescope and Slave Cylinders NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKI
125. G Initial display when system testis 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 or traction 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 TOOLOW The system test cannot run with battery voltage below minimum BATTERY TOO HIGH The system test cannotrun with battery voltage above maximum CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform ground and positrac tilt modules The system test cannot run 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 Thetraction current measurementis open circuit Check wiring between power 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 Aninternal problem was detected in the power module BAD POWER WIRING Traction point Ais high probably ca
126. G OR NOT REMOVING CELL CAPS WHILE CHARGING A WARNING RISK OF ELECTRIC SHOCK CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK DO NOT USE GROUND ADAPTERS OR MODIFY PLUG DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY WHILE CHARGING DO NOT OPEN OR DISASSEMBLE CHARGER DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW BEEN DROPPED OR OTHERWISE DAMAGED IN ANY WAY REFER ALL REPAIR WORK TO QUALI FIED PERSONNEL NOT FOR USE BY CHILDREN Operating Instructions ALWAYS USE GROUNDED OUTLET WHEN USING AN SION CORD AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3 WIRE 12 AWG CORD 1 charger will automatically turn and go through a short self test All LED s will flash in an up down sequence for two seconds The yellow Charg ing LED will turn on and a trickle current will be applied until a minimum voltage is reached 2 Onceaminimum battery voltage of 2 volts per cell is detected the charger will enter the constant current charging stage and the yellow LED will remain on The length of charge time will vary by input voltage and ambient temperature 3 When the green C
127. INFORMATION 8 SCHEMATICS JIB CYL BORE 2 5 4 908 SO IN ROD 1 5 1 77 SQ IN ANNULUS 5 14 STROKE 22 842 RATIO JIB VALVE E400A NARROW UPPER LIFT CYL BORE 3 7 065 SQ ROD 1 75 2 405 SQ ANNULUS 4 660 SQ zzz E450A UPPER LIFT CYL BORE 5 7 065 SQ IN ROD 1 5 1 76 SQ IN ANNULUS 5 305 SQ IN LC LR LOWER LIFT DOWN LU LOWER LIFT UP LOWER CYL 277 CYL BLEEDER FITTING FOR PURGING AIR FROM CIR STEER CYL BORE 2 5 14 SQ IN ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN 2792505 Figure 7 31 Hydraulic Schematic M450AJ E450AJ Sheet 2 of 2 3121829 JLG Lift 7 43 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 44 O GQ Gl N OI fF A A gt C4 G G C4 N S NN SN NS SN S AS N gt gt G O WAN O G N WON O Q G N O QO O O Q G NS DO O OA G N oo e PROPORT 2 POS 5 5 5 5 2 5 2 5 2 5 3 5 S POS RELIEF RELIEF RELIEF RELIEF ONAL 2 4 4 4 2 5 5 WAY 4 4 VALVE VALVE VALVE VALVE RELIEF V
128. 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 9 Install new case seal 4 in cover 21 10 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 11 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 CAUTION IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI 137 9 BAR UNLESS TWO ADDITIONAL 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 3121829 SECTION 3 CHASSIS amp TURNTABLE NOTE speed sensor port the cover 21 should be 180 from the brake release port in the pressure plate 3 1 Capscrew 7 Piston 13 Rotor Disc 19 Retaining Ring 2 Washer 8 O ring 1
129. JLG Lift 1 15 SECTION 1 SPECIFICATIONS 1 16 Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE Torque Torque Lub OR Loctite amp Size PITCH Clamp Load Dry or Loctite 2427 or 271 263 OR 13 17 16 _ 80 NENNEN T o set a om pne wo ow om o pw om om 192 1195 95 35 ms 1525 1890 75 668 353 2200 s Lx s x eme ome onm 3 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 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 JLG Lift 3121829 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by t
130. L8 0018U5NIMS S IVO SEV 509 S IVO 4 L8 0018 S IVO 4 SEV 5091 S IVO 440 MS ODNIMS STVO 3NIHOVI 9 sseooy Ajuo 30 500191411 STVO 3NIHOVI sseooy ul CE S0 08l3IT STVO ANIHOVI 505 0019 i9 STVO 129 STVO WHHTIOHIL 08 0018MO IJ Id 51 2 441 51 VO YATTI InOLnO sAINd TISGOW 06 gp ON 0 ON 0 SHA T dNLas 4 qvo wuviv wuoaivid dunous grr 2 100100 HONOLLAOS 6199 6 19 JLG Lift 3121829 SECTION 6 JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure the next outer level The LEFT RIGHT arrow keys move between items in the same level The UP DOWN arrow In the following structure descriptions an intended item is keys alter a value if allowed selected by pressing ENTER pressing ESC steps back to Table 6 5 DIAGNOSTICS Menu Descriptions DRIVE DRIVE Displays drive joystick direction amp demand
131. MATICS 7 3 MULTIMETER BASICS nal and the lead on the other port goes to the positive side of the signal A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment This Scale section shows diagrams of a common digital VOM con figured for several different circuit measurements Instruc M Mega 1 000 000 Displayed Number tions for your VOM may vary Please consult the meter k kilo 1 000 Displayed Number operator s manual for more information m milli Displayed Number 1 000 Grounding micro Displayed Number 1 000 000 Grounding the meter means to take the black lead Example 1 2 1200 O which is connected to the COM common or negative Example 50 mA 0 05 A port and touch it to a good path to the negative side of the Voltage source Voltage Measurement 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 Itis possible to inspect a c
132. ME 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 1 14 JLG Lift 3121829 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M5 Torque Torque Lub OR Loctite amp Torque enste Clamp DryorLoctite8 242 or 271 OR Loctite 2627 OR Size PITCH Stress TM i A Nea Load 263 111 or Vibra TITE 131 K 0 20 140 K 0 15 5 03 3 13 5 2 2142 __4 o7 se 5 1420 rs Lu d EX 7 115 830 24 353 2220 _ 1065 960 6 4 2 45 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 8 Torque Chart METRIC Fasteners Sheet 6 of 7 3121829
133. N URP PR IR b oe 5 10 5 15 Level Cylinder 1 5 11 5 16 Level Cylinder amp AJP 5 12 5 17 uuu ue u Re do d dU 5 13 s dace doceo eo b M IRE D e UH d odio o do ES Se dae b Ead 5 14 51 Upper EM CYINAEF 5 tn atu d es di o ead bcd dit a el de plo o d 5 15 5 20 Master Cylinder 5 5 16 5 21 Master Cylinder Models a 444 fies ae oboe Fac Vote RR YA acd 5 17 5227 VICO u s So 5 18 529 Telescope OyliRger s ovde Re icu 5 19 524 Jib VaWE EOCAION dm 5 22 5 25 Brake Steer Valve 5 23 5 26 Main Valve Components Prior to S N 62642 5 24 5 27 Main Valve Components S N 62642 to 5 25 6 1 Control Module 6 1 6 2 Analyzer Flow Chart Software Version 3 x Sheet 1 6 17 6
134. NG CAP SCREWS Figure 5 4 Tapered Bushing Removal Screw the piston CCW by hand and remove the piston from cylinder rod Hemove 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 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage 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 5 5 SECTION 5 HYDRAULICS 10 11 12 13 14 15 16 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 Inspect cylinder head inside diameter for scoring or other damage and for
135. NG ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1 INCH 2 54 CM BELOW THE MAIN BOOM IF WORKING ON LOWER BOOM LIFT CYLINDER RAISE LOWER BOOM HALFWAY FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT LEAVING APPROXIMATELY 1 INCH 2 54 CM OF SLACK IN CHAIN OR SLING FOR TEST PURPOSES 2 When working on the platform slave cylinder stroke platform slave level cylinder forward 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
136. ONTROL SYSTEM 6 1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS lt POWER MODULE V GENERATOR CONTROL MODULE POSITRAC TILT MODULE Figure 6 1 Control Module Location Introduction NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC NOTICE TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CON CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC TROLLER FOR THE PROPER MACHINE CONFIGURATION INCLUD OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A ING OPTIONS 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 3121829 JLG Lift 6 1 SECTION 6 JLG CONTROL SYSTEM The JLG designed Control System is a 48 volt based To Connect the JLG Control System Analyzer motor control unit installed on the boom lift 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 nect the remaining end of the cable to the analyzer 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
137. OT Do the Following When Welding on JLG Equipment Ground on frame and weld on any other area than the chassis Ground on turntable and weld on any other area than the turntable Ground on the platform support and weld on any other area than the platform support Ground on a specific boom section and weld on any other area than that specific boom section Allow pins wear pads wire ropes bearings gearing seals valves electrical wiring or hoses to be between the grounding position and the welded area FAILURE COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COMPONENT DAMAGE I E ELECTRONIC MODULES SWING BEARING COLLECTOR RING BOOM WIRE ROPES ETC JLG Lift 2 5 2 Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Deliverv 4 ES Pants Ni Weary Eve 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 3 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 15 Lanyard Anchorage Point 2 1 2 10 1 2 10 Turntable Assem
138. Pin Assignments 3 65 3 10 ABS Alarms andFlash amp odGeSs Fc tm e itle ap e x weak Sie wa ons 3 68 3 11 TROUDIGSNOOUAG etat ua TD en aod a enu 3 69 4 1 Wear Pad Thickness 4 7 4 1 TWOUDIGSNOOUING 4 27 5 1 Cylinder Head Tapered Bushing Torque 5 5 9 5 2 Cylinder Piston Nut Torque Specifications 5 9 5 3 Holding Valve Torque Specifications 5 9 5 4 Pressure Settings Prior to S N 0300062642 5 22 5 5 Pressure Settings S N 0300062642 to Present 5 22 6 1 Porsonality Rariges Derdllls s Oe 6 6 6 2 Machine Setup 5 6 9 6 3 JLG Control System Flash 5 6 10 6 4 Help Descriptions and Fault Flash Codes 6 11 6 5 DIAGNOSTICS Menu 6 20 6 6 System Test 6 22 6 7 System Test 6 23 6 8 D
139. RIVE amp BOOM PREVENTED FUNCTION CUTOUT ACTIVE Drive or a boom function is selected while function cutout is active and configured to cutout all functions DRIVE PREVENTED ABOVE ELEVATION Drive is selected while above elevation and drive cutout is configured to prevent drive DRIVE PREVENTED BOOM 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 config ured to prevent drive DRIVE PREVENTED TILTED AND ABOVE ELEVATION Drive is selected while drive cutout is active and drive cutout is configured to prevent drive TILT MODULE FAILURE NOT COMMUNICATING There is a problem with the positrac tilt module the controller defaults to massively tilted and does not try to prevent vehicle roll on the grade 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 not increase to battery supply this occurs if the line contactor coil wiring is swapped with that for a direction contactor coil OPEN CIRCUIT FORWARD DIRECTION CONTACTOR OR TRACTION MOTOR Traction point A did not go high when forward contactor was energized this coul
140. S 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 bank to 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 S C The named contactor coil overloaded its driver circuit so is presumed to be short circuit Check contactor wiring contname DIDN T CLOSE The named contactor appears to have not closed Check contactor wiring Check power wiring CONT TEST DONE Indicates that the contactor test is complete with or without faults 6 24 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 7 System Test Messages CHECKING INPUTS Indicates thatthe inputs test is beginning Every inputis checked to ensure thatitis in its normal position function switches should be open cutout switches should be closed joysticks should be in neutral In platform mode inputs are tested in the order UL U UL D UL JOY SWINGL SWING R SWING JOY LEVEL U LEVEL D PUMP POT ROTATEL ROTATE R LL U LL D JIB U JIB D TELE TELE DRIVE FWD DRIVE REV DRIVE JOY STEERL 5 POSITRAC DRIVE C O ELEV C O FUNC C O BRAKE PRES In ground m
141. S 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 3121829 JLG Lift 1 13 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque Loctite amp Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or Tensile Torque Size PITCH Stress Dry or Loctite Area 2637 f sos 5 03 5 1420 618 62 46 56 68 d 584 Ak mg C L5 3650 19 23 12 175 8430 367 79 97 _ as MN NN 5 1e p 25 on _ 245 426 320 383 469 3 as s se we ms 38 35 694 3020 1990 1490 29 36 4 817 3555 2560 1920 290 260 42 45 1120 4870 400 300 420 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SA
142. S 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 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 2 Unplug the left speed sensor from the posi trac tilt module 10 11 12 13 14 15 16 17 3 16 JLG Lift 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 Use the right and left cursor keys to display SPEED 0 on the analyzer While watching the analyzer display select drive for ward Be ready to remove 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 2096 FWD when forward is selected at the platform The percentage
143. S TO AVOID ENTRY OF CON TAMINANTS b 3121829 INTO SYSTEM Tag and disconnect hydraulic lines from boom to control valve Use a suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports Using a suitable lifting equipment adequately support boom weight along entire length Remove hardware securing the lift cylinder pin 1 Using a suitable brass drift and hammer remove pin 1 from the base boom e Remove hardware securing the master cylinder pin 2 Using a suitable brass drift and hammer remove pin 2 from the base boom f Remove hardware securing the base boom pin 3 Using a suitable brass drift and hammer remove pin 3 from the upright g Using all applicable safety precautions carefully lift boom assembly clear of upright and lower to ground or suitable supported work surface Figure 4 1 Location of Components Boom Removal Disassembly Boom Sections 1 JLG Lift Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments Using a portable power source attach hose to tele scope oylinder port block Using all applicable safety precautions activate hydraulic system and extend cylinder to gain access to cylinder rod pin 1 Shut down hydraulic system Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After initial d
144. S 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 3121829 Priming the Fuel Line 5 The following procedure is for re priming the fuel line 6 the generator engine in the event fuel system components have been replaced or the unit has been run dry of fuel 7 1 Make sure the fuel line isn t blocked or kinked 2 Make sure fuel tank has fuel 8 3 Disconnect the rubber fuel line at the fuel injector 9 10 4 When fuel starts to flow out of the rubber line connect the fuel line to the fuel injector pump 3121829 JLG Lift SECTION 3 CHASSIS amp TURNTABLE 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 fuel 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 sp
145. SSURE SETTING PROCEDURES Cold temperatures have a significant impact on pressure readings JLG Industries Inc recommends operating the machine until hydraulic system has warmed to normal operating temperatures prior to checking pressures We also recommend using a calibrated gauge Pressure read ings are acceptable if within 5 of specified pres sures Main Relief 1 Install pressure gauge at port G on Steer Brake valve 2 Activate and bottom out either Upper or Lower Lift Up Adjust Main Relief to value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Upper Lift Down Relief 1 With pressure gauge at G port on main valve acti vate and bottom out Upper Lift Down 2 Adjust Upper Lift Relief to value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Lower Lift Down Relief 1 With pressure gauge at G port on main valve acti vate and bottom out Mid Lower Lift Down 2 Adjust Mid Lower Lift Relief to value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Telescope Relief 1 With pressure gauge at G port on main valve acti vate and bottom out Telescope In 2 Adjust Telescope Relief to value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure
146. STARTER MOTOR LOW OIL PRESSURE SWITCH FUEL 5108 SOLENOID 128 501120 4 109 ENGINE OIL Terres 1 TEMPERATURE 28 SENSOR 118 E o3 ENGINE GRD BLK 137 35 V OUTI BRN 112 113 ux x aM DOS SS SS SEE 20 DIESEL ENGINE HEATER GLOW PLUG OB GLOW PLUG I MENSES 30 x 9 Aes 19 GAS ENGINE CHOKE SOLENOID 25 81 81a RELAY AE so ERE 1 Nu P O ERU Figure 7 24 Electrical Schematic Sheet 5 of 6 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS SEE SHEET 1 125 114 109 108 21 128 SEE SHEET 118 12 129 130 131 SEE SHEET 133 gt SEE SHEET I 135 137 114 117 13 134 116 106 120 SEE SHEET 136 i l5 0 esq 9 116 YANMAR ENGINE INTAKE AIR HEATER UAI23 EM J2 PLUG ASSEMBLY GENERATOR CONTROL MODULE 04 12 13 14 5 16 17 18 19 20 Po Po Q
147. Settings S N 0300062642 to Present Platform Level Up Relief 1 On machines prior to S N 0300062642 install the pressure gauge at the G port on Main Control valve activate and bottom out Platform Level Up On machines S N 0300062642 to present install the pressure gauge at the B2 port on the back of the Main Control Valve activate and bottom out Platform Level Up 5 C CO amr UA SF Mu 2 Adjust Platform Level Up Relief to value given in 5 20 JLG Lift Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present 3121829 Platform Level Down Relief 1 On machines prior to S N 0300062642 install the pressure gauge at the G port on Main Control valve activate and bottom out Platform Level Down On machines S N 0300062642 to present install the pressure gauge at the B1 port on the back of the Main Control Valve activate and bottom out Platform Level Down NN 60
148. TION IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED IN EXCESS OF 200 F 93 3 C SEALS IN THE SYSTEM CAN SHRINK HARDEN OR CRACK THUS LOSING THEIR SEALING ABILITY 3121829 JLG Lift 3 21 SECTION 3 CHASSIS amp TURNTABLE Table 3 3 Swing Motor Troubleshooting Trouble Cause Oil Leakage 1 Hosefittings loose worn or damaged 2 Oilsealrings 4 deteriorated by excess heat Special bolt 1 1 A 1B or 1C loose orits sealing area deteriorated by corrosion 4 Internal shaft seal 16 worn or damaged 9 Worn coupling shaft 12 and internal seal 16 Remedy Check amp replace damaged fittings or O Rings Torque to manufacturers specifications Replace oil seal rings by disassembling unit a Loosenthen tighten single boltto torque specification b Replace bolt Replace seal Disassembly of motor unit necessary Replace coupling shaft and seal by disassembling unit Lack of sufficient oil supply oignificantloss of speed under load High internal motor leakage Severely worn or damaged internal splines Excessive heat Low mechanical efficiency or undue Line blockage high pressure required to operate unit Internal interference Lack of pumping pressure 4 Excessive binding orloading in system external to motor unit a Check for faulty relief valve and adjust or replace as required b Checkfor and repair worn pump c Checkfor and use correctoil for
149. TION PREVENTED SELECTED BEFORE EMS Function was CLOSED at power up 321 32 LINE CONTACTOR WELDED OR MISWIRED The capacitor bank charge did not decrease from battery supply when line contactor was de energized this could be caused due to a power wiring error 325 32 LINE amp DIRECTION CONTACTORS MISWIRED When the line contactor was closed traction point A went HIGH andthe capacitor bank charge did notincreaseto battery supply this occurs if the line contactor coil wiring is swapped with that for a direction contactor coil 33300 33 LINE CONTACTOR COIL OPEN CIRCUIT The capacitor bank did not increase to battery supply when the line contactor was CLOSED 33301 33 LINE CONT ACTOR COIL SHORT TO GROUND Line contactor was not energized when required due to over cur rent protection 33361 33 DIRECTION CONTACTOR COIL OPEN CIRCUIT Traction point is collapsing when the traction MOSFETs are pulsed This maybe dueto an open circuittraction motor or power wiring error 3121829 JLG Lift 6 29 SECTION 6 JLG CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash DTC Code Fault Message Description 33364 33 FORWARD CONTACTOR COIL OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized This maybe due to an open circuit traction motor or power wiring error 33369 33 REVERSE CONTACTOR COIL OPEN CIRCUIT Traction point
150. TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS 1 H the housing 18 bearing components were removed for replacement thoroughly coat and pack a new outer bearing bushing 19 with clean corro sion resistant grease recommended in the material section Press the new bearing bushing into the counterbore at the mounting flange end of the hous ing using the appropriate sized bearing mandrel as described which will control the bearing bushing depth The housing requires the use of bearing mandrel to press bearing bushing 19 into the housing to a required depth of 0 151 0 161 inches 3 84 4 09 mm from the end of the bearing counterbore NOTE Bearing mandrel must be pressed against the tered end of bearing shell Take care that the hous ing bore is square with the press base and the bearing bushing is not cocked when pressing a bearing bushing into the housing 3121829 SECTION 3 CHASSIS amp TURNTABLE CAUTION IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE METHODS ARE USED TO PRESS IN BEARING BUSHING 13 AND 19 THE BEARING BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADEQUATE BEARING SUPPORT AND COR RECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN ASSEMBLED RU UE yu TUHIN CAUTION BECAUSE THE BEARING BUSHINGS 13 AND 19 HAVE PRESS FIT INTO THE HOUSING THEY MUST DISCARDED WHEN REMOVED THEY MUST NOT BE REUSED 2 The inner housing bearing bushi
151. 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 SECTION 3 CHASSIS amp TURNTABLE 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 9 Controller Interface Pin Assignments PIN FUNCTION 1 System 48VDC 2 system OV DC 3 Fuel solenoid 4 Starter Solenoid 5 Manual call to start 6 Low oil pressure 7 Not used 8 Engine oil temperature 9 opeed sensing input 10 RS 232 12V 11 RXD 12 TXD 13 LED Driver GND 14 LED Driver 48V 15 Speed sensor GND 16 Notused 17 Notused 18 Output voltage 19 Engine oil temperature ambienttemp 8V 20 Speed Sensing 8V 21 Output current sensor GND 22 Not used 23 RS 232 GND 24 Field drive 25 4 Star
152. VAC at the charger 2 Ifthe AC voltage is verified to be correct at the con nection to the charger and the charger still displays no lights at all return the charger for service FAULT LED FLASHING The Fault LED flashes to indicate the microcontroller inside the battery charger has detected a fault The fault detected is indicated by the number of flashes Count the number of flashes to determine the fault With any battery system the most common problem will be a faulty battery connection Because of the high likeli hood of a battery connection problem it is always worth while to confirm that all connections are good before checking for any other problems 1 Flash High Battery Voltage 1 Indicates a high battery voltage Check that the bat tery charger voltage is consistent with the battery pack voltage The first two digits of the four digit model name indicate the battery voltage the charger supports 2 Check for wiring errors 3 This fault will automatically clear and the charger will restart charging when this problem is removed 4 High battery voltage could also occur if there is another source charging the battery Disconnect any other sources during charging 5 If this problem does not clear after the battery volt age is confirmed to be less than 2 4V per cell return the charger for service 2 Flashes Low Battery Voltage 1 Indicates either a battery failure no battery con nected or a lowe
153. WER LIFT DOWN PERMANENTLY Input was CLOSED during startup SELECTED 2259 22 FUNCTION PROBLEM DRIVE FORWARD PERMANENTLY Input was CLOSED during startup SELECTED 2260 22 FUNCTION PROBLEM DRIVE REVERSE PERMANENTLY Input was CLOSED during startup SELECTED 2261 22 FUNCTION PROBLEM MULTIPLE SWITCHES PERMANENTLY Input was CLOSED during startup SELECTED 2262 22 FUNCTION PROBLEM PLATFORM LEVEL UP PERMANENTLY Input was CLOSED during startup SELECTED 2263 22 FUNCTION PROBLEM PLATFORM LEVEL DOWN PERMA Input was CLOSED during startup NENTL Y SELECTED 2264 22 FUNCTION PROBLEM DOS DOWN PERMANENTLY SELECTED Input was CLOSED during startup 2265 22 FUNCTION PROBLEM POSI DOWN PERMANENTLY SELECTED Input was CLOSED during startup 2266 22 LIFT SWING JOYSTICK FAULTY Joystick was out of the Neutral position during startup 226 22 DRIVE STEER JOYSTICK FAULTY Joystick was out of the Neutral position during startup 2268 22 JOYSTICKS FAULTY Both Joysticks are faulty or one joystick is faulting the 5 volt sup ply to both joysticks 23 6 23 SWING SWITCH FAULTY Both states actively HIGH in Ground Mode 2387 23 JIBLIFT SWITCH FAULTY Both states actively HIGH 2308 23 JIB SWING SWITCH FAULTY Both states actively HIGH 2309 23 PLATFORM ROTATE SWITCH FAULTY Both states actively HIGH 2390 23 TELESCOPE SWITCH FAULTY Both states actively HIGH 2391 23 MAIN LIFT SWITCH FAULTY Both states actively HIGH 2392 23 TOWER LIFT SWITCH FAULTY Bot
154. a 1 2 1 7 Hydraulic Pump Electric Motor Assembly 1 2 1 8 d 1 2 1 9 FUNGCUON OPECS x ce derat aer nei ne bd heed toe et eee he 1 2 1 10 PIOSSUIC SCUINOGS 2 2 oy ahaa 1 3 1 11 3 ex E gu eke ne de ewe eA 1 4 1 12 EUIDMGAON SDeCHICAIIONS s a ades cedes saree eee Tc tee a ew aina 1 4 tae eee pas zs hrs eee ede ars 1 4 13 Stability 1 4 14 2a Bt ok W u hae eee a 1 5 1 15 Major Component 1 5 16 Serial N mber Locations es x emo as MCN oe t edd 1 5 17 Operator Maintenance Lubrication 1 7 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 oes Gah el te 2 1 Preparation Inspection and Maintenance 2 1 Pre Start 2516 2194181 s un 2 1 Pre Delivery
155. ade for open and short circuit valve coils The valves are tested in the order PROP main proportional LL U LL D ULU UL D SWINGL SWING SWING REST LEVEL U LEVEL D ROTATE L ROTATE JIB U JIB D TELE TELE BYPASS STEER L STEER STEER PROP BRAKE NOTE platform mode the footswitch must be closed NOTE jib valves are not tested if JIB NO 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 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 test is 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 positrac contactors are energized and de energized checks are made for short circuit and open circuit coils Problems which can be reported include CANT TEST CONT
156. ag 3 53 TIMING SEQUENCES usse xao REED E eer epe bcd boe aus 3 55 To Connect the JLG Control System Analyzer to the Generator 3 56 Alarms and Fault Flash Codes 3 56 Output Current and Voltage Settings 3 58 PRIMING Ine Eel Ene d dd 3 59 3 13 Generator S N 88539 to Present 3 60 Fili 3 60 cott dm ME eh Oe 3 60 Dynamo and Dynamo Voltage 3 60 Dynamo OUMU FUSE d ete am 3 60 3 60 olal Bale aao rset 3 62 Engine Slater codd tee irae 3 62 Start Control CLAY csc aeo uten Sra 3 62 ruel Gontol Helay iu mee bo Ex Pad ew Exe 3 63 Glow Plug Gonmol Relay 331 dio v 3 63 llo te 3 63 RSW UND ati a cen dem 3 64 3 64 Engine Low Oil Pressure
157. al component not subject to further disassembly for service Compare configura tion of both sides of the manifold to ensure that same surface is reassembled against the rotor set Remove drive link 10 from coupling shaft 12 if it was not removed with rotor set and wear plate Inspect drive link for cracks and worn or damaged splines No perceptible lash play should be noted between mating spline parts Remove and discard seal ring 4 from housing 18 mi 3 27 SECTION 3 CHASSIS amp TURNTABLE 12 Check exposed portion of coupling shaft 12 to be keyway Replace coupling shaft if any of these con sure you have removed all signs of rust and corro ditions exist sion which might prevent its withdrawal through the seal and bearing Crocus cloth or fine emery paper may be used 13 Remove coupling shaft 12 by pushing on the out put end of shaft Inspect coupling shaft bearing and seal surfaces for spalling nicks grooves severe wear or corrosion and discoloration Inspect for damaged or worn internal and external splines or NOTE Minor shaft wear in seal area is permissible If wear exceeds 0 020 inches 0 51 mm diametrically replace coupling shaft NOTE A slight polish is permissible in the shaft bearing areas Anything more would require coupling shaft replacement 14 Remove and discard seal ring 4 from housing 18 3 28 JLG Lift 3121829 15 Remove thrust bearing 15 and thrust washer
158. ar plate stationary 6 Remove the two assembled bolts 1 if used to retain stator and wear plate Go to assembly procedure 15 to continue assem bly 3121829 JLG Lift 3 37 SECTION 3 CHASSIS amp TURNTABLE Two Piece Stator Construction A disassembled rotor set 8 that cannot be readily assem bled by hand and has a two piece stator can be assem bled by the following procedures 1 NOTE Place stator half onto wear plate 9 with seal ring 4 side down after following motor assem bly procedures 1 through 13 Be sure the seal ring is in place Align stator bolt holes with wear and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary Assemble rotor counterbore down if applicable into stator half and onto wear plate 9 with rotor splines into mesh with drive link 10 splines Use any marking you applied to rotor set compo nents to reassemble the components in their original relationship to ensure ultimate wear life and perfor mance Assemble six vanes or as many vanes that will read ily assemble into the stator vane pockets A CAUTION EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA TOR VANE POCKETS 5 3 38 Grasp the output end of coupling shaft 12 with locking pliers or other appropriate turning device and ro
159. arm sounds continuously during an overload condition 13 Remove weight from the basket 14 Adjust P2 until the load 096 15 Place 455 LBS in the center of the basket 16 Adjust P1 until the load 100 17 Remove weight from the basket 4 12 18 Seal potentiometer with fingernail polish Torque to 54 N M 40 LB FT Transducer Figure 4 11 Load Sensing System 4 10 SYNCHRONIZING PROCEDURE NOTE If the Lower Boom assembly does not fully lower 1 2 Remove all personnel from the platform Pull the red knob located under the main control valve From Ground Control activate the lift control switch raise Lower Boom 6 feet 1 8m After raising Lower Boom release the red knob Activate Lower Boom Down fully lower boom Repeat step 1 thru 5 if necessary 4 11 FOOTSWITCH ADJUSTMENT Adjust switch so that functions will operate when pedal is at center of travel If switch operates within last 1 4 inch 6 35 mm of travel top or bottom it should be adjusted JLG Lift 3121829 SECTION 4 amp PLATFORM 4 12 Theory Of Operation Tools Required for Assembly Disassembly Upon assembly and disassembly of the actuator there are basic tools required The tools and their 3121829 The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into pow
160. ass MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C MPG may be substituted for these lubricants if necessary but service intervals will be reduced LUBRICATION INTERVALS BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRON MENTS OR CONDITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY 1 Swing Bearing Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access 3121829 SECTION 1 SPECIFICATIONS 2 Swing Bearing Worm Gear Teeth Lube Point s 2 Grease Fittings Capacity Spray On Lube Mobiltac 375NC Interval A R Comments necessary install grease fittings into worm gear housing and grease bearings DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL RESULT IN BLOWING OUTER SEAL IN HOUSING Lube Point s Fill Cap Capacity 4 Gal 15 1 L Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation Comments On new machines those recently over hauled or after changing hydraulic oil operate all systems a minimum of two complete cycles and recheck oil level in reservoir JL G Lift 1 27 SECTION 1 SPECIFICATIONS 4 Hydraulic Return Filter oy Interval Change after first 50 hrs and every 6 months or 300 hrs th
161. ave cylinder not functioning properly Electrical failure Orifice plugged JLG Lift Run System Test Clean repair or replace line or fitting Repair or replace cylinder See proper wiring diagram Run System Test Clean orifice 3121829 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION SCHEMATICS Table 7 1 Platform Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered Check wiring Run System Test Personalities not set correctly Check settings JLG Lift 7 3 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 2 Boom Assembly Troubleshooting TROUBLE Valve spool sticking Valve leaking No responseto lift control switch Joystick 7 4 PROBABLE CAUSE CONTROL VALVES Dirt in oil causing excessive temperature build Up Moisture in oil Incorrect valve mounting causing warping of the unit Valve spool scored Tie bolts in valve over torqued Return spring weak or broken Relief valve malfunctioning causing excessive pressure within valve Dirt or other foreign material under seal Valve spool scored Excessive back pressure caused by restricted return line to reservoir Damaged valve seals BOOM ELEVATION SYSTEM Liftfunction not activated within 7 seconds after footswitch was depressed Lift control switch inoperative Lift cylinder holding valve inope
162. 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 Silicone grease should be applied at the time and location of the final connection of the pins into the housings and plugs into receptacles This will mini mize exposure to the elements as a lubricated wet connector 4 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 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 6 CONNECTOR Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent oxidation and low level conductivity sili cone dielectric grease must be packed complete
163. bly 9 Swing Bearing or Worm Gear 1 2 14 1 2 3 13 14 Oil Coupling 9 Swing Drive System 11 11 Turntable Lock 1 2 5 1 2 9 Hood Hood Props Hood Latches D 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 9 8 Outrigger or Extendable Axle Systems 9 0 9 0 Steer Components Drive Motors Drive Hubs 11 11 Functions Controls 9 Platform Controls 5 5 6 6 2 6 JLG Lift 3121829 2 Table 2 3 Inspection and Preventive Maintenance Schedule INTERVAL Deliverv 4 pesmi she Maintenance Maintenance nspection Inspection Ground Controls 5 5 6 6 Function ControlLocks Guards or Detents 1 5 1 5 5 5 Footswitch 1 5 5 5 Emergency Stop Switches Ground amp Platform 5 5 9 Function Limit or Cutout Switch Systems 5 5 5 Capacity Indicator 5 Drive Brakes 9 Swing Brakes 9 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 1 9 7
164. chanical 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 3 62 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE Fuel Control Relay Glow Plug Control Relay 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 The heater is energized by the glow plug control relay 3121829 JLG Lift 3 63 SECTION 3 CHASSIS amp TURNTABLE Fuel Pump Engine Low Oil Pressure Switch The fuel pump runs in parallel with the fuel solenoid hold coil 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 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 p
165. ckname direction TO MIN The named joystick should be returned to neutral from the named direction PUMP POT TOMAX The pump pot should be turned to maximum PUMP POT TOMIN The pump pot should be turned to minimum MULTIPLE CLOSURE More than one operator input is closed if only one has been operated there could be a short between two inputs TESTS COMPLETE Indicates that the system testis complete Any problems reported should have been noted and should now be rectified Press ESC to return to the RUN SYSTEM TEST Analyzer menu 6 26 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash T DTC Code Fault Message Description 001 00 EVERYTHING The normal help message in platform mode 002 00 GROUND MODE OK The normal help message in ground mode 0010 00 RUNNING AT CUTBACK OUT OF TRANSPORT POSITION Drive speed is limited to ELEVATED MAX while the vehicle is out of transport position 0011 00 FSW OPEN A drive or boom function has been selected but footswitch is open 0012 00 RUNNING AT CREEP CREEP SWITCH OPEN All function speeds are limited to creep because the creep switch is open 0013 00 RUNNING AT CREEP TILTED AND ABOVE ELEVATION All function speeds are limited to creep because the vehicle is tilted and above elevation 0032 00 PUMP MOTOR AT CURRENT LIMIT Pump current has reached cont
166. ctuated 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 the 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 21 7 22 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 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 switc
167. d be due to traction motor open circuit or a power wiring error OPEN CIRCUIT LINE CONTACTOR OR TRACTION MOTOR 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 DIRECTION CONTACTOR Traction point A did not go high when reverse contactor was energized this could be due to traction motor open circuit or a power wiring error 3 2 Flash code 3 2 indicates that a contactor did not open when energized 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 3121829 JLG Lift 6 13 SECTION 6 JLG CONTROL SYSTEM 6 14 3 3 3 5 4 2 4 4 9 5 Table 6 4 Help Descriptions and Fault Flash Codes Flash code 3 3 indicates that a contactor coil is short circuited OVERLOADED VALVE SUPPLY CHECK WIRING There is high current draw from the valve supply when no valve is energized this is probably due to a wir ing error at the 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 overcur
168. d 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 JLG Lift 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 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 CT
169. d 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 protection 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 JLG Lift 3 53 SECTION 3 CHASSIS amp TURNTABLE CONTROL FUSE OIL FILTER
170. did not charge in the Charge allowed time This could occur if the batteries 3 are a larger capacity than the algorithm is intended for or if the batteries are damaged old or in poor condition Indicates the batteries could not be trickle 4 Check battery charged up to the minimum voltage per cell level required for the charge to be started Over Auto recover Indicates charger has shut temperature down due to high internal temperature Indicates that the battery will not accept charge current or an internal fault has been detected in the charger This fault will nearly always be set within the first 30 seconds of operation Once ithas been determined that the batteries and connections are not faulty and fault 6 is again displayed after interrupt ing AC power for at least 10 seconds the charger must be broughtto a qualified service depot 6 QuiQ fault 3121829 SECTION 3 CHASSIS amp TURNTABLE 1 ACVoltage InputCable 3 Power Cable to Batteries 2 ChargerlnterlockCable 4 LED Indicator Cable Figure 3 19 Battery Charger S N 0300059350 to Present 3121829 JLG Lift 3 49 3 50 SECTION 3 CHASSIS amp TURNTABLE NO LIGHTS ALL No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low It could also indicate an internal failure in the charger 1 Check the connections to AC power Check for AC voltage between 90 and 260
171. drain ora very low battery volt age 6 30 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash DTC Code Fault Message Description 7 6 77 STALLED PUMP MOTOR OR POWER WIRING ERROR The power module pump MOSFET protection circuit is active This is due to a massive current drain and could be a stalled pump motor or a power wiring error 777 77 OPEN CIRCUIT PUMP MOTOR WIRING Pump point A is collapsing when the pump MOSFETS are pulsed this maybe due to an OPEN circuit pump motor or a power wiring error 7734 77 TRACTION A HIGH CHECK POWER CIRCUITS Traction point A is near battery supply when neither direction con tactor is energized and the traction MOSFETS are OFF this maybe due to a welded direction contactor or a power wiring error 7735 77 TRACTION A LOW CHECK POWER CIRCUITS Traction point is near ZERO volts when neither direction contac toris energized and the traction MOSFETs are OFF this maybe due to a power wiring error 7136 77 TRACTION MOTOR OVERLOADED The traction motor has been operating in current limit at alow per centage on for along time greater than 10 seconds 7737 77 MOTOR OVERLOADED The pump motor has been operating in current limit at a low per centage on for along time greater than 10 seconds 7738 77 PUMP A LOW CHECK POWER CIRCUITS Pump point A is near ZERO volts whe
