JLG E450A Service And Maintenance Manual
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JLG E450A Service And Maintenance Manual

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Service and Maintenance Manual
AS/NZS
Models
E450A
E450AJ
M450A
M450AJ
SN 0300208529
to Present
PN - 3121714
November 30, 2018 - Rev D

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Summary of Contents for JLG E450A

  • Page 1 Service and Maintenance Manual Models E450A E450AJ M450A M450AJ SN 0300208529 to Present PN - 3121714 November 30, 2018 - Rev D AS/NZS...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - October 31, 2016 Revised B - August 23, 2017 Revised C - June 29, 2018 - Revised Covers Revised D - November 30, 2018 3121714...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment .......
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Inflation.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Battery Charger ..................3-57 Operating Instructions .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Boom Cleanliness Guidelines ............... 4-9 Articulating Jib Boom.
  • Page 9 To Connect the JLG Control System Analyzer........
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 11 Platform Components and Attaching Hardware (M450A & E450A) ....... . .
  • Page 12 Lower Lift Cylinder - E450A (SN 0300239756 to Present) ....... .
  • Page 13 Upper Lift Cylinder - E450A (SN 0300239756 to Present) ....... .
  • Page 14 Telescope Cylinder (E450A only) ........
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-165. Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 2 of 7 ... 5-153 5-166. Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 3 of 7 ... 5-154 5-167.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-36. Chassis Traction Harness - Sheet 1 of 4 ............. . 7-36 7-37.
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Tire Specifications.
  • Page 18 JLG Control System Flash Codes ........

  • Page 19: Specifications

    Maximum Travel Grade (Gradeablility) 1.3 CAPACITIES Maximum Travel Grade (Side Slope) 5° Table 1-3. Capacities Maximum Height: (Stowed) E450A 6 ft. 6.25 in. (1.9 m) Generator Fuel Tank 4 Gallons (15.1 L) E450AJ/M450AJ 6 ft. 7 in. (2.0 m) Hydraulic Oil Tank...

  • Page 20: Dimensional Data

    Platform Height 45 ft. 0 in. (13.72 m) NOTE: Aside from JLG recommendations, it is not advisable to mix Track Width 5 ft. 0 in. (1.51 m) oils of different brands or types, as they may not contain...

  • Page 21: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS Table 1-8. Mobil EAL 224H Specs Table 1-10. Major Component Weights Type Synthetic Biodegradable Component ISO Viscosity Grade 32/46 Platform and Support 97.5 Specific Gravity .922 Upper Boom Complete Pour Point, Max -25°F (-32°C) Mid Boom Complete Flash Point, Min.

  • Page 22: Maintenance & Lubrication Diagram

    SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance & Lubrication Diagram 3121714...

  • Page 23: Maintenance And Lubrication

    Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L-2105. Hydraulic Oil. Mobil DTE-10 Lube Point(s) - Grease Fittings Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG Part Capacity - Spray On No. 3020027) Lube - OG or Mobiltac375NC Interval - A/R Bearing Grease (JLG Part No.
  • Page 24 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - Under certain conditions, it may be neces- sary to replace the hydraulic filter on a more frequent basis.
  • Page 25 SECTION 1 - SPECIFICATIONS 6. Wheel Bearing 9. Engine 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;...

  • Page 26: Torque Chart (Sae Fasteners - Sheet 1 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121714...

  • Page 27: Torque Chart (Sae Fasteners - Sheet 2 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5) 3121714...

  • Page 28: Torque Chart (Sae Fasteners - Sheet 3 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 5) 1-10 3121714...

  • Page 29: Torque Chart (Metric Fasteners - Sheet 4 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 4 of 5) 3121714 1-11...

  • Page 30: Torque Chart (Metric Fasteners - Sheet 5 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 1-12 3121714...

  • Page 31: General

    Trained Service Technician as a person who has successfully care, maintenance, and inspections performed per JLG's rec- completed the JLG Service Training School for the subject JLG ommendations, and with any and all discrepancies corrected, product model. Reference the machine Service and Mainte- this product will be fit for continued use.

  • Page 32: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...

  • Page 33: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING your work to assure that nothing has been overlooked.

  • Page 34: Lubrication

    When recommended lubricants are not avail- 2. JLG recommends Mobil DTE-10 hydraulic oil, which has able, consult your local supplier for an equivalent that meets an SAE viscosity of 10W and a viscosity index of 168.