172. dreplace with recommended oil Refer to Hydraulic Oils Leak in component line or fitting Repair or replace component line or fitting Scored valve spool scored cylinder Replace valve replace cylinder Hydraulic Filter clogged Replace filter Amperage too low on controller Correctly adjust controller Low voltage in electrical system Correct low voltage problem System s operate erratically Sticking or binding valve spools pistons Clean repair or replace components as required 7 16 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE No power to platform controls Starter will not crank Travel warning horn inoperative 3121829 PLATFORM CONTROLS 15 Amp self reset circuit breaker open Contact block in footswitch malfunctioning Faulty power circuit wiring Platform EMS or Ground EMS switch in wrong position ENGINE STARTER SYSTEM GENERATOR Discharged battery or loose battery terminals otarter relay faulty or faulty relay connections Malfunctioning starter solenoid or motor Malfunctioning manual start switch Faulty ignition and or starter circuit wiring Faulty start switch INSTRUMENTS AND INDICATORS Machine set up incorrect Damaged wiring in horn circuit Damaged horn JLG Lift Table 7 6 Electrical System Troubleshooting PROBABLE CAUSE REMEDY Check footswitch to ensure
173. e 1 Perform the first oil change after approximately 150 hours Subsequent changes every 1500 hours or annually whichever occurs first NOTE Flush the drive before filling with new Setting of Tapered Roller Bearings NOTE The numbers in parentheses reference the figure Drive Hub Cutaway De grease threads of the spindle 60 and shaft nut 4 Spin the shaft nut onto spindle by hand to insure the threads are in good condition Apply Loctite 270 evenly to threads of the shaft nut Rotate the support ring repeatedly in one direction only during setting of the tapered roller bearings Tighten shaft nut to 626 ft Ibs 850 Nm Do not use the hub for 24 hours to allow the Loctite to harden properly Do not fill with oil for 24 hours to allow the Loctite to harden properly Securing of the Shaft Nut 1 JLG Lift After proper bearing setting is completed use a suit able punch to place ball 24 0 04 to 0 05 inches 1 1 to 1 3 mm into the spindle thread Then set ball 24 in position by punching in expander 25 3121829 SECTION 3 CHASSIS amp TURNTABLE 3121829 a LX INI Sun Gear Shaft Nut Planet Bolt support Ring Planet Carrier Cover Not Used Roller Bearing Roller Bearing Tapered Roller Bearing Not Used Retaining Ring Retaining Ring Retaining Ring Support Disc Not Used
174. e 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 Ibs 21 1 Nm Insert the first stage planetary assembly 7 into drive Install o 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 2 us gallons 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 3 6 Maintenance Daily Check for oil leakage Weekly Check oil level Monthly Check mounting bolt torque Oil Change Interval Gear Driv
175. e This side faces the solid seal See magni fied insert in Figure 5 9 The split of seals and 3121829 JLG Lift 5 SECTION 5 HYDRAULICS 12 13 5 8 screws through the drilled holes the bushing and into the tapped holes in the piston PISTON TAPERED CAP SCREWS Figure 5 10 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 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 JLG Lift b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON TAPERED BUSHING BRASS SHAFT Figure 5 11 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 9 Piston Seal Kit Installation PISTON REF Figure 5 12 Poly Pak Piston Seal Installation 3
176. e 4 Dry K 17 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 0 16 99894 oos LLL L P j J 618 00140 p LLL 0075 j J L a I EBENE 02500 00364 139 tt 6 omm ie T 7 20 124 03125 0 0580 5220 25 35 24 03750 0 0878 7900 40 80 5 75 50 20 04375 0 1187 10700 6 9 60 120 85 5 9 10 20 0500 0159 14400 10 15 9 10 9 120 130 155 18 05625 0 2030 18250 145 175 180 220 18 06250 0250 23000 205 245 320 380 16 07500 0 3730 33600 355 430 7 8 9 0 8750 0 4620 41600 515 70 48 660 45 620 570 680 1 8 1000 0 6060 51500 730 875 845 1015 1095 1310 12 11250 0856 77000 1225 1475 1855 12 1250 1030 96600 170 2325 1610 2190 1510 2055 138 6 1370 1 1550 104000 2025 2755 1905 2590 1785 2430 12 13750 1 3150 118100 2300 3130 2165 245 2030 2760 112 6 1500 1 4050 126500 2690 3660 250 3440 2370 3225 12 1500 15800 142200 3020 405 245 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO
177. e actua clearly indicate the timing marks between shaft and tor piston This will greatly simplify timing during assem 8 Every actuator has timing marks for proper engage ment 10 Remove the shaft 2 It may be necessary to strike C the threaded end of the shaft with a rubber mallet na 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 Le Hd 3121829 JLG Lift 4 17 SECTION 4 amp PLATFORM 12 To remove the piston 3 use a rubber mallet and a plastic mandrel so the piston is no damaged 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 4 18 JLG Lift 15 Remove the wear guides 302 from the end cap 4 and shaft 2 16 To remove the main pressure seals 205 it is easi est to cut them using a sharp razor blade being careful not to damage the seal groove 17 Remove the thrust washers 304 from the end _ 4 and shaft 2 3121829 SECTION 4 amp PLATFORM 18 Remove the wiper seal 304 1 from its groove in the Inspection end cap 4 and shaft 2 N 1 Clean all parts in
178. e flange end of the shaft with a rubber mallet until the gear teeth engage JLG Lift 13 Install 2 bolts in the threaded holes the flange Using a bar rotate the shaft in a clockwise direction until the wear guides are seated inside the housing bore 14 Install the stop tube onto the shaft end Stop tube is an available option to limit the rotation of an actua tor 15 Coat the threads on the end of the shaft with anti seize grease to prevent galling 3121829 16 Install the 204 back up ring 207 into the inner seal groove on the end cap 4 17 Thread the end cap 4 onto the shaft 2 end Make sure the wear guide stays in place on the end cap as it is threaded into the housing 1 18 Tighten the end cap 4 In most cases the original holes for the lock pins will line up SECTION 4 BOOM amp PLATFORM 19 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 20 Insert the set screws 113 over the lock pins Tighten them to 25 in lbs 2 825 Nm 3121829 JLG Lift 4 23 SECTION 4 amp PLATFORM Installing Counterbalance Valve Refer to Figure 4 14 Rotator Counterbalance Valve 1 4 24 Make sure the surface of the actuator is clean free of any contamination and foreign debris including old Loctite Mak
179. e loaded with programming algorithms for the specific batteries detailed in Table 3 4 Battery Algorithms NOTE Contact JLG if your specific battery model is not listed Each time AC power is applied with the battery pack not connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the Yellow Charging LED A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm 7 is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause To check change the charging algorithm 1 3 52 Disconnect the charger positive connector from the battery pack Apply AC power and after the LED test the Algorithm will display for 11 seconds To change the algorithm touch the connector to the battery s positive terminal for 3 seconds during the 11 second display period and then remove The Algorithm will advance after 3 seconds Repeat this procedure until the desired Algorithm is dis played A 30 second timeout is extended for every increment Incrementing beyond the last Algorithm will recycle back to the first Algorithm When the desired Algorithm is displayed touch the charger connector to the battery positive terminal until the output relay makes a clicking noise approx 10 sec onds The algorithm i
180. e 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 13 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 JLG Lift 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 210 bar and maintain pressure Remove the hydraulic line from the non pressurized side Continuous oil flow from the open housing port indicates interna
181. e the machine Service and Maintenance Manual and appropri ate JLG inspection form for performance of this inspec tion Reference the JLG Annual Machine Inspection Form and the Inspection and Preventive Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventive 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 Preventive Maintenance Schedule and the appropriate areas of this manual for servicing and mainte nance procedures The frequency of service and mainte nance must be increased as environment severity and frequency of usage requires 3121829 JLG Lift 2 1 2 Table 2 1 Inspection and Maintenance om oo
182. ear Ring 15 Rod Wiper 16 Locking Primer 17 Loctite 242 18 Loctite 222 Figure 5 20 Master Cylinder A Models JLG Lift 1883525 1683932 0 3121829 SECTION 5 HYDRAULICS 20 1683923 D 1 Loctite 2242 6 Piston 11 Not Used 16 O ring 21 Bolt 2 Locking Primer 7 Washer 12 Lock Ring 17 Wiper 3 Bolt 8 Head 13 Wear Ring 18 Seal 4 TaperedBushing 9 Barrel 14 BackupRing 19 Backup Ring 9 Bushing 10 CylinderRod 15 O ring 20 Seal Figure 5 21 Master Cylinder AJ Models 3121829 JLG Lift 5 17 SECTION 5 HYDRAULICS Wiper Spanner Nut Retaining Ring Lip Seal Wear Ring 6 BackupRing 11 Piston 16 Rod 7 O ring 12 WearRing 17 Rod 8 13 Seal 9 Barrel 14 O ring 10 Tube 15 O ring Figure 5 22 Steer Cylinder JLG Lift 3121829 SECTION 5 HYDRAULICS 1 Barrel 7 Bolt 13 Cap Seal 19 2 Rod 8 Plug 14 O Ring 20 3 Piston 9 Setscrew 15 Wear Ring 21 4 Head 10 Locknut 16 O ring 22 5 Spacer 11 RetainingRing 17 Rod Seal 23 6 Counterbalance Valve 12 Wear Ring 18 Wiper 24 Torque to 150 foot pounds 203 Nm Torque to 19 foot pounds 26 Nm Figure 5 23 Telescope Cylinder 3121829 JLG Lift Loctite 242 Not Used Fitting Cap O Ring Plug Bolt 25 Fitting 26 Cap 27 Lockwasher 1683798 SECTION 5 HYDRAULICS 5 5 PRE
183. earing Grease Grease fitting is on inside wall of inner race of bearing NOTE If Tribol Molub Alloy 936 Open Gear Compound or Mobilith SHC Bearing Grease are not available Multi Purpose Grease MPG can substituted however the service interval will be shorter e Using suitable lifting equipment install bearing rotation box assembly to frame with soft spot red 90 degree relative 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 NUTS AND BOLTS SINCE THE SWING BEARING 15 THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE IT IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED f Apply a light coating of Loctite 271 to the new bearing bolts and loosely install the bolts and washers through the frame and outer race of bearing JLG Lift 3 41 SECTION 3 CHASSIS amp TURNTABLE ft 16 175 Nm Then following the same CAUTION sequence tighten the bolts to 190 ft 16 260 IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT Nm WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH mi Remove iha liitingedupment MENT BOLTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE n Route hydraulic lines through cente
184. ee certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventive 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 on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Indus tries recommends this task be performed by a Factory Trained Service Technician JLG Industries Inc recog nizes a Factory Trained Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model Referenc
185. eed Sensor Orientations 3 12 3 4 Frame Mounted Electrical Components Sheet 1 0f2 3 13 3 5 Frame Mounted Electrical Components Sheet 2 of 3 14 3 6 Voltade Cree KS av 3 15 3 7 Steering Components and 3 18 3 8 DIVeXompoHeLiiSs sca d ded rasa asam dette ra abd eai i RS a 3 19 3 9 TIL LOCATION sn due Traya a dde R 3 20 3 10 Swing doe drm BE P e dr xe p adeo d tp 3 21 3 11 Swing Motor Exploded 1 3 23 3 12 Swing Bearing Feeler Gauge 3 39 3 13 Swing Bearing Tolerance Boom 3 40 3 14 Swing Bearing Tolerance Measuring 3 40 3 15 Swing Bearing Torquing Sequence 3 42 9 16 Swing Gombobehlts 2 2 dd du EHE Sa E HERE Pa kx RV e wr 3 44 Svs Genero ced ses Hcet cs acr doe Sacr dU de RC Ra Want dra 3 46 3 18 Batteries and Battery 3 47 3 19 Battery Charger S N 0300059350 to Present
186. ef valve improperly set or not functioning properly Steer cylinder not functioning properly Wiring on control switch is damaged Wiring on solenoid valve damaged Coilin solenoid damaged No oil flow or pressure to steer circuit Bent cylinder rod Damaged rod Cylinder packing defective Crossover relief valve set too low or not function ing properly Steer linkages loose Steer wheel toe in not set properly Spindle bushings badly worn DRIVE BRAKE Table 7 4 Chassis Assembly Troubleshooting PROBABLE CAUSE Proportional Flow Valve not functioning properly REMEDY Repair or replace valve Repair or replace pump Adjust settings Repair or replace cylinder See proper wiring diagram Run System Test Repair or replace valve Replace switch Run System Test Reset repair or replace valves as required Repair or replace cylinder See proper wiring diagram Run System Test Repair or replace wiring Run System Test Replace coil Take pressure reading at steer valve and adjust as necessary Repair or replace cylinder Replace tie rod Repair or replace cylinder Reset repair or replace valve as required Tighten linkage Adjusttoe in for 1 4 inch overall Replace bushings 3121829 Excessive pressure in hydraulic system Disc plates worn oprings broken or have taken a permanent set JLG Lift Check hydraulic filter restrictions in other hydraul
187. en and submerge in solvent to check for external leaks Check motor for rotation Torque required to rotate coupling shaft should not be more than 50 ft 16 68 N m Pressure port with A cast under it on housing 18 is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft Pressure port with B cast under it is for counter clockwise cou pling shaft rotation Use test stand if available to check operation of the motor 3121829 3 8 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 torque chart after lubricating the bolt threads with loctite 271 After replacing and retorquing bolt or bolts recheck all existing bolts for looseness 1 Check the frame to bearing Attach bolts as follows a Elevate the fully retracted boom to 70 degrees full elevation b At the positions indicated on Figure 3 13 try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indi cated position c Assure that the 0 0015 feeler gauge will not penetrate under the bolt head
188. ereafter Comments Under certain conditions it may be necessary to replace the hydraulic filter on a more frequent basis A common symptom of a dirty filter is sluggishness experienced in hydrau lic functions 5 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 17 oz 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation 1 8 JLG Lift 6 Wheel Bearings Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 7 Spindles Bushing Capacity A R Lube Lithium Lubricant Interval Every 2 years or 1200 hours of operation Comments At Spindle Bushing Replacement Coat I D of bushings prior to installing king pins 8 Boom Pivot Pins Bushing Capacity A R Lube Lithium Lubricant Interval Every 2 years or 1200 hours of operation Comments At boom pivot pins bushing replace ment Coat 1 0 of bushings prior to installing pivot pins 3121829 Lube Point s Fill 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 3121829 JLG Lift SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Tens
189. erful shaft rotation Each actuator is com posed of a housing with integrated gear teeth 01 and only two moving parts the central shaft with integrated bearing tube and mounting flange 02 and the annular piston sleeve 03 Helical spline teeth machined on the shaft engage matching splines on the 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 pres sure is applied the piston is displaced axially within the housing similar to the operation of a hydraulic cylinder while the splines cause the shaft to rotate When the con trol valve is closed oil is trapped inside the actuator pre venting piston movement and locking the shaft in position 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 intended functions are as follows 1 Flashlight helps examine timing marks component failure and overall condition 2 Felt Marker match mark the timing marks and out line troubled areas Allen wrench removal of port plugs and setscrews 4 Box knife removal of seals 5 Seal tool assembly and disassembly of seals and wear guides 6 Pry bar removal of end cap and manual rotation of
190. ert sealing plugs for full environmental sealing 7 28 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 UNLOCK CONTACT TOOL AND CONTACT REMOVED Figure 7 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS This page left blank intentionally 3121829 JLG Lift 7 29 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 30 ALA h WA PLATFORM CONSOLE 32 Og A 72 0 N lt UON raa gt SS N x PS N N 4 57 MAR N x gt x XE 2 ad lt A X h Q p BOOM LIMIT b SWITCHES PLATFORM WORK LIGHTS RECEPTACLE AT PLATFORM Figure 7 18 Electrical Components Installation Sheet 1 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TILT MODULE POWER z BATTERY CHARGER SENSOR
191. f E M450AJ 2200 152 S N 86022 to Present Releveling Relief E M450A 1200 83 Priorto S N 91053 Releveling Relief E M450A 2200 152 S N 91053 to Present Lift Down Relief Jib Relief Up and Down 3121829 SECTION 5 HYDRAULICS 9 MAIN RELIEF STEER RELIEF CHECK CARTRIDGE PRESSURE SWITCH GAUGE PORT BRAKE RELEASE CARTRIDGE STEER m _ CARTRIDGE SHUTTLE Is PROPORTIONAL N HYDRAULIC FLOW CONTROL FILTER CARTRIDGE Figure 5 25 Brake Steer Valve Components 3121829 JL G Lift 5 23 SECTION 5 HYDRAULICS EMERGENCY DESCENT VALVE EMERGENCY DESCENT HAND PUMP LOWER LIFT DOWN RELIEF UPPER LIFT DOWN RELIEF GAUGE PORT Ge Se bw e VALVE PLATFORM LEVEL RELIEF FORWARD RELEVELING RELIEF PLATFORM LEVEL RELIEF BACKWARD Figure 5 26 Main Valve Components Prior to S N 62642 5 24 JLG Lift 3121829 EMERGENCY DESCENT VALVE UPPER LIFT DOWN RELIEF _ LOWER LIFT DOWN RELIEF GAUGE PORT TELESCOPE RELIEF PLATFORM LEVEL RELIEF BACKWARD PLATFORM LEVEL RELIEF FORWARD SECTION 5 HYDRAULICS EMERGENCY DESCENT HAND PUMP _ RELEVELING VALVE RELEVELING RELIEF Figure 5 27 Main Valve Components S N 62642 to Present 3121829 5 25 SECTION 5 HYDRAULICS 2 NOTES 5 26 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM SECTION 6 JLG C
192. following help messages they are intended to hint ata 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 BRAKES RELEASED Indicates manual brake release in ground mode DRIVING AT CREEP TILTED Drive speed is limited to creep because the vehicle is tilted FWS 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 CUTBACK ABOVE ELEVATION All function speeds are limited to cutback speed because the vehicle is above elevation RUNNING AT CREEP TILTED AND ABOVE ELEVATION All function speeds are limited to creep because the vehicle it tilted and 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 interface circuitry the controller defaults to massively tilted and does not try to prevent vehicle roll on the grade TRACTION MOTOR AT CURRENT LIMIT Traction current has reached controller current limit or safe operating area limit WATER BATTERIES The batteries have been charged a number of times set by machine digit and need a to
193. g Tolerance Boom Placement 2 At the same point with the boom positioned over the side of the machine the Upper Boom fully ele vated and the Mid Lower Boom fully elevated See Figure 3 13 using a magnetic base dial indicator measure and record the distance between the swing bearing and turntable See Figure 3 14 TURNTABLE MEASURING BEARING Figure 3 14 Swing Bearing Tolerance Measuring Point 3 40 JLG Lift 3121829 3121829 09 Sb 0 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 Metal particles in the grease Increased drive power Noise Rough rotation If bearing inspection shows no defects reassemble bearing and return to service Replacement of Swing Bearing 1 Remowval a Attach an adequate support sling to the boom and draw all slack from sling Prop or block the boom if feasible b Tag and disconnect hydraulic lines running through center of turntable and frame Use a suitable container to retain any residual hydrau lic fluid Cap lines and ports c Attach suitable overhead lifting equipment to the base of turntable weldment d 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
194. ger will shut off automatically when the bat teries are fully charged The charge cycle is complete when the ammeter reads O amps Any reading indicates the charge cycle is not complete 5 Depleted batteries will take approximately 17 hours A WARNING to charge 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 On 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 overflow do not top off the fluid level until charging BATTERY BATTERY BOX Figure 3 18 Batteries and Battery Charger 3121829 JLG Lift 3 47 SECTION 3 CHASSIS amp TURNTABLE 3 10 BATTERY CHARGER S N 0300059350 TO PRESENT A WARNING LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION KEEP SPARKS FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES PROVIDE ADEQUATE VENTILATION DURING CHARGING NEVER CHARGE A FROZEN BATTERY STUDY ALL BATTERY MANUFACTURERS SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVIN
195. h 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 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 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 a
196. h Strength Red Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 7 1 10 JLG Lift 3121829 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque i Bolt Dia Tensile Clamp Load Dry or Loctite amp 263 Hodes 242 271 Loctite or Vibra DA Vibra TITE 111 or TITE Hon NEN INE DNE UM _ 4 40 48 0 1120 0 00661 6 32 0130 000909 T T Rj 40 01380 001055 yq yj o 8 32 01640 0040 L 36 0160 0 01474 1320 43 5 jJ 2 4 10 24 0 1900 001750 15800 60 7 32 0 1900 0 02000 100 68 8 jJ 1 4 0250 00318 260 143 16 129 15 J 0200 3580 4 m Sam Nm Nm FB Nm 24 03125 00580 5220 25 35 2 35 2 25 3 8 16 0370 00775 700 45 60 40 5 5 50 ____ 24 03750 00878 790 5 70 45 6 5 50 7A6 14 0435 0 1063 950 70 95 65 90 50 70 20 04375 0 187 10700 80 7110 70 80 1 2 13 0 5000 0 1419 1250 105 15 95 10 90 20 0 5000 0 1599 14400 120 165 10 10 90 120 18
197. h states actively HIGH 2393 23 PLATFORM LEVEL SWITCH FAULTY Both states actively HIGH 2394 23 PUMP POT FAULTY Creep potis OPEN circuit 2395 23 FUNCTION SWITCHES FAULTY Function switch has both direction selected atthe same time 253 25 DRIVE PREVENTED CHARGER CONNECTED Driving is not possible while the vehicle is charging 254 25 DRIVE amp LIFT UP PREVENTED CHARGER CONNECTED Drive or Liftis not possible while the vehicle is charging AND is configured to prevent all motion 2510 25 DRIVE PREVENTED BRAKES NOT RELEASING No Brake pressure was detected when running the pump motor and energizing the brake valve 6 28 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash Code Fault Message Description 2514 25 BOOM PREVENTED DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configuredto notallow simultaneous drive amp boom opera tion 2516 25 DRIVE PREVENTED ABOVE ELEVATION Driving is not possible while Boom functions are selected AND is configured to not allow simultaneous drive amp boom operation 2517 25 DRIVE PREVENTED TILTED amp ABOVE ELEVATION Driving is not possible while the vehicle is tilted and above eleva tion AND is configured to prevent drive while tilted and above ele vation 2518 25 DRIVE PREVENTED BOOM SELECTED Driving is not possible while the vehicle boom function
198. harged LED turns on the batter ies are completely charged The charger may now be unplugged from AC power If left plugged in the charger will automatically restart a complete charge cycle if battery voltage drops below a minimum volt age or 30 days have elapsed 3 48 JLG Lift 4 f a fault occurred during charging the red Fault LED will flash with a code corresponding to the error Maintenance Instructions 1 For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the safety instructions recommended by the battery manufacturer 2 Make sure charger connections to battery terminals are tight and clean 3 Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle Battery Charger Fault Codes If a fault occurred during charging the red Fault LED will flash with a code corresponding to the error Refer to the table following for the flash codes and their removal Table 3 11 Battery Charger Fault Codes Delta Q Flash s Fault Batteryvoltage Auto recover Indicates a high battery pack high voltage Auto recover Indicates either a battery pack Batteryvoltage failure battery pack not connected to charger Fault Removal 1 2 low or battery volts per cell is less than 0 5 VDC Checkthe battery pack and connections Indicates the batteries
199. he allowed test time 99129 09 POWER MODULE FAILURE HWFS CODE 11 Hardware failsafe tests failed because the hardware failsafe tripped too slowly 99130 99 POWER MODULE FAILURE HWFS CODE 12 Hardware failsafe tests failed because the hardware failsafe tripped too Quickly 99131 99 POWER MODULE FAILURE HWFS CODE 13 Hardware failsafe tests failed because the hardware failsafe remained tripped when the traction MOSFETs were turned OFF 99132 99 POWER MODULE FAILURE HWFS CODE 14 Hardware failsafe tests failed because the hardware failsafe the line contactor could not be energized when the hardware failsafe was tripped 3121829 JLG Lift 6 31 SECTION 6 JLG CONTROL SYSTEM Table 6 8 Diagnostic Fault Codes Flash DTC Code Fault Message Description 99133 99 POWER MODULE FAILURE HWFS CODE 15 Hardware failsafe tests failed because the hardware failsafe the contactor drive failsafe did nottrip within the allowed test time 99134 99 POWER MODULE FAILURE HWFS CODE 16 Hardware failsafe tests failed because the hardware failsafe the contactor drive failsafe tripped tooslowly 99135 99 POWER MODULE FAILURE HWFS CODE 17 Hardware failsafe tests failed because the hardware failsafe the drive contactor failsafe tripped too quickly 99136 99 POWER MODULE FAILURE HWFS TEST STALLED Hardware failsafe tests did not complete but no reason can be determined 99137 99 POWER MODULE FAILURE LINE
200. hose personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection 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 equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degr
201. hub 3121829 Drive function not activated within 7 seconds after footswitch was depressed Hydraulic system oil low Hydraulic pump not functioning properly Restricted or broken pump supply line Restricted or broken line on valve bank Air in wheel brake circuit Damaged wiring on joystick JLG Lift Recycle footswitch Replenish oil as necessary Repair or replace pump Clean repair or replace line Clean repair or replace line Bleed circuit determine and correct cause Repair or replace wiring Run System Test SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 4 Chassis Assembly Troubleshooting PROBABLE CAUSE Joystick not functioning properly TROUBLE Machine will not travel in forward Motor turns slowly at maximum command Poor response function shuts off slowly when command is removed No response to steer control Machine hard to steer or steering is erratic Charger plugged in Drive prevented Brake s not releasing Hydraulic system oil low Restricted or broken hydraulic line or fitting Cutback Tilted Speed Sensor Cutback Elevation Ramp set too high in controller Sticking control handle STEERING SYSTEM Hydraulic system pressure too low Damaged wiring on control switch or solenoid valve Control switch not functioning properly Restricted or broken hydraulic line on valve bank hydraulic
202. iagnostic Fault Codes aes Sot d E bak a E edis 6 27 7 1 Platform Assembly 0 7 2 7 2 Boom Assembly Troubleshooting 7 4 7 3 Turntable Assembly Troubleshooting 7 9 7 4 Chassis Assembly 7 10 7 5 Hydraulic System Troubleshooting 7 15 7 6 Electrical System 7 17 JLG Lift 3121829 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 OPERATING SPECIFICATIONS Table 1 1 Operating Specifications Maximum Work Load Capacity Unrestricted Travel Speed Maximum Travel Grade Gradeablility Maximum Travel Grade Side Slope Maximum Height stowed E450A M450A E450AJ M450AJ Maximum Horizontal Platform Reach E450A E450AJ Turning Radius Curb to Curb Turning Radius inside Maximum Tire Load 450 E450A 450 E450AJ Ground Bearing Pressure M450A E450A M450AJ E450AJ System Voltage Battery Life per Charge Battery Recharge Time Charger Generator E450A M450A E450AJ M450AJ 50016 230 kg 3 2 mph 5 2 kph 3090 6ft 6 25 in 1 9 m 6 ft 7 in 2 0 m 23ft 1in 7 0m 231 91 7 24
203. ible move the machine to a cooler location 3 Confirm that dirt or mud is not blocking the cooling fins of the charger Clean the charger Rinse the charger with a low pressure hose if required Do no use high pressure Do not us a pressure washer 6 Flashes Over Load Over Temperature This fault indicates that the batteries will not accept charge current or an internal fault has been detected in the char ger This fault will nearly always be set within the first 30 seconds of operation If it occurs after the charger has started charging normally be sure to make a note of it 1 Remove excessive AC loads from inverter if installed 2 Try to clear the fault by unplugging the AC waiting 30 seconds and reconnecting the ac power 3 Check battery connections Look for high resis tance connection The most likely reason for this fault is a fault in the battery such as a bad battery con nection an open cell or insufficient water 4 This fault will occur if an internal fuse inside the char ger blows If the green wire is shorted to ground even momentarily this fuse will blow To check the fuse measure with an ohmmeter between the green and red wires with the AC disconnected If a short circuit is not measured the fuse has blown Return unit to a service depot to have this fuse replaced 5 If this fault occurs after battery charging has started confirm that AC power was not interrupted and that all battery connec
204. ic components Check disc thickness Check release pressure 7 13 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Brake Drags or runs hot Table 7 4 Chassis Assembly Troubleshooting PROBABLE CAUSE REMEDY Brake will not release Low actuation pressure Place pressure gauge in bleed port amp check pres sure with system on Bearing failure Replace bearing Stuck or clogged valve Place pressure gauge in bleed port check for adequate pressure Replace defective line or component Bad o rings Replace o rings Discs frozen Replace disc stack JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 5 Hydraulic System Troubleshooting TROUBLE Hydraulic pump noisy Pump cavitating Vacuum in pump due to oil starvation System overheating Pump not delivering oil 3121829 PROBABLE CAUSE HYDRAULIC SYSTEMS GENERAL Air entering system through broken line or fitting Suction Side Air bubbles inoil Reservoir oil too low Suction hose squeezed shut Oil filter dirty Wrong type of hydraulic oil Restricted suction line Restricted reservoir air vent Oil viscosity too high Air leak in suction side of tank Oil viscosity too high Bypass valve not operating properly Main relief valve set too low Hydraulic system oil low Port relief set too high Restricted or b
205. ile Torque Torque Loctite 242 or 271 Loctite 262 ibra Size Bolt Dia Stress Area Clamp Load Dry Loctite r or Vibra 140 6 32 01380 0 00909 50 16 18 12 14 49 0 1380 0 01015 60 18 20 133 15 f 4 _ 8 32 0160 0 01400 90 30 34 22 25 C f 36 01640 001474 940 35 23 26 10 24 01900 0 01750 1120 j 43 48 3 35 Jj C j f j 32 0190 00200 1288 49 55 36 4 j 1 4 20 02500 0 0318 2020 96 108 75 9 j 105 12 029 004 2320 120 f 135 p 0 __ m Sam iB Nm FTB 124 0325 0 05880 370 19 26 14 19 2 29 17 23 0 8750 0 0878 590 51 47 25 34 40 _54 3 45 _ 716 14 0 4375 01063 6800 5 35 47 5 75 45 20 0 4375 018 750 55 75 400 5 6 82 50 12 13 0 5000 0149 954 75 5 75 85 16 68 20 0500 0 1599 1070 90 122 65 98 100 16 108 9 16 12 0 5625 0 1820 11600 10 19 80 18 120 163 98 133 18 0565 0 2030 12950 120 163 90 122 15 184 109 148 18 0 6250 0 2560 16300 170 230 10 176 190 258
206. ill from the fuel injector pump Engine might run rough for 20 seconds or so but it will clean out 3 59 SECTION 3 CHASSIS amp TURNTABLE 3 13 GENERATOR S N 88539 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 diodes and output current sensor are located in the alternator endbell Dynamo Output Fuse E ES 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 _ This fuse protects the dynamo output it is located on the left side of the engine Rating 20ADC Control
207. impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set 3121829 SECTION 3 CHASSIS amp TURNTABLE 15 Assemble the manifold 7 over the alignment studs 18 Assemble a new seal ring 3 flat side up into com and drive link 10 and onto the rotor set Be sure the mutator 5 and assemble commutator over the end correct manifold surface is against the rotor set of drive link 10 onto manifold 7 with seal ring side up 16 Apply grease to a new seal ring 4 and insert it in the seal ring groove exposed on the manifold 19 Assemble a new seal ring 4 into end cover 2 and assemble end cover over the alignment studs and onto the commutator set If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing 18 The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown below 17 Assemble the commutator ring 6 over alignment studs onto the manifold 3121829 JLG Lift 3 35 SECTION 3 CHASSIS amp TURNTABLE 20 Assemble the bolts 1 and screw in finger tight Remove and replace the two alignment studs with bolts after the other bolts are in place Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 25 30 ft 16 34 41 m NOTE If the end cover has a valve 24 or has five bolt holes use
208. ine surges Strong fuel odor 7 10 GENERATOR Enable switch is open Fuses open Ground EMS is open Defective starter motor Damaged wiring in ignition circuit broken wire on starter Manual start switch not functioning properly Ignition relay not functioning properly Ignition circuit shorted to ground Battery cable s not making contact No fuel Clogged fuel filter Choke solenoid malfunction Restricted or broken fuel line Fuel shut off valve in carburetor stuck or frozen Battery discharged Cam timing belt jumped time or broken Ignition timing slipped Table 7 4 Chassis Assembly Troubleshooting PROBABLE CAUSE REMEDY Actuate switch Determine and correct cause replace fuse Pull out EMS to activate Replace starter motor Repair replace wiring Replace switch check wiring Replace relay See proper wiring diagram Cleanand tighten cable s Replenish fuel as necessary Replace fuel filter Replace choke solenoid Clean or replace fuel line Repair or replace fuel shut off Check for electri cal power Charge battery replace if defective Repair or replace timing belt Repair timing Governor not adjusted properly Correctly adjust governor Fuel tank overfilled Fuel tank damaged Fuel line from tank damaged Carburetor flooding JLG Lift Check fuel tank and immediately wipe up spilled fuel Drain all fuel from tank and
209. installing a new positrac tilt module always ensure 6 Verily that the tilt reading is now 0 0 0 0 that it is calibrated using the JLG Control System analyzer before operating the machine Refer to Section 6 JLG Control System Analyzer Kit Instructions Use a standard WARNING bubble level in two different directions to ensure that the TO ASSURE PROPER OPERATION THE MACHINE MUST BE machine s frame is level prior to installing the new posi LEVEL WHEN INSTALLING AND CALIBRATING A NEW POSI trac tilt module TRAC TILT MODULE 1 Place the machine on a flat level surface Check for level by placing a bubble level on the frame in both directions 2 Plugin the analyzer Analyzer p n 1600244 Cable p n 1600633 into port J9 on the power module or port J1 on the platform module 3 Use the right arrow key to curse over to ACCESS LEVEL 2 Depress Enter 4 Use Up Down arrow keys to enter the following password 33271 Depress Enter 3121829 JLG Lift 3 19 SECTION 3 CHASSIS amp TURNTABLE 4 S G Figure 3 9 Tilt Sensor Location 3 20 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE 3 7 SWING MOTOR S N 0300135649 TO PRESENT COUPLING SHAFT HIGH PRESSURE SEAL NEEDLE THRUST BEARING HOUSING DRIVE LINK 12 TOOTH SPLINES DIRT amp WATER SEAL BUSHING MATCHED SET MATCHED COMMUTATOR SET Figure 3 10 Swing Motor Cutaway A CAU
210. into the container Remove excess hydraulic oil from the brush so even film of oil is applied on the o ring FX 3121829 JLG Lift 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 A small leak proof container Sponge cut to fit inside the container small 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
211. ion 20 If the bearings bushing or thrust washers must be the disassembly of the motor is completed replaced use a suitable size bearing puller to remove bearing bushings 19 and 13 from hous ing 18 without damaging the housing Remove thrust washers 14 and thrust bearing 15 if they were previously retained in the housing by bearing 13 NOTE The depth or location of bearing bushing 13 in rela tion to the housing wear plate surface and the depth or location of bearing bushing 19 in relation to the beginning of bearing bushing counter bore should be measured and noted before removing the bearings bushings This will facilitate the correct reassembly Assembly of new bearings bushings Replace all seals and seal rings with new ones each time you reassemble the motor unit Lubricate all seals and seal rings with SAE 10 40 oil or clean grease before assembly NOTE Unless otherwise indicated do not oil or grease parts before assembly Wash all parts in clean petroleum based solvents before assembly Blow them dry with compressed air Remove any paint chips from mating surfaces of the end cover commutator set manifold rotor set wear plate and hous ing and from port and sealing areas 3 30 JLG Lift 3121829 A WARNING SINCE THEY ARE FLAMMABLE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH A WARNING WEAR EYE PROTECTION AND BE SURE
212. is within the design limits of the engine Verify correct operation of engine temperature sensor 1 3 Overspeed Verify setting of governor lever Readjust if required Referto Kubota Workshop manual WSM 0660 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 Refer to Kubota OC60 Engine Manual Overcrank Check fuel level Check fuel connections Verify operation of fuel solenoid and fuel pump Check the start battery voltage Ifthe engine exhaust contains white smoke then fuel is entering the engine but the engine is not firing Refer to the Kubota 0060 Engine Manual for further checks Ifthe ambient temperature is low verify thatthe heater and or glow plug are operating 1 5 No Speed Signal Check wiring connections 2 1 Overvoltage Check alternator output voltage 3121829 JLG Lift 3 69 SECTION 3 CHASSIS amp TURNTABLE Table 3 11 Troubleshooting Flash Code Problem 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
213. ischarge there should be no further leakage from the retract port 4 1 SECTION 4 amp PLATFORM Remove hardware securing telescope cylinder 1 to the fly boom section then remove pin from fly Remove hardware securing telescope cylinder to the base boom section WHEN REMOVING TELESCOPE CYLINDER FROM 00 SEC TIONS CARE SHOULD BE TAKEN NOT TO LET CYLINDER REST ON POWERTRACK WHICH COULD CAUSE DAMAGE TO POW ERTRACK 6 Using suitable lifting device remove telescope inder from boom sections T Using a piece of tape mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly 8 Remove hardware securing the front cover on base boom section 9 Loosen jam nuts on front wear pad adjustments and loosen adjustments 10 Remove hardware securing the front wear pads on base boom section remove wear pads 11 Remove wire clamp on the inside of the fly nose 12 Manually push the fly boom section into base boom section to gain access to the powertrack attachment bolts on the right side of the base boom section 13 Remove hardware securing the powertrack to the aft end of the fly boom section 14 Using a suitable lifting device remove fly boom from boom section 15 Remove hydraulic lines and electrical cables from powertrack 16 Remove hardware securing powertrack to the base boom section Remove powertrack 4 2 Inspection 1 Inspect b