  • Page 35: Cylinder Drift

    SECTION 2 - GENERAL CYLINDER DRIFT Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...

  • Page 36: Pins And Composite Bearing Repair Guidelines

    Noise originating from the joint during operation. • Ground only to structure being welded. 2. Filament wound bearings should be replaced if any of Do NOT Do the Following When Welding on JLG the following is observed: Equipment a. Frayed or separated fibers on the liner surface.

  • Page 37: Inspection And Preventive Maintenance Schedule

    SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Boom Assembly 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 Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
  • Page 38 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator Drive Brakes...
  • Page 39 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...

  • Page 40: Engine Operating Temperature Specifications - Kubota

    F(82 (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120 F(49 NO OPERATION ABOVE THIS PROLONGED OPERATION IN AMBIENT TEMPERATURE 110 F(43 AMBIENT AIR TEMPERATURES OF 100 F(38 C) OR ABOVE.

  • Page 41: Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the air on the same axle should be the same. pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.

  • Page 42: Spindle

    SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Fol- 7. Insert the dust cap and check to make sure the cotter lowing the recommended sequence, tighten nuts per pin is not going to interfere. Cap must be pressed all the wheel torque chart.

  • Page 43: Spindle Assembly

    SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle 2780241 C 1001180839 D Figure 3-1. Spindle Assembly 3121714...

  • Page 44: Chassis Component Location

    SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 6. Battery 11. Drive Module (Left/Slave) 2. Steer Angle Sensor 7. Hydraulic Tank 12. Drive Hub 3. Steer Valve 8. Swing Bearing 13. Drive Motor 4. Motor/Pump 9. Swing Motor 14. Drive Brake 5.

  • Page 45: Tilt Module

    5. Use the right arrow to curse over to “LEVEL VEHICLE”. Depress Enter. Depress Enter again. the machine. Refer to Section 6, JLG Control System Analyzer Kit Instructions. Use a standard bubble level in two different 6. Verify that the tilt reading is now “0.0: 0.0".

  • Page 46: Speed Sensor

    SECTION 3 - CHASSIS & TURNTABLE GROUND STUD RHT PWR MOD PUMP CONTACTOR LFT LFT PWR MOD B+ RHT PWR MOD B- CONTACTOR RHT LFT PWR MOD U LFT PWR MOD B- RHT PWR MOD B+ POWER STUD 48V TO 12V DC/DC LFT PWR MOD W RHT PWR MOD U CONVERTER...

  • Page 47: Relay

    SECTION 3 - CHASSIS & TURNTABLE OPTIONAL INVERTER RL-2 VOTE RL-1 RELAY IGNITION RELAY Figure 3-5. Relay 3121714...

  • Page 48: System Fuses

    SECTION 3 - CHASSIS & TURNTABLE FC-3 OPTION FUSE (5A) FC-1 48V B+ (20A) FC-601 DELTA Q (30A) FC-2 12V SYSTEM (15A) NOTE: CHARGER FUSE SHOULD BE IN PLACE. Figure 3-6. System Fuses 3121714...

  • Page 49: Ignition Relay Fuse

    SECTION 3 - CHASSIS & TURNTABLE FC-4 IGNITION RELAY FUSE Figure 3-7. Ignition Relay Fuse 3121714...

  • Page 50: Drive Fuses

    SECTION 3 - CHASSIS & TURNTABLE IP 409 LEFT BRAKE POWER STUD IP 408 RIGHT BRAKE (10Amp) (10Amp) Figure 3-8. Drive Fuses 3-10 3121714...

  • Page 51: Drive Limit Switch

    SECTION 3 - CHASSIS & TURNTABLE 1001116232-A Figure 3-9. Drive Limit Switch 3121714 3-11...

  • Page 52: Steering Installation And Spindle

    SECTION 3 - CHASSIS & TURNTABLE 1. Steer Cylinder 7. Castle Nut 13. Hub 18. Castle Nut 2. Rod End 8. Thrust Washer 14. Lug Nut 19. Dust Cap 3. Nut 9. Lip Seal 15. Outer Bearing Cup 20. Cotter Pin 4.