214. iston will not hold pressure brake will not release These brakes are designed for only limited dynamic braking severe emergency stop or prolonged reduced release pressure operation may result in this type of damage JLG Lift Corrective Action Checkfilters hose size restrictions in other hydraulic components Replace oil seal in brake Check motor seal Check piston seals Note Internal components will needto be inspected cleaned and replaced as required See spring replacement Place pressure gauge in bleed port amp check pressure with system on Replace bearing Place pressure gauge in bleed port check for adequate pressure Replace defective line or compo nent Replace o rings Replace disc stack 3121829 3 5 SPEED SENSOR ADJUSTMENT 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 A 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 CONTROL LER SENSES A PROBLEM AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED IF BOTH SENSORS ARE ADJUSTED TOO F
215. it Installation BACKUP RING 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible Figure 5 8 Installation of Head Seal Kit 9 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are 4 Install washer ring onto rod carefully install the head not damaged or dislodged gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head 10 Thread piston onto rod until it abuts the spacer end along the rod to the rod end as applicable and install the tapered bushing 5 Carefully slide the piston spacer on the rod NOTE When installing the tapered bushing piston and mat 5 ing end of rod must be free o oil 6 If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved A WARNING 7 f applicable correctly place new seals and guide WHEN REBUILDING THE STEER LOWER LIFT LEVEL CYLINDER lock rings in the outer piston diameter groove A OR UPPER LIFT CYLINDER APPLY LOCTITE 2242 TO TAPERED tube with I D slightly larger than the O D of the pis BUSHING BOLTS THEN TIGHTEN SECURELY ton is recommended to install the solid seal 11 Assemble the tapered bushing loosely into the pis NOTE The backup rings for the solid seal have a radius on ton and insert JLG capscrews not vendor cap one sid
216. iteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable crite ria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts 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
217. ken hydraulic line or fitting on slave cylinder or main lift cylinder Worn seal s in slave level or main lift cylinder Counterbalance valve in slave cylinder defec tive Slave levelor main lift cylinder not functioning properly Counterbalance valve on slave leveling cylinder improperly adjusted or not functioning properly Worn seal s in slave level or main lift cylinder Damaged slave level or main lift cylinder Level function notactivated within 7 seconds after footswitch was depressed Level control switch inoperative Hydraulic system oil low Proportional Flow Regulator not powered Restricted or broken hydraulic line or fitting Directional valve not functioning properly No electric power to directional control valve Slave cylinder not functioning properly REMEDY Replenish oil as necessary Clean or replace as necessary Clean repair or replace line or fitting Replace seal s Replace counterbalance valve Slave level or main lift cylinder not functioning properly Replace valve Replace seal s Repair or replace cylinder Recycle footswitch Repair or replace control switch lever Replenish oil as necessary Wiring Run System Test Clean repair or replace line or fitting Repair or replace valve See proper wiring diagram Run System Test Repair or replace pump 7 2 Hydraulic pump not functioning properly Restricted or broken hydraulic line or fitting Sl
218. l 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 3121829 SECTION 4 8 PLATFORM Figure 4 14 Rotator Counterbalance Valve 3121829 JLG Lift 4 25 SECTION 4 amp PLATFORM Installation and Bleeding 1 Connect a 3 16 inside diameter x 5 16 outside diameter x 5 foot clear vinyl drain tube to each of the After installation of the actuator on the equipment it is two bleed nipples Secure them with hose clamps important that all safety devices such as tie rods or safety Place the vinyl tubes in a clean 5 gallon container to cables are properly reattached collect the purged oil The oil can be returned to the To purge air from the hydraulic lines connect them together to create 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 TYPICAL CONFIGUR
219. lanet gears 2 4 Pull cylindrical roller bearing 10 out of the planet gears 2 5 Remove snap ring 16 from sun gear 8 and Remove planet carrier 7 from sun gear 3 6 Remove thrust washer 49 Disassembly of Second Stage Planet Gears 1 1 3121829 Press cylindrical roller bearings out of planet gears 1 SECTION 3 CHASSIS amp TURNTABLE Assembly of First Stage Planetary Assembly 7 1 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 48 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 Assembly of End Cover Unit 8 DU M x JLG Lift 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 SECTION 3 CHASSIS amp TURNTABLE Final Assembly 1 10 11 12 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 spindl
220. le keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering 3121829 3121829 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
221. lide fly boom sec tion out to gain access to telescope cylinder attach pin hole Measure the distance between the telescope cylin der port block attach point on base boom section and the attach point on fly boom section Connect a suitable auxiliary hydraulic power source to the telescope cylinder port block Extend the telescope cylinder the distance of the two attach points Secure the sling and lifting device at the telescope cylinder s approximate center of gravity and lift the cylinder to the aft end of the boom assembly WHEN INSERTING THE TELESCOPE CYLINDER INTO THE CARE MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK ASSEMBLY 11 12 13 14 15 3121829 Slowly slide the telescope cylinder into boom assembly align rod end with attach point in fly sec tion Insert pin and secure with retaining ring Align bolt holes at aft end of base boom section with telescope cylinder port block Secure telescope inder with hardware Install wear pads at end of base boom section Adjust the adjustable wear pads to zero clearance Adjust pads alternately side to side so that fly boom section is centered in base boom section Retract boom section fully Adjust wear pads at aft end of boom section to zero clearance Adjust pads alternately side to side so that fly boom section is centered in base boom section Disconnect auxiliary power source from telescope cylinder Installation
222. lied RBS shutdown Callto startremoved Manually Automati Cally Engine runtime delay 1 Battery voltage above 54 0 and finish charging cur rent below 30ADC 2 Engine temperature above 8 C Start battery voltage above 12 9V and finish charging cur rent below 30ADC This period ensures that no fur ther callto start conditions occur priorto cool down period Cool down period Alternator output is reduced to a minimallevelto allow the engine to cool down JLG Lift 3 67 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 10 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 3 failed crank cyclesCall to start removed 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 2 4 Loss Of Voltage Sense Alternator output less than 1 2 ofthe system Shutdown nominal voltage 58VDC steady Unit Enabled no faults Unit can respond to any call to start Unit Off Disabled Unit will not respond to any call to start Notes 1 Enabled oncetime delay by
223. locked return line Restricted suction line Air entering system through broken line or fitting Broken pump drive shaft pump coupling JLG Lift REMEDY Repair or replace line or fitting Replenish oil as required Determine cause and repair Replace hydraulic filter Replace hydraulic oil Clean repair or replace line Cleanor replace vent Drain system and replace with recommended oil Refer to Hydraulic Oils Repair leak Drain system and replace with recommended oil Refer to Hydraulic Oils Repair or replace valve Resetvalve as required Replenish oil as necessary Resetvalve as required Repair or replace line Clean repair or replace line Repair or replace line or fitting Repair or replace pump pump coupling Note Any time pump or pump drive coupling is removed coat pump and drive coupling splines with Lithium Soap Base Grease TEX ACO CODE 1912 OR EQUIVALENT 7 15 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 5 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function sluggish during operation System pressure too low Main relief valve set too low Reset valve as required Pump section not delivering sufficient oil Repair or replace pump section or pump Main relief valve stuck in open position Clean repair or replace valve Checksystemoil for contamination Oil viscosity too low Drain system an
224. lve 15 Wear Ring 21 Loctite 222 4 Piston 10 Pipe Plug 16 O ring 22 Locking Primer 5 Cylinder Head 11 Setscrew 17 Rod Seal 23 Bushing 6 HexNut 12 Piston Seal 18 Wiper Figure 5 17 Lower Lift Cylinder 3121829 JLG Lift 5 13 SECTION 5 HYDRAULICS 450AJ 2 2 29 20 1 Barrel 6 HexNut 11 Plug 16 Not Used 2 Cylinder Rod 7 Washer 12 Setscrew 17 O ring 3 Retainer 8 Spacer 13 Lock Ring 18 Backup Ring 4 Piston 9 Holding Valve 14 Piston Seal 19 Rod Seal 5 Cylinder Head 10 Holding Valve 15 NotUsed 20 Rod Wiper Figure 5 18 Mid Lift Cylinder 5 14 JLG Lift 1683713 A 1683825 A 1683942 C 1684057 B 21 Loctite 242 22 Loctite 222 23 Locking Primer 24 Not Used 25 Bushing 3121829 SECTION 5 HYDRAULICS 1683708 1683813 1683945 1684061 1 Barrel 6 HexNut 11 Setscrew 16 Wear Ring 21 Locking Primer 2 Cylinder Rod 7 Tube Spacer 12 Setscrew 17 O ring 22 Loctite 222 3 EndCap 8 NotUsed 13 Wear Ring 18 Seal 23 Bushing 4 Piston 9 Holding Valve 14 Seal 19 Wiper 5 Cylinder Head 10 O ring Plug 15 O ring 20 Loctite 242 Figure 5 19 Upper Lift Cylinder 3121829 JLG Lift 5 15 SECTION 5 HYDRAULICS De c Barrel Cylinder Rod Piston Cylinder Head 6 7 Retainer 8 9 1 HexNut 11 O ring TubeSpacer 12 O ring oetscrew 13 Wear Ring T Seal 14 Rod Seal 0 W
225. ly around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY Assemhly Check to be sure the wedge lock is in the open or as shipped position See Figure 7 5 Proceed as follows CONTACT PARTIALLY ppm INSERTED RETENTION FINGERS lt Ec NA SASS Z i wisa ER E DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 7 5 Connector Assembly Figure 1 1 Toinsert a contact push it straight into the appropri ate circuit cavity as far as it will go See Figure 7 7 2 Pull back on the contact wire with a force of 1 or 2 lbs to be sure the retention fingers are holding the contact See Figure 7 7 RETENTION LEG WEDGE LOCK HOUSING Figure 7 6 AMP Connector
226. m 15ft 3in 4 65 7 Sr Sr Sr 2ft 0 61 m 6100 Ibs 2 767 kg 6900 Ibs 3 130 kg 64 psi 4 5 kg cm 75 psi 5 2 kg cm 48 volts 7 hours continuous 17 hours from full discharge 6 2 hours Gross Machine Weight Platform Empty 13 100 Ib 5942 kg 15 100 Ib 6804 kg 1 2 CAPACITIES Table 1 2 Capacities 4 Gallons 15 11 5 Gallons 19 L w 10 air space Hydraulic System Including Tank 9 Gallons 34 1 L 17 ounces 0 50 L Torque hubs should be one half full of lubricant Generator Fuel Tank Hydraulic Oil Tank Torque Hub Drive 3121829 1 3 TIRES Table 1 3 Tire Specifications IN240 55 17 5 IN240 55 17 5 26 7 20 PPyRaing Rating 7 Pressure x psi 6 2 Bar Filled TENE Non Marking 1 4 BATTERY CHARGER Table 1 4 Generator 110 VAC 60 HZ 48 VDC 25 Amps Output Quantity of Batteries 8 Battery Spec 6 Volt 370 Amp Hour 20 hour rate 1 5 DIMENSIONAL DATA Table 1 5 Dimensional Data Machine Length stowed M450A E450A M450AJ E450AJ 18ft 8 0in 5 69 m 21 ft 2in 6 45 m Up and Over Platform Height M450A E450A M450AJ E450AJ 241 7 in 7 49 m 25 ft 3in 7 7 m Horizontal Reach o Maximum Up and Over M450 A E450A 23 ft 1 in 7 0 m 450 E450AJ 231 9in 7 24 m k Ground Clearance 450
227. m in stowed position Check hydraulic fluid and adjust accordingly 4 4 LOWER BOOM LIFT CYLINDER Removal 1 Place machine on flat and level surface Place the Upper Boom in a horizontal position Place the Mid and Lower Booms in a 10 degree elevated position Support Upper Boom with a prop Support upright with an overhead crane 2 Using slings restrain the lower lift cylinder 3121829 JLG Lift 3 SECTION 4 BOOM amp PLATFORM Remove the hardware securing the cylinder rod attach pin 5 to the boom Using an appropriate brass drift drive out the cylinder rod attach pin 5 Figure 4 4 Lower Boom Lift Cylinder Removal 4 Tag disconnect and cap the lift cylinder hydraulic lines and ports 5 Remove the hardware securing the barrel end attach pin 6 to the boom Using an appropriate brass drift drive out the cylinder barrel pin 6 6 Carefully remove cylinder from boom Place in a suitable work area Installation NOTE Coat of bushings with specified lubricant prior to installing pins With the booms positioned and supported place cylinder in position and secure in place using slings Install the cylinder barrel pin 6 being sure to align the hole in the cylinder barrel pin with the retaining pin screw hole When holes align install hardware Correctly install hydraulic lines to cylinder as previ ously tagged Extend cylinder rod slowly until attach pin hole aligns with those in b
228. mps BATTERY Displays measured battery voltage TEMPERATURE Displays measured heatsink temperature FSW1 Displays footswitch status FSW2 Displays footswitch status NOTE FSW2is wired to the platform module DRIVE 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 6 20 JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 5 DIAGNOSTICS Menu Descriptions TILT Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direction pitch The second value indicates tilt in the left right direction roll DATALOG Displays maximum measured heatsink temp Displays minimum measured heatsink temp BATTERY Displays maximum measured battery voltage 2 Displays total controller 5 time DRIVE Displays total controller drive operation time PUMP Displays total controller pump running time NOTE includes all boom functions steer and brake release Displays total controller lift operation time SWING Displays total controller swing operation time TELE Displays total controller tele operation time RENTAL Displays total contr
229. mps 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 SECTION 3 CHASSIS amp TURNTABLE 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 solenoid 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 an
230. n gt Figure 4 7 Platform Support Torque Values 4 8 JLG Lift 3121829 SECTION 4 amp PLATFORM l L x oe a uu 7 Lo P 4 UPPER UPRIGHT sl T Ec lo UPPER LIFT CYLINDER Em LOWER LEVEL LINK VIEW A A VIEW B B pM lt 8 olg The following measurement is used fo set the upper limit O switch A 32 feet 9 75 meters A p The following measurement is used to set the lower limit Switch M 17 feet 5 2 meters Ift an AJ model the jib is to All measurements are to be completely lowered be taken from the bottom of the basket NOTE The limit switches control amp set Drive speed to Elevated Speed Figure 4 8 Boom Limit Switches 3121829 JLG Lift 4 9 SECTION 4 amp PLATFORM EN PLATFORM FLY BOOM SECTION REF CYLINDER CYLINDER PLATFORM SUPPORT Figure 4 9 Platform Components and Attaching Hardware M450A amp E450A 4 10 JLG Lift 3121829 SECTION 4 amp PLATFORM 4 8 ARTICULATING Inspection Removal NOTE When inspecting pins and bearings refer to Section 1 For platform support removal see platform support removal diagram See Section 4 1 Boom Mainte nance Position the articulating jib boom level with ground Remove mounting hardware from slave leveling cyl
231. n installed The Control System may be accessed in one of two ways Utilizing a custom designed hand held analyzer Ana lyzer JLG part no 1600244 amp Cable JLG part no 1600633 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 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 6 2 JLG Lift 3121829 3121829 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 EP LOGGED HELP 1 STARTUP 2 1 ESC LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will
232. n 5 Cylinder Repair For Bearing Replacement Inspect lift cylinder attach pin for wear scoring tapering and ovality or other damage Ensure pin surfaces are protected prior to installation Replace pins as necessary Inspect inner diameter of rotator attach point bear ings for scoring distortion wear or other damage Replace bearing as necessary See Section 5 inder Repair For Bearing Replacement Inspect all threaded components for damage such as stretching thread deformation or twisting Replace as necessary Inspect structural units of articulating jib boom assembly for bending cracking separation of welds or other damage Replace boom sections as necessary Assemhly NOTE For location of components See Section 4 10 Loca tion of Components Articulating Jib Boom Align lift cylinder with attach holes in articulating jib boom Using a soft head mallet install cylinder pin 7 into articulating jib boom and secure with mount ing hardware Align rotator support with attach hole in articulating jib boom Using a soft head mallet install rotator support pin 6 into articulating jib boom and secure with mounting hardware SECTION 4 amp PLATFORM Align bottom tubes with attach holes rotator sup port Using a soft head mallet install rotator support pin 5 into articulating jib boom and secure with mounting hardware Align articulating jib boom with attach hole in articu la
233. n the pump MOSFETs are OFF this maybe due to a power wiring error 7739 77 B AND A CROSSED CHECK POWER CIRCUITS startup test detected B 4 is connected to point A and point A is connected to B 7740 77 TRACTION CURRENT AT ZERO CHECK SHUNT WIRING Traction current is at ZERO this maybe due to an open circuit between the current measurement shunt and the power module 026 82 RUNNING AT CREEP PLATFORM OVERLOADED All functions at creep the Load Sensing System indicates the Platform is overloaded AND is configured to warn only while the Platform is overloaded 827 82 DRIVE amp BOOM PREVENTED PLATFORM OVERLOADED Driving and boom functions are not possible while the Load Sens ing System indicates the Platform is overloaded AND is config uredto prevent drive and boom functions while the Platform is overloaded 99125 99 POWER MODULE FAILURE HWFS CODE 2 Hardware failsafe tests did not com plete because traction point is not safe or the hardware failsafe is permanently tripped 99126 99 POWER MODULE FAILURE HWFS CODE 3 Hardware failsafe tests did not complete because a contactor was energized when all should be turned off 99127 99 POWER MODULE FAILURE HWFS CODE 4 Hardware failsafe tests did not complete because the hardware failsafe tripped immediately when the traction MOSFETs were turned ON 99128 99 POWER MODULE FAILURE HWFS CODE 10 Hardware failsafe tests failed because the hardware failsafe did not trip within t
234. ng 13 can now be pressed into its counter bore in housing 18 flush to 0 03 inch 0 76 mm below the housing wear plate contact face Use the opposite end of the bearing mandrel that was used to press in the outer bearing bushing 19 JLG Lift 3 31 SECTION 3 CHASSIS amp TURNTABLE 3 Press a new dirt and water seal 20 into the housing 6 Assemble thrust washer 14 then thrust bearing 15 18 outer bearing counterbore The dirt and water that was removed from the motor seal 20 must be pressed in until its flange is flush against the housing NOTE The motor requires one thrust washer 14 with thrust bearing 15 The coupling shaft will be seated 4 Place housing 18 assembly into a soft jawed vise directly against the thrust bearing with the coupling shaft bore down clamping against the mounting flange 7 Apply masking tape around splines or keyway on shaft 12 to prevent damage to seal 5 Assemble a new backup ring 17 new backup washer 25 and new seal 16 with the seal lip fac ing toward the inside of the motor into their respec tive counterbores in housing 18 Housing Steel Thrust 3 32 JLG Lift 3121829 8 Be sure that generous amount of clean corrosion 9 resistant grease has been applied to the lower outer housing bearing bushing 19 Install the coupling shaft 12 into housing 18 seating it against the thrust bearing 15
235. nt key designations appearing in the Lubrication Chart 2 4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods Platform Drift Measure the drift of the platform to the ground Lower booms if equipped slightly elevated 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 Max Acceptable Drift in 10 Minutes inches mm inches mm 3 76 2 0 026 0 66 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 152 4 0 006 0 15 7 177 8 0 005 0 13 8 203 2 0 0039 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 mal platform load applied If the cylinder passes this test it is acceptable NOTE This information is based on 6 drops per minute cyl inder leakage JLG Lift 3121829 2 2 5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings 1 3121829 Pinned joints should be disassembled inspected if the following occurs a Excessive sloppiness in joints
236. o connect the new link to the powertrack TE 74 CENTER PINS 3121829 JLG Lift 4 33 SECTION 4 amp PLATFORM 7 Install the snap ring the groove the pin Repeat NOTE When installing snap rings make sure they are the pin installation steps for all center holes that seated in pin groove and closed properly have the rivets removed 8 i CLOSED SNAP RING SNAPRINGNOT CLOSED PROPERLY 8 Hold new aluminum round bar tightly then install new 8 32 x 0 500 self threading torx head screw into one end 4 34 JLG Lift 3121829 SECTION 4 amp PLATFORM NOTE Maximum tightening torque is 18 20 16 9 Pull up on the other end of the round bar and slide the new poly roller onto the bar 3121829 JLG Lift 4 35 SECTION 4 amp PLATFORM 10 Install new 8 32 x 0 500 self threading screw the other side NOTE When tightening screws make sure screw head is seated against link with no space in between the link and underside of screw head Maximum tightening torque is 18 20 in Ibs i al m 4 4 kil 4 36 JLG Lift Replacing Fixed End Brackets 1 Remove the rivets the same way as shown under the link removal instructions MOVE THE CABLES HOSES OUT OF THE DURING THE GRINDING PROCESS TO PROTECT THEM KEEP THE HOSES AND CABLES COVERED TO
237. ode inputs are tested in the order ROTATE L ROTATE R LEVEL U LEVEL D U JIB D TELE I TELE UL U UL D LLU LL D SWING L SWING ELEV FUNC C O BRAKE PRES MAN BRAKE NOTE switches which are notin use due to the settings of machine digits are not checked NOTE the pump pot is checked only for a wire off condition it can be atany demand from creep to maximum Problems which can be reported include CHECK switchname The named switch is not in its normal position Check switch amp wiring CHECK switchname JOY The named joystick appears to be faulty Check joystick INPUTS DONE Indicates that the inputs test is complete with or without faults TESTING LAMPS Indicates that the lamps test is beginning Each lamp is energized in turn a prompt asks for confirmation that the lamp is lit ENTER mustbe pressed to continue the test Lamps are tested in the order ENABLE FAULT TILT CREEP POSITRAC WATER 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 A short circuit condition appeared while the named lamp was being tested presumably because itis short circuit LAMP TEST DONE Indicates that the lamps test is complete TESTING ALARMS Indicates that the alarms test is beginning Each alarm is energized in turn a prompt asks for confirmation that the alarm is sounding ENT
238. of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After initial discharge there should be no further leakage from the retract port 3 Activate hydraulic system and activate cylinder extend function 4 lf 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 oylinder extend port 6 Activate hydraulic system and activate cylinder retract function Check extend port for leakage 7 port leakage is less than 6 8 drops per min ute carefully reconnect hose to extend port then 3121829 SECTION 5 HYDRAULICS activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valve Upper Lift Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1 INCH 2 54 CM BELOW THE MAIN BOOM IF WORKING ON LOWER BOOM LIFT CYLINDER RAISE LOWER BOOM HAL
239. oller operation time NOTE can bereset ERASE RENTAL Not available at password level 2 YES ENTER NO ESCENTER Enterresets rental datalog time to zero VERSIONS POWER Displays power software version PLATFORM Displays platform software version GROUND Displays ground software version POSITILT Displays positilt software version ANALYZER Displays analyzer software version 3121829 JLG Lift 6 21 SECTION 6 JLG CONTROL SYSTEM System Self Test The system self test is utilized to locate typical problems See Table 6 6 System Test Descriptions and Table 6 7 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 When the controller sees that the lower lift up switch has been closed it will move on to the next input lower lift 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
240. om Using a suitable brass drift drive out the cylinder rod attach pin 1 Figure 4 2 Upper Boom Lift Cylinder Removal 4 Secure the cylinder with suitable slings or supports as required Remove the hardware securing the bar rel end attach pin 2 Using a suitable brass drift drive out the barrel end attach pin 2 5 Remove the cylinder from the boom and place suitable work area Installation NOTE Coat 1 0 of bushings with specified lubricant prior to 4 4 installing pins Install Lift Cylinder in place using suitable slings or supports aligning attach pin mounting holes on upright Using a suitable drift drive the barrel end attach pin 2 through the mounting holes in the lift cylinder and upright Secure in place with pin retaining hard ware Remove oylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports With function speed switch at its slowest setting extend the cylinder rod until attach pin hole aligns with those in boom Using a suitable drift drive the cylinder rod attach pin 1 through the aligned holes Secure the pin in place with pin retaining hardware Cycle cylinder completely to check for proper func tioning Place boom in stowed position Check hydraulic fluid level and adjust accordingly 4 3 MID BOOM LIFT CYLINDER Removal 1 4 5 JLG Lift Place machine on flat and level surface Place the Upper Boom in a horizontal position
241. om end cover 2 to housing 18 to facilitate reassembly orientation where required 3 24 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE 5 Thoroughly wash end cover 2 in proper solvent and blow dry Be sure the end cover valve apertures are free of contamination Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replace end cover as neces sary 3 Remove the special ring head bolts 1 using appropriate 1 2 or 9 16 inch size socket Inspect bolts for damaged threads or sealing rings under the bolt head Replace damaged bolts NOTE A polished pattern not scratches on the cover from rotation of the commutator 5 is normal Discolor ation would indicate excess fluid temperature ther mal shock or excess speed and require system investigation for cause and close inspection of end cover commutator manifold and rotor set 6 Remove commutator ring 6 Inspect commutator ring for cracks or burrs 4 Remove end cover assembly 2 and seal ring 4 Discard seal ring 3121829 JLG Lift 3 25 SECTION 3 CHASSIS amp TURNTABLE Remove commutator 5 and seal ring 3 Remove seal ring from commutator using an air hose to blow air into ring groove until seal ring is lifted out and dis card seal ring Inspect commutator for cracks or burrs wear scoring spalling or brinelling If any of these conditions exist replace commutator and c
242. ommutator ring as a matched set 3 26 JLG Lift Remove manifold 7 and inspect for cracks surface scoring brinelling or spalling Replace manifold if any of these conditions exist A polished pattern on the ground surface from commutator or rotor rota tion is normal Remove and discard the seal rings 4 that are on both sides of the manifold NOTE The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service Compare configura tion of both sides of the manifold to ensure that same surface is reassembled against the rotor set 3121829 3121829 Remove commutator 5 seal ring 3 Remove seal ring from commutator using an air hose to blow air into ring groove until seal ring is lifted out and dis card seal ring Inspect commutator for cracks or burrs wear scoring spalling or brinelling If any of these conditions exist replace commutator and commutator ring as a matched set 10 SECTION 3 CHASSIS amp TURNTABLE Remove manifold 7 and inspect for cracks surface scoring brinelling or spalling Replace manifold if any of these conditions exist A polished pattern on the ground surface from commutator or rotor rota tion is normal Remove and discard the seal rings 4 that are on both sides of the manifold NOTE The manifold is constructed of plates bonded 11 JLG Lift together to form an integr
243. on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines 2 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 E
244. on time 15s 3 66 JLG Lift 3121829 System Settings CALL TO START SETTINGS Low battery voltage callto start level 48 0 VDC Low battery voltage remove call to start level 54 0 VDC Low temperature call to start level 5 C Low temperature remove callto start level 8 C Low start battery voltage call to start level 12 2 V Low start battery voltage remove callto start level CURRENT AND VOLTAGE SETTINGS 12 9 V Normal output voltage level Extend output voltage level 58 0 VDC 58 0 VDC Current limit level 45 ADC High voltage shutdown level 63 ADC RBS Start Call to start Manual 48V DC applied to the input Automatic 1 Low battery voltage below 48VDC 2 Low engine temperature below 5 C Lowstartbattery voltage below 12 2V Engine start delay RBS waits to verify that call to Start is valid nota transient con dition Preheat delay if engine temperature is below 32 F 0 C Crank time RBS will crank and rest until Rest 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 3121829 SECTION 3 CHASSIS amp TURNTABLE Inhibit run input app
245. onnection 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 f 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 Figure 7 1 Voltage Measurement DC e meter is not auto ranging set it to the correct range See multimeter s operation manual Polarity Use firm contact with meter leads 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 tion of the signal and that the leads are connected to the device under test correctly Also check that the lead on the COM port goes to the Ground or negative side of the sig 3121829 JLG Lift 7 19 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Resistance Measurement 7 20 Figure 7 2 Resistance Measurement First test meter and leads by touching leads together Resistance should read a short circuit very low resistance Circuit power must be turned OFF before testing resistance
246. onnector with rear grommet facing you 3 Push contact straight into connector grommet until a click is felt slight tug will confirm that it is properly locked in place 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way 3121829 JLG Lift NOTE The receptacle is shown use the same procedure for plug 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 27 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 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 CONTACT LOCKED IN POSITION LOCKING FINGERS CONTACT UNLOCKED POSITION Figure 7 15 HD HDP Locking Contacts Into Position NOTE For unused wire cavities ins
247. onths 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 10 Decals installed and legible 11 Check for proper fluid level 12 Check for chafing and proper routing 13 Check for proper tolerances 14 Properly lubricated 15 Torqued to proper specification 16 No gouges excessive wear or cords showing 17 Properly inflated and seated around rim 18 Proper and authorized components 19 Fully charged 20 Noloose connections corrosion or abrasions 21 Verify 22 Perform 23 Sealed Properly 24 Drain Clean Refill O1 2 8 JLG Lift 3121829 2 TEMPERATURE ENGINE SPECIFICATIONS 120 F 49 C NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F 43 C 8 100 F 38 C 5 lt 90 F 32 C T 80 27 70 F 21 C 60 16 G N 50 F 10 C ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY
248. oom Using a suitable brass drift drive the cylinder rod attach pin 5 through the aligned holes Secure the pin in place using retaining hardware Remove boom prop and overhead crane Take the lift cylinder through one complete cycle to assure correct functioning Place boom in stowed position Check hydraulic fluid and adjust accordingly 4 5 SECTION 4 amp PLATFORM 4 5 UPPER TELESCOPE CYLINDER Removal 1 Place machine on flat and level surface with Upper Boom in the horizontal position Extend Upper Boom until fly attach pin 1 is accessible on fly Figure 4 5 Upper Telescope Cylinder Removal NOTE 4 6 Support Upper Boom basket end with a prop Sup port Upper Upright end with an overhead crane Tag disconnect hydraulic lines to telescope cylinder Use suitable container to retain any residual hydrau lic fluid Cap hydraulic lines and ports Remove the retaining rings that retain the telescope cylinder rod to the fly boom Using a suitable brass drift carefully drive the tele scope cylinder rod pin 1 from the fly boom Remove the four 4 bolts securing the telescope cylinder barrel end to the base boom Care should be taken when removing the telescope cylinder do not leave cylinder rest on powertrack which could cause damage to powertrack Using a suitable brass drift carefully drive the tele scope cylinder pin from the base boom Attach a suitable sling to the tele
249. oom pivot pin for wear scoring or other damage and for tapering or ovality Replace pin as necessary Inspect lift and master cylinder pins for wear scoring or other damage and for tapering or ovality Ensure pin surfaces are protected prior to installation Replace pins as necessary Inspect telescope cylinder rod attach pin for wear scoring or other damage Replace pin as necessary Inspect inner diameter of boom pivot bushings for scoring distortion wear or other damage Replace bushings as necessary Inspect wear pads for wear as shown in Section 4 6 Wear Pads Inspect all threaded components for damage such as stretching thread deformation or twisting Replace as necessary Inspect structural units of boom assembly for bend ing cracking separation of welds or other damage Replace boom sections as necessary Assemhly 1 JLG Lift Install power track to the attach point on the inside of the base boom section Secure power track with hardware Install hydraulic lines and electrical cables into the power track Install wear pads to the aft end of the fly section Using suitable lifting equipment slide fly section into the base section until power track attach point aligns with holes in side of base section Attach the power track to the aft end of fly boom section Secure power track with hardware 3121829 SECTION 4 amp PLATFORM 10 Using suitable lifting equipment s
250. p PLATFORM 5 After grinding it may be neccesary to help the rivet 6 Using a flat head screwdriver between the links out by using a center punch with a hammer twist the screwdriver and pull the links apart m 7 NOTE may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links 4 30 JLG Lift 3121829 SECTION 4 amp PLATFORM 7 Remove the link from the other section of the pow Installing a New Link ertrack using a screwdriver 1 Squeeze the peanut cut out end of the new link into the half shear female end of the track section lt 3121829 JLG Lift 4 31 SECTION 4 amp PLATFORM 2 Spread apart the half shear female end of the new 3 After the new link is installed in the powertrack the link and slide the peanut end of the track section round half shears will not fit properly in the peanut into it a screwdriver may be necessary to do this cut outs yet Ba CENE a im P BEN t oU m oto ale 4 32 JLG Lift 3121829 SECTION 4 amp PLATFORM 4 Pull the moving end out over the track so that the 6 Push pin thru center hole then slide washer on pin new connection is positioned in the curve of the powertrack In this position the round half shears will rotate into the peanut cut outs 5 The parts shown below will be used t
251. p up when this is done the count will reset 2 1 Flash code 2 1 indicates problems with the footswitch FWS FAULTY The two footswitch signals do not agree EMS recycle required START UP Neither EMS input is active the system is just switching on or is discharging the capacitor bank A welded line contactor might also cause this 3121829 JLG Lift 6 11 SECTION 6 JLG CONTROL SYSTEM 6 12 2 2 2 3 Table 6 4 Help Descriptions and Fault Flash Codes Flash code 2 2 indicates problems with drive amp steer selection DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range or the wiper is wire off DRIVE LOCKED JOYSTICK MOVED BEFORE EMS FWS Drive was selected before and during footswitch closure FWS INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected STEER LOCKED SELECTED BEFORE EMS FWS was selected before and during footswitch closure STEER SWITCHES FAULTY Both steer switches are active together WAITING FOR FWS TO BE OPEN Footswitch was closed when platform mode was selected JOYSTICK FAULTS CHECK PLATFORM BOX WIRING More than one of the drive lift and swing joystick center tap or wiper voltages is out of range This is probably due to a short circuit across a joystick port Flash code 2 3 indicates problems with boom function selection LIFT SWING JOYSTICK FAULTY The lift or s
252. pass 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 3 68 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE Troubleshooting Table 3 11 Troubleshooting Flash Code Problem Solution Unit Off Disabled engine will not Check position of selector switch crank Verify thatthe inhibit run is released Checkthe warning LED Remedy fault if present and restartthe RBS Checkthe start battery voltage Check control fuse Check for loose wiring or connection 1 1 Low Oil Pressure Check oil level Check oil supply lines Refer to Kubota Workshop manual WSM 0660 80 95 Verify correct operation of oil pressure switch with a test gauge 1 2 High Engine Temp Checkfor obstructions in the cooling airflow to the engine Checkthatthe ambienttemperature
253. perature of 20 degrees F 29 degrees C Changing Hydraulic Oil 1 2 4 Filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and synthetic base oils Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible 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 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 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 lubrica
254. 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 6 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 during the TDC period the CTS must last for at least the TDES period for the RBS to return to normal running operation Table 3 7 RBS Shutdown Sequence Remove CTS TDER Engine Run TDC Cooldown Engine Stop 3 55 SECTION 3 CHASSIS amp TURNTABLE To Connect the JLG Control System Analyzer to the Generator The JLG Control System Analyzer can be used to monitor generator settings and conditions Connect the analyzer as follows 1 Connect the four pin end of
255. pump or rotary coupling If equipped Steer proportional flow valve not functioning properly Steer control valve not functioning properly Steer cylinder not functioning properly REMEDY Replace joystick Run System Test Checkhelp message Checkhelp message Determine cause and repair or replace Replenish oil as necessary Clean repair or replace line or fitting Checkhelp message Checkhelp message Check elevation switch Check personality Repair or replace controller Adjust pressure Check wiring Run System test Run system test Clean repair or replace line Run System Test Repair or replace valve Repair or replace cylinder 7 12 Hydraulic system oil low Restricted hydraulic line or fitting Steer system pressure low Bentlinkage tie rods JLG Lift Replenish oil as necessary Clean repair or replace line or fitting Adjust pressure Repair or replace linkage as required 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Steering inoperative Machine will not steer left or to the right Machine wanders steering not firm Brake Slips Hydraulic pump not functioning properly Personality Settings Incorrect Steer cylinder not functioning properly Damaged wiring on control switch or solenoid valve Solenoid valve not functioning properly Control switch not functioning properly Reli
256. r 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 3 72 JLG Lift 3121829 SECTION 4 amp PLATFORM SECTION 4 amp PLATFORM 4 1 BOOM MAINTENANCE Removal 1 Remove the platform support as follows a Disconnect electrical cable from control con sole Using an overhead crane or suitable lifting device strap support the platform support Remove hardware from pin 1 Using a suitable brass drift and hammer remove pin 1 from the platform support Supporting the platform support remove the hardware from pin 2 Using a suitable brass drift and hammer remove pin 2 from the fly boom and remove the rotator Supporting the slave cylinder remove the hard ware from pin 3 Using a suitable brass drift and hammer remove pin 3 from the fly boom Tag and disconnect hydraulic lines to the slave leveling cylinder Use a suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports Remove the slave cylinder 2 Remove the boom from upright as follows a HYDRAULIC Remove hardware securing the cover plate on the side of the base boom section and remove hose clamps Disconnect wiring harness from ground control harness connector NOTICE LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINE
257. r of turntable and frame and connect as tagged prior to g Following the torque sequence diagram shown removal in Figure 3 15 tighten the bolts to an initial o Using all applicable safety precautions activate torque of 130 ft Ibs 175 Nm Then following the hydraulic system and functionally check the same sequence tighten to a final torque of swing system for proper and safe operation 190 ft Ibs 260 Nm h Remove lifting equipment from bearing i Use suitable lifting equipment to carefully posi tion the turntable assembly above the machine frame j 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 turntable 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 k Apply a light coating of Loctite 271 to the new bearing bolts and install through the turntable and inner race of bearing Following the torque sequence shown in Figure 3 15 tighten the bolts to an initial torque of 130 Figure 3 15 Swing Bearing Torquing Sequence 3 42 JLG Lift 3121829 3121829 Swing Bearing Torque Value Install with Loctite 190 ft lbs 260 Nm Checking Worm Gear End Play NOTE JLG Industries requires that a annual inspection be performed on the worm gear end play Using a dial indicator measure end play of worm gear b
258. r than expected battery voltage Check the battery and battery connections 2 Check the nominal battery voltage The first two dig its of the four digit model name indicate the battery voltage the charger supports Confirm that a nomi nal battery voltage is the same as the charger volt age 3 This fault will clear automatically when the low bat tery voltage problem is rectified 4 lf this problem does not clear after the battery volt age is confirmed to be higher than 1 0V per cell and all connections are good return the charger for ser vice JLG Lift 3 Flashes Charge Timeout Indicates the battery failed to charge within the allowed time This could occur if the battery is of larger capacity than the algorithm is intended for In unusual cases it could mean charger output is reduced due to high ambi ent temperature It can also occur if the battery is dam aged old or in poor condition 1 Check the battery for damage such as shorted cells and insufficient water Try the charger on a good bat tery 2 Ifthe same fault occurs on a good battery check the connections on the battery and connection to AC and the AC voltage itself 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 This fault must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 5 charger displays this fault on a battery pack and the pack i
259. rative Bypass valve not operating Electrical malfunction Hydraulic system oil low JLG Lift REMEDY Flush system and change oil using recom mended viscosity Flush system and change oil using recom mended viscosity Loosen valve and check mounting Repair as necessary Remove valve and repair or replace as neces Sary Correctly torque bolts Remove valve and repair or replace as neces sary Check pressure delivery to and from valve and repair or replace as necessary Remove and repair valve as necessary Remove valve and repair or replace as neces sary Remove line and clear obstruction or replace line as necessary Remove valve and repair or replace as neces sary Recycle footswitch Repair or replace control switch Run System Test Repair or replace holding valve Determine cause and repair or replace valve See wiring diagram Run System Test Replenish oil as necessary 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE Boom will not raise Boom will not lower Boom raises and lowers erratically Boom drifts down 3121829 Restricted or broken supply line on valve bank or hydraulic pump Directional valve not functioning properly Lift cylinder not functioning properly Liftfunction not activated within 7 seconds after footswitch was depressed Load capacity exceeded personnel or equip menton platform Lift s
260. red all the way pull the red releveling knob and activate lower lift down Adjust the releveling pressure relief to the value given in Table 5 4 Pressure Settings Prior to S N 0300062642 or Table 5 5 Pressure Settings S N 0300062642 to Present Turning clockwise increases the pressure and turning counterclockwise decreases pressure The relief valve is located directly below the red releveling knob 5 21 SECTION 5 HYDRAULICS Table 5 4 Pressure Settings Prior to S N 0300062642 ___ m Brake Steer Valve Steer Relief 2300 Main Relief E450A M450A 3200 Main Relief E450AJ M450AJ 3400 Jib Valve 1500 103 Releveling Valve Jib Relief Up and Down Releveling Relief Figure 5 24 Jib Valve Location 0 22 JLG Lift Table 5 5 Pressure Settings S N 0300062642 to Present Circuit Main Control Valve Tower Lift Down Relief E M450Au 1700 117 Tower Lift Down Relief 2600 179 S N 86022 to Present Tower Lift Down Relief E M450A 1700 17 Priorto 5 91053 Tower Lift Down Relief E M450A 2600 179 S N 91053 to Present Telescope Relief A 3000 Telescope Relief AJ amp AJP 3100 Platform Level Up Relief 3000 Platform Level Down Relief 1200 Brake Steer Valve Steer Relief 2300 Main Relief E450A M450A 3200 Main Relief E450AJ M450AJ 3400 Jib Valve 2200 152 Releveling Valve Releveling Relief E M450AJ 1200 83 Priorto S N 86022 Releveling Relie
261. remove tank for replacement or repair Replace fuel line Repair replace or adjust carburetor 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS TROUBLE One or both wheels will not steer One or both front wheels will not rotate or rotate erratically Difficulty encountered when moving machine No response to control Table 7 4 Chassis Assembly Troubleshooting PROBABLE CAUSE FRONT FRAME AXLE AREA Steering link ortie rod broken or attaching hard ware missing Wheel hub or bearings damaged or not lubri cated REAR FRAME AXLE AREA Load capacity exceeded Hubs Disconnected Machine being moved up too steep a grade Grade too steep Towing valve not closed Drive wheel tire treads worn smooth Drive brakes dragging system pressure too low Drive hub s defective DRIVE SYSTEM REMEDY Replace steering link tie rod or hardware as nec essary Replace hub or bearings as necessary and repack bearings with approved grease Reduce load Apply loads only in accordance with load capacity indicator Engage hubs as outlined in Operators Manual Remove machine from grade and check that drive system operates correctly see WARNING Placard on platform for specified grades and sideslopes Close towing valve Replace tires as necessary and inflate to speci fied pressure Re adjust pressure Re adjust pressure Repair or replace
262. rent protection SHORT CIRCUIT REVERSE CONTACTOR COIL The reverse contactor was not energized when required due to coil overcurrent protection 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 Flash code 4 2 indicates that the controller is over temperature CONTROLLER TOO HOT PLEASE WAIT The controller heatsink temperature reached 75 degrees The controller is shut down until it cools to below 70 degrees 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 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 wir ing error a speed encoder fault the brakes not releasing although brake Pressure is OK or the vehicle being overloaded so that the motor cannot turn the wheels DRIVE PREVENTED BOTH SPEED ENCODERS FAULTY Both speed encoder inp
263. ressure is below 7psi It is mounted on the side cover Fuel Solenoid Engine 0il Temperature Sensor The solenoid actuates the run stop lever of the engine This solenoid has a pull coil energized by the start control relay and hold energized by the fuel control The engine oil temperature sensor is used to sense the rs 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 3 64 JLG Lift 3121829 3121829 engine 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 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
264. roller current limit or safe operat ing area limit 0033 00 TRACTION MOTOR AT CURRENT LIMIT Traction current has reached controller current limit or safe operating area limit 0034 00 DRIVING AT CREEP TILTED Drive speed is limited to creep because the vehicle is tilted 211 21 POWER CYCLE The normal help message is issued at each power cycle 212 21 KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously 213 21 FSW FAULTY Both Footswitch Inputs are closed for more then one second 221 22 FUNCTION PROBLEM HORN PERMANENTL Y SELECTED Input was CLOSED during startup 224 22 FUNCTION PROBLEM STEER LEFT PERMANENTLY The Steer Left Switch was closed during power up SELECTED 225 22 FUNCTION PROBLEM STEER RIGHT PERMANENTLY The Steer Right Switch was closed during power up SELECTED 227 22 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are closed simultane ously 2211 22 FSW INTERLOCK TRIPPED The Footswitch was closed for more then seven seconds 2212 22 DRIVE LOCKED JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Footswitch open 2213 22 STEER LOCKED SELECTED BEFORE FOOTSWITCH A steer function was selected with Footswitch open 2221 22 LIFT SWING LOCKED JOYSTICK MOVED BEFORE FOOT A lift swing function was selected with Footswitch open SWITCH 2222 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed during Platform selection 2245 22 FUNCTION PROBLEM JIB SWING LEFT PERMANENTLY
265. s 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 JLG Lift 6 3 SECTION 6 JLG CONTROL SYSTEM Once the correct password is displayed press ENTER Adjusting Parameters Using the Hand Held The access level should display the following if the pass word was entered correctly Analyzer Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to MENU ACCESS LEVEL 1 adjust its value for example ENTER PERSONALITIES DRIVE ACCEL 1 0s MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular 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 4 JLG Lift 3121829 Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for
266. s are selected AND is configured to not allow simultaneous drive amp boom operation 2536 25 ALL FUNCTIONS PREVENTED FUNCTION CUTOUT Machine Setup s setfor 1 CHARGER amp BOOM and machine is above elevation 2542 25 FUNCTION PREVENTED BRAKES ELECTRONICALL Y Indicates Manual Brake release active in Ground mode RELEASED FOR TOWING 2548 25 SYSTEM TEST MODE ACTIVE system test mode active 2549 25 DRIVE amp BOOM PREVENTED SOFT TOUCH ACTIVE Machine Setup s SOFT TOUCHis setfor 2 BOOM amp DRIVE and Softtouch switch is OPEN 2550 25 BOOM PREVENTED FUNCTION CUTOUT Machine Setup s DRIVE CUTOUT is setfor 1 CHARGER 4 and machine is above elevation 2551 25 TELESCOPE OUT PREVENTED TIL TED amp ABOVE ELEVATION Telescope OUT is notpossible while the vehicle is tilted and above elevation AND is configured to prevent drive while tilted and above elevation 2552 25 LIFT UP PREVENTED TILTED amp ABOVE ELEVATION Lift UP is not possible while the vehicle is tilted and above eleva tion AND is configured to prevent drive while tilted and above ele vation 2553 25 LEVELING PREVENTED ABOVE ELEVATION Machine Setup s LEVEL inhibitis setfor 1 ELEV and machine is above elevation 2554 25 DRIVE PREVENTED SPEED SENSORS FAULTY Both Speed sensor input voltages are out of range 2555 25 FUNCTION PREVENTED SELECTED BEFORE FSW Function switch was selected before and during foot switch clo Sure 2556 25 FUNC
267. s contained in this book 3 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 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 4 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 Cleanliness 1 Ihe most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this 9 Should it be necessary to remove a component on 2 2 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 JLG Lift an ang
268. s now in the permanent mem Ory 3 Remove the AC power from the charger and recon nect the charger s positive connector to the battery It is recommended to check a newly changed algo rithm by repeating the above steps 1 and 3 Table 3 4 Battery Algorithms Proper Algorithm JLG P N Battery Type Algorithm Setting 173 1001114782 DISCOVER EV305A A 43 173 0400055 USBATTL16 173 3121829 JLG Lift 3121829 3 12 GENERATOR PRIOR TO S N 88539 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 directed 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 A
269. s of questionable status reset the charger by disconnecting AC for 30 seconds and then reconnect the AC to start a new charge cycle After a few charge cycles this problem could stop occur ring as the pack recovers 4 Flashes Check Battery This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal charge cycle to be started 1 Check that none of the battery pack connections between modules are reversed or incorrectly con nected 2 Check that one or more cells in the battery are no shorted 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 Try the charger on a good battery 5 If this fault occurs the battery is likely in poor condi tion Try to recover the pack with a charger that can charge the individual cells such as an automotive charger Be sure to set this charger to the appropri ate voltage 6V per 6V battery 12V per 12V string battery 3121829 3121829 5 Flashes Over Temperature This fault indicates the charger has become too hot during operation Though not damanging to the charger charge time will be extended significantly 1 This fault indication will not clear automatically but the charger will restart charging automatically when the temperature drops The fault indicaiton must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 2 If poss
270. s or 150 hours of operation 3 2 SPINDLE Setting Wheel Bearing End Play NOTICE BE SURE NOT TO OVER TIGHTEN THE SPINDLE NUT Tighten the spindle nut to assure the bearings are properly seated Loosen the spindle nut completely until the nut can be turned by hand Tighten the spindle nut by hand using a socket with out rotating the hub If the cotter pin can be assembled with the spindle nut finger tight insert cotter pin without backing the nut off If the cotter pin cannot be assembled with the spindle nut hand tight tighten the spindle nut to the nearest available slot and insert cotter pin If more than 5 of the cotter pin hole in the spindle can be seen in a slot back nut off to nearest slot and insert pin JLG Lift 5 Check the unit for end play by moving the hub up amp down parallel along the centerline of the spindle If you can feel excessive end play over the 0 010 0 25 mm specification recheck the nut to see what is causing the excessive end play Keep in mind that there can be some movement and still be within the 0 010 0 25 mm maximum specification If there is no way of getting the excessive end play out by using your fingers a socket or wrench may have to be used to set the end play 6 The units should be checked visually to make sure the cotter pins are installed and that the correct components have been used Each unit must also be checked for the proper feel to make sure there
271. scope cylinder Using a suitable lifting device attached to the sling carefully pull the telescope cylinder from the boom assembly 10 10 JLG Lift Using another lifting device support the rod end of the cylinder and remove the cylinder from the boom assembly Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area Installation 1 Attach a hydraulic power supply to the telescope cylinder ports Using suitable supports or lifting devices at each end of the cylinder extend the rod so that the cylinder pin attach holes are the same distance apart as the boom pin attach holes Using suitable lifting equipment carefully lower the cylinder to the boom assembly Using another lifting device support the rod end of the cylinder and install the cylinder into the boom assembly Remove lifting devices from the telescope cylinder Carefully install the telescope cylinder rod pin 1 through the fly boom and secure it with the retaining rings Carefully install the telescope cylinder barrel end to base securing cylinder to the base boom with four 4 bolts and hardware Remove applicable hydraulic line and port caps and correctly connect the hydraulic lines to the tele scope cylinder Ensure all hoses are correctly routed Remove boom prop and overhead crane Activate hydraulic system Using all applicable safety precautions operate the boom functions
272. sing s valve ports Operate the actuator through the housing ports Conductthe internal leakage test as described in the Testing section on page 24 of this manual c Purge air from actuator See bleeding proce dures 3121829 JLG Lift 4 27 SECTION 4 amp PLATFORM 4 13 POWERTRACK MAINTENANCE 2 Repeat step 1 and remove the screw from the other side of track Remove the bar poly roller from the Removing a Link poene R NOTE Hoses shown in the powertrack are for example only 2 Actual hose and cable arrangements will be differ 1 ent T 1 Clamp the bar and poly roller tightly so they do not spin when removing the screw With a small 4 ratchet and a t 20 torx bit remove the 8 32 x 0 500 screw from one side 4 28 JLG Lift 3121829 SECTION 4 amp PLATFORM 3 To remove link the rivets holding the links together 4 insert the tool into the rolled over end of the rivet as must be removed Use a right angle pneumatic die shown Grind out the middle of the rivet until the grinder with a 1 4 ball double cut bur attachment rolled over part of the rivet falls off Repeat this step for all the rivets that must be removed MOVE THE CABLES HOSES OUT OF THE DURING THE GRINDING PROCESS TO PROTECT THEM KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM 3121829 JLG Lift 4 29 SECTION 4 am
273. splays adjusts battery monitor which indicates WATER BATTERIES after a number of charge discharge cycles 3 Machine Configuration Programming Information 4150286 9 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 4 configuration will cause the personality settings to return to default values Default settings will be shown in bold type 1 MODELS names may change 1 Model E300 2 Model 400 3 Model 45 450 The elevated drive speed setting must be changed to 10 for E45AJ M45AJ E40AJP M450AJ E450AJ M400AJP E400AJP E400A and M400A machines going to Europe CE Also the elevated drive 6 speed setting must be changed to 15 for 4 M40APn E400AJP narrow MAOOAJPn E400A narrow and narrow machines going to Europe 3121829 JLG Lift SECTION 6 JLG CONTROL SYSTEM TILT SWITCH When tilted the tilt light is lit continuously and drive speed is reduced to the creep speed setting 1 5 degree reduces the maximum speed of all platform functions to creep when tilted and above elevation Reduces drive speed to creep when tilted Domestic Japan 2 3 degree reduces the maximum speed of all platform functions
274. stem 2 3 Not Used Not Used 2 4 Loss of Voltage Shutdown due to loss of volt Sense age sensing Contin Unit Disabled No Faults RBS enabled and nen can respond to any CTS Off Unit Disabled RBS off or disabled Will not respond to any CTS Low Pressure 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 3121829 SECTION 3 CHASSIS amp TURNTABLE SINOH sinoH uu ls s 66660 JequunwN yeya Jez euy uu 9 s S 12 2 4 yuen SUI 1 5 YURID spuooeg SOA GL spuooeg 1002 GL uny euiBu3 a spuooes ssed g QL eDung GL spuooeg AL 19109 559 1 191U3 559 dois puuo 19 UJ 889 4 9uON snjels 584 Od SHOA 2 2
275. t battery 26 Start battery 27 Pre heat 28 Inhibit run 29 Engine temp switch 30 Output voltage 31 opeed sensing 4 5V 32 Output current sense 33 Not used 34 Not used 35 Field Drive JLG Lift 3 65 SECTION 3 CHASSIS amp TURNTABLE Warnings and Safety Precautions WARNING THE RBS MAY START WITHOUT WARNING WARNING MORE THAN ONE LIVE CIRCUIT IS USED INSIDE THE RBS CON TROL PANEL EXERCISE CAUTION WHEN THE CONTROL PANEL IS OPEN EVEN WHEN THE RBS IS NOT RUNNING System Controls INHIBIT RUN INPUT The inhibit run input prevents the RBS from starting clears any existing calls to start and stops the engine immedi ately To return to normal operating mode the inhibit run input must be removed 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 2S CRANK SETTINGS Crank time 15s Hesettime 15s Crank cycles 3 SPEED TIME AND GLOW PLUG SETTINGS TD no speed signal 9S TD DC sensing fault 10s Starter disconnect 1000 Hz Overspeed shutdown 3800 RPM Underspeed shutdown 2000 RPM Glow plug on temperature 5 C Glow plug
276. t 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 plat form or ground modules to transmitted data This is probably due to wiring problems between the ground and power modules Flash code 7 7 indicates problems with a motor CAPACITOR BANK FAULT CHECK POWER CIRCUITS The capacitor bank is not charging This is probably due to a 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 OPEN CIRCUIT DIRECTIONAL CONTACTOR OR TRACTION MOTOR Traction point is collapsing when the traction MOSFETs are pulsed This is probably due to an open cir cuit traction motor or a power wiring error NOTE This fault is unlikely to be seen due to interaction with speed control PUMP POINT A LOW CHECK POWER CIRCUITS Pump point A is near OV when the pump MOSFETS are off This is probably due to a power 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
277. t both power ter minals with respect to battery ground The difference between those two measurements is the voltage applied to the load 7 5 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE Do NOT apply dielectric grease to the following con nections Main Boom Rotary sensor connections on Celesco Sensor JLG Lift LSS Modules connections Deutz EMR 2 connection Silicone Dielectric Compound must be used on all electri cal connections except for those mentioned above 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 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
278. tate coupling shaft drive link and rotor to seat the rotor and the assembled vanes into stator half creating the necessary clearance to assemble the seventh or full complement of seven vanes Assemble the seven vanes using minimum force Place second stator half on a fl at surface with seal ring groove up Apply a small amount of grease to a new seal ring 4 and assemble it into stator half ring groove Assemble the second stator half over the two align ment studs and rotor with seal ring side down onto the first stator half aligning any timing marks applied for this purpose A CAUTION IF THE STATOR HALF 8B IS A DIFFERENT HEIGHT THICKNESS THAN STATOR HALF 8D THE STATOR VANES 8 OR 8E OF THE SAME LENGTH HEIGHT AS THE STATOR HALF MUST BE REASSEMBLED IN THEIR RESPECTIVE STATOR HALF FOR THE ROTOR SET TO FUNCTION PROPERLY 8 Assemble six vanes or as many vanes that will read ily assemble into the stator vane pockets Grasp the output end of coupling shaft 12 with locking pliers or other appropriate turning device and rotate coupling shaft drive link and rotor to seat the rotor and the assembled vanes into sta tor creating the necessary clearance to assemble the seventh or full complement of seven vanes Assemble the seven vanes using minimum force Go to assembly procedure 15 to continue assem bly Final Checks 1 JLG Lift Pressurize the motor with 100 p s i dry air or nitro g
279. temperature of opera tion Replace worn rotor set by disassembling unit Replace rotor set drive link and coupling shaft by disas sembling unit Locate excessive heat source usually a restriction in the system and correctthe condition Locate blockage source and repair or replace Disassemble unit identify and remedy cause and repair replacing parts as necessary Checkfor and repair worn pump Locate source and eliminate cause 3 22 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE 1 Bolt 6 CommutatorRing 8C Stator Vane 12 Coupling Shaft 17 Backup Ring 22 Not Used 2 EndCover 7 Manifold 8D Stator Half 13 Inner Bushing 18 Housing 23 Not Used 3 Seal Ring 8 Rotor Set 9 Wear Plate 14 Thrust Washer 19 Outer Bushing 24 NotUsed 4 Seal Ring 8A Rotor 10 Drive Link 15 Thrust Bearing 20 Dirt amp WaterSeal 25 Backup Washer 5 Commutator 8B Stator Half 11 ThrustBearing 16 Seal 21 NotUsed Figure 3 11 Swing Motor Exploded View 3121829 JLG Lift 3 23 SECTION 3 CHASSIS amp TURNTABLE Preparation Before Disassembly Before you disassemble the motor unit or any of its components read this entire section It provides impor tant information on parts and procedures you will need to know to service the motor Thoroughly clean off all outside dirt especially from around fittings and hose connections before discon necting and removing the motor Remove rust or corro
280. that both switches are making contact when pedal is depressed Repair or replace footswitch as necessary Repair replace or adjust contact block as required Check wiring continuity Refer to proper wiring diagram Place switch to correct position Check and charge battery or replace battery as necessary Clean and secure battery terminals Usinga test meter check relay coil terminals for presence of electrical power and for energization ofrelay coil Also check relay terminals for cor rect switching of contacts Replace relay as nec essary Replace solenoid or motor in accordance with applicable manufacturer s manual Using atest meter check ignition switch for cor rect switching of contacts Replace switch as necessary Check wiring continuity See proper wiring dia gram Replace switch Adjust control module settings properly Repair or replace wiring Run System Test Replace horn SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS Table 7 6 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hourmeter inoperative Damaged wiring in hourmeter circuit Repair or replace wiring Inoperative hourmeter Replace hourmeter Platform alarm circuit Platform alarm inoperative Check platform alarm Run System Test Defective bulb in tilt light Replace bulb 7 18 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHE
281. the line you previously scribed on the cover to radially align the end cover into its original position 3 36 JLG Lift 3121829 SECTION 3 CHASSIS amp TURNTABLE One Piece Stator Construction 4 Assemble six vanes or as many vanes that will read ily assemble into the stator vane pockets A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the fol lowing procedures 1 Place stator onto wear plate 9 with seal ring 4 side down after following assembly procedures 1 through 13 Be sure the seal ring is in place 4 CAUTION EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA TOR VANE POCKETS 5 Grasp the output end of coupling shaft 12 with locking pliers or other appropriate turning device and rotate coupling shaft drive link and rotor to seat the rotor and the assembled vanes into stator creat ing the necessary clearance to assemble the sev enth or full complement of seven vanes Assemble 3 Assemble the rotor counterbore down if applicable the seven vanes using minimum force into stator and onto wear plate 9 with rotor splines into mesh with drive link 10 splines 2 f assembly alignment studs are not being utilized align stator bolt holes with wear plate and housing bolt holes and turn two bolts 1 finger tight into bolt holes approximately 180 degrees apart to retain sta tor and we
282. the piston seals are defective and must be replaced 6 If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 7 boom prop overhead crane activate hydraulic system and run cylinder through complete cycle to check for leaks and operation 5 4 JLG Lift 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 specific cylinder will be so noted Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 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 dum TED CLAMP ES I Z gt 4 Figure 5 1 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen
283. the turnta ble In addition the serial number is stamped on top of the end of the upper boom mid boom and lower boom at the left rear of the booms SERIAL NUMBER TURNTABLE _ SERIAL NUMBER FRAME SERIAL NUMBER PLATE Figure 1 1 Serial Number Locations JLG Lift 1 5 SECTION 1 SPECIFICATIONS Figure 1 2 Operator Maintenance amp Lubrication Diagram 3121829 JLG Lift 1 6 1 17 OPERATOR MAINTENANCE amp LUBRICATION NOTE The following numbers correspond to those in Fig ure 1 2 Operator Maintenance amp Lubrication Dia gram Table 1 19 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds min imum EPGL Extreme Pressure Gear Lube oil meeting API Service Classifi cation 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 3020022 EO Engine crankcase Oil Gas API SF SG cl
284. ting jib boom pivot weldment Using a soft head mallet install rotator support pin 4 into articulating jib boom and secure with mounting hardware Align bottom tubes with attach holes in articulating jib boom pivot weldment Using a soft head mallet install rotator support pin 3 into articulating jib boom pivot weldment and secure with mounting hardware Align articulating jib boom pivot weldment with attach holes in fly boom assembly Using a soft head mallet install pivot pin 2 into fly boom assembly and secure with mounting hardware Align the slave leveling cylinder with attach holes in articulating jio boom pivot weldment Using a soft head mallet install slave leveling cylinder pin 1 into articulating jib boom pivot weldment and secure with mounting hardware 4 9 LOAD SENSING SYSTEM Calibration 1 Place the machine in a stowed position 2 Activate both Emergency Stop switches and turn the Key switch to the platform position 3 Remove all loads from the basket including opera tor 4 Turn P1 clockwise in until the potentiometer begins to click 5 Plug the analyzer into port in the platform 6 Enter password 33271 7 Select Machine Set up Load Cell 1 Warn Only 8 Select Diagnostics System Load Cell on analyzer 9 Adjust P2 until the load 0 10 Place 455 LBS in the center of the basket 11 Adjust P1 until the load 100 12 Verify that the overload lamp lights continuously and the al
285. tions are good 6 battery connections are good an internal fault has been detected and the charger must be brought to a qualified service depot SECTION 3 CHASSIS amp TURNTABLE Excessive Battery Watering Requirements or Strong Sulphur Rotten Egg Smell These symptoms indicate over charging or high battery temperature These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack The most likely cause for this problem is incorrect charge algorithm setting and or high ambient temperatures 1 Confirm that the battery pack is not too small usu ally gt 50Ah 2 Confirm that the nominal battery voltage matches the charger output voltage 3 Confirm the correct battery charge algorithm If the battery pack is new the algorithm will need to be changed if the pack is not the same as the old one for instructions on how to determine and change the battery charge algorithm see the following sub sec tion 4 Ifthe output voltage of the charger seems excessive return the charger for service Contact JLG to get the expected battery voltage settings for the charger in question Be sure to have the charger s serial num ber and charge algorithm setting available when calling JLG Lift 3 51 SECTION 3 CHASSIS amp TURNTABLE Checking Changing the Battery Charger Algorithm The charger is pr
286. uously when above elevation and tilted and in conjunction with fault code flashes Option 8 SOFT TOUCH 0 Soft Touch System Installed 1 Soft Touch System Installed 9 LOAD CELL 0 Load Cell Installed 1 Warn Only 2 Warn amp Cutout 3 Warn amp Boom Cutout Level Vehicle Description NEW MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED A WARNING DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE LEVEL VEHICLE YES ENTER NO ESO LEVEL VEHICLE YES ENTER NO ESC 6 10 JLG Lift Not available at password level 2 ENTER confirms that vehicle is currently level and zeroes the tilt sensor mea surements Help Descriptions and Fault Flash Codes Table 6 3 JLG Control System Flash Codes Code Description 2 1 Faulty Footswitch EMS 2 2 Drive Steer inputs Footswitch Interlocks 2 3 Boom function inputs Lift Swing Joystick 2 5 Function Cutout Drive Cutout 3 1 Contactors miswired Motors miswired 3 2 Line contactor welded 3 3 Contactor short circuit or valve short circuit 3 5 Brake pressure input 4 2 Controller Overtemperature 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 3121829 SECTION 6 CONTROL SYSTEM Table 6 4 Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the
287. used by incorrect faction motor wiring Check all power wiring Checktraction motor HIGH TILT ANGLE The vehicle is very tilted or the tilt sensor has been damaged Check tilt sensor HOT POWER MODULE The heatsink temperature exceeds 75 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 switchon Check and if necessary correct all personality settings WAIT CAPBANK HI This message can be displayed if the system testis run shortly after the vehicle was used after a short wait it should clear OPEN FWS In platform mode the footswitch must be open at the start of the test CLOSE FWS In platform mode the footswitch must be closed when this message is displayed the foot switch MUST BE KEPT CLOSED during the valve amp contactor tests BAD FWS The two footswitch signals are not changing together probably because 15 open circuit One footswitch signal FSW1 is routed to the power module the other FSW2 is routed to the platform module Check footswitch and wiring 3121829 JLG Lift 6 23 SECTION 6 JLG CONTROL SYSTEM Table 6 7 System Test Messages TESTING VALVES Indicates that the valve test is beginning Each valve is alternately energized and de energized checks are m
288. using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading NOTICE 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 3121829 JLG Lift 7 25 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS WIRE STRANDS MUST BE VISIBLE lt INTHIS AREA WIRE STRANDS AND INSULATION MUST _ BOTH BE VISIBLE IN THIS AREA vx w gt 4 CUTOFF 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 26 JLG Lift 3121829 SECTION 7 BASIC TROUBLESHOOTING ELECTRICAL INFORMATION 8 SCHEMATICS 7 7 DEUTSCH CONNECTORS DT DTP Series Assembly C D Figure 7 12 DT DTP Contact Installation 1 Grasp crimped contact about 25mm behind the con tact barrel 2 Hold c
289. ut voltages are out of range LEFT SPEED ENCODER FAULTY The left speed encoder input voltages are out of range The vehicle will continue to drive at cutback using the right speed encoder RIGHT SPEED ENCODER FAULTY The right speed encoder input voltages are out of range The vehicle will continue to drive at cutback using the left speed encoder 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 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 incorrectly it could also be due to a speed encoder fault or faults as for NO VEHICLE MOVEMENT DETECTED with the vehicle on a grade JLG Lift 3121829 6 6 7 7 3121829 SECTION 6 CONTROL SYSTEM Table 6 4 Help Descriptions and Fault Flash Codes Flash code 6 6 indicates problems with the CANbus 48V PROTECTION TRIPPED CHECK INTER MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data and the protection circuit which supplies the platform and ground modules has tripped This is proba bly due to wiring problems at the platform or ground module CANbus FAILURE GROUND MODULE The power module is receiving from the platform module but not the ground module This should no
290. very precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci JLG Lift 2 3 2 fied intervals required the Lubrication Chart Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives 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 Refer to Section 1 for recommendations for viscosity ranges JLG recommends Mobil DTE 11 hydraulic oil which has an SAE viscosity of 10W and a viscosity index of 140 Start up of hydraulic system with oil temperatures below 20 degrees F 29 degrees C is not recom mended If it is necessary to start the system sub zero environment it will be necessary to heat the oil with a low density 100VAC heater to a mini mum tem
291. wing Joystick center tap is out of valid range or the wiper is wire off LIFT SWING LOCKED JOYSTICK MOVED BEFORE EMS FWS Upper Lift or swing was selected before and during footswitch closure PUMP POT FAULTY The pump pot is open circuit all plattorm boom functions except upper lift amp swing will run at creep PUMP SWITCHES FAULTY CHECK DIAGNOSTICS BOOM A boom function lower lift telescope basket level basket rotate jib has both directions selected together PUMP SWITCHES LOCKED SELECTED BEFORE EMS FWS A boom function lower lift telescope basket level basket rotate jib was selected before and during foot switch closure PUMP SWITCHED LOCKED SELECTED BEFORE EMS A ground boom function lower lift telescope basket level basket rotate jib was selected before key switch SWING LIFT JOYSTICK FAULTY The swing joystick center tap is out of valid range or the wiper is wire off JLG Lift 3121829 SECTION 6 CONTROL SYSTEM Table 6 4 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 A boom 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 A boom function is selected while function cutout is active and configured to cutout boom functions D
292. witch Joystick not functioning Hydraulic system oil low Electrical failure to valves Restricted or broken hydraulic line or fitting Directional valve not functioning properly Pressure relief valve not functioning properly Lift cylinder not functioning properly Binding lift cylinder or boom pivot pin See Boom will not raise Pressure relief valve not functioning properly Holding valve not functioning properly Hydraulic system oil low Restricted or broken hydraulic line or fitting Counterbalance valve on lift cylinder improperly adjusted or not functioning properly Directional valve not functioning properly Worn sealsin lift cylinder Cylinder not functioning properly Table 7 2 Boom Assembly Troubleshooting PROBABLE CAUSE REMEDY Clean or replace line Repair or replace valve Repair or replace cylinder Recycle footswitch Reduce load Refer to capacity placard Check wiring Run System Test Replenish oil as necessary See proper wiring diagram Runs System Test Clean repair or replace line or fitting Repair or replace valve Re adjustor replace valve Repair or replace cylinder Repair or replace cylinder or pin Re adjust or replace valve Re adjust or replace valve Replenish oil as required Clean repair or replace line or fitting Replace valve Repair or replace valve Replace seals Repair or replace cylinder Worn sealsin lift cylinder
293. y applying side to side movement by hand to platform If tolerance exceeds 0 010 reduce end play to less than 0 005 Refer to Adjusting End Play Allowable Tolerance 001 to 005 JLG Lift SECTION 3 CHASSIS amp TURNTABLE Adjusting End Play 1 2 Remove end plate Measure and record total thickness of existing shim pack Determine thickness of shim pack required to obtain 0 001 0 005 end play Adjust shim pack thickness as required to obtain proper end play Reduce end play by removing thicker shims and replacing with thinner shims included in kit Replace end plate and torque bolts to 90 ft 16 122 Nm end play Fig 2 Adjusting End Play END PLATE 3 43 SECTION 3 CHASSIS amp TURNTABLE SWING MOTOR SWING ROTATION BOX lt LLI m 2 gt 3121829 o me c VE ZG T NE idal l lt n V LAM NG NON veh gt A p M 22 o e o dL LN 2 gt NE Ja Z 2 D Z V M p IN j E 7 NN NA s y Z o gt 7 2 LL 7 A Y f lt gt 7662 l NN I N x ON B A 22 NN Y

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