  • Page 53: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE HUB Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll and Leak Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 54: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove the First Stage Sun Gear (10) if applicable. NOTE: On units with ratios greater than 36:1 numerically, there NOTE: Refer to Figure 3-11., Main Assembly - Sheet 1 of 2 and Fig- will not be a separate First Stage Sun Gear (10), as the gear ure 3-12., Main Assembly - Sheet 2 of 2.

  • Page 55: Main Assembly - Sheet 2 Of 2

    SECTION 3 - CHASSIS & TURNTABLE 1F. Ring Gear 9. Input Shaft 1G. Housing 10. First Stage Sun Gear 4. Output Carrier Subassembly 11. Second Stage Sun Gear 5. Retaining Ring 18. O-ring 6. Cover Assembly 19. Flat Head Bolt 6G.

  • Page 56: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 4. Slide the Planet Gear Sub-assembly (4) out of the Output Carrier (4A) being careful to not drop the Needle Bear- ings (4C) in the process. NOTE: Refer to Figure 3-13., Output Carrier and Figure 3-14., Planet Gear.

  • Page 57: Planet Gear

    SECTION 3 - CHASSIS & TURNTABLE 4B. Thrust Washer 4C. Needle Bearing 4D. Thrust Spacer 4F. Planet Gear Figure 3-14. Planet Gear 3121714 3-17...

  • Page 58: Input Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly NOTE: The Roll Pins (4G} should not be reused when reassembling the unit. NOTE: Refer to Figure 3-15., Input Carrier. 4. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A).

  • Page 59: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-spindle Disassembly 6. If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end. NOTE: Refer to Figure 3-16., Hub Spindle. 7. Remove Seal (1B) from Hub (1G). NOTE: The Seal (1B) should NOT be reused when reassembling the 1.

  • Page 60: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A). 5. Use appropriate tool to remove O-Ring (6E) from inter- NOTE: Refer to Figure 3-17., Cover Assembly. nal groove in Cover (6A). 6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A). 1.

  • Page 61: Input Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Assembly Output Planet Gear Assembly NOTE: Refer to Figure 3-15., Input Carrier. NOTE: Refer to Figure 3-14., Planet Gear. 1. Apply a liberal coat of grease to the bore of one Input 1.

  • Page 62: Output Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Assembly Hub-spindle Assembly NOTE: Refer to Figure 3-13., Output Carrier NOTE: Refer to Figure 3-16., Hub Spindle 1. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during (4A).

  • Page 63: Cover Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Assembly Main Assembly NOTE: Refer to Figure 3-17., Cover Assembly. NOTE: Refer to Figure 3-11., Main Assembly - Sheet 1 of 2 and Fig- ure 3-12., Main Assembly - Sheet 2 of 2. 1.

  • Page 64: Drive Hub - Sheet 1 Of 2

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Drive Hub - Sheet 1 of 2 3-24 3121714...

  • Page 65: Drive Hub - Sheet 2 Of 2

    SECTION 3 - CHASSIS & TURNTABLE 1A Spindle 1K Retaining Ring 3F Planet Gear 5 Retaining Ring 9 Input Shaft 1B Lip Seal 1L Spring 4A Output Carrier 6A Cover 10 Input Sun Gear 1C Tapered Bearing Cone 1M Thrust Washer 4B Thrust Washer 6B Disengage Cap 11 Output Sun Gear...

  • Page 66: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE MOTOR 8. Remove the screws (22) from the retaining plate (23). 9. Remove the retaining plate (23) from the cover (21). Removal 10. Remove the cover (21) from the shield end (18). 1.

  • Page 67: Assembly

    Tighten the bolts to torque 35 ft. lbs. (48 Nm). 7. Install the shaft seal (10). NOTE: Apply JLG Threadlocker PN 0100011 to bolts before instal- 8. Attach four bolts to secure the drive end plate with the lation.

  • Page 68: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 1. Not Included 10. Shaft Seal 19. Seal 28. O-Ring 2. Stator 11. Bearing 20. Seal 29. Rotor 3. Terminal Board 12. Washer 21. Cover 30. Retainer Clip 4. Nut 13. Sensor 22. Screw 31.

  • Page 69: Swing Bearing

    NOTE: This check is designed to replace the existing bearing bolt insert the 0.0015" feeler gauge between the bolt torque checks on JLG Lifts in service. This check must be head and hardened washer at the arrow indicated performed after the first 50 hours of machine operation position.

  • Page 70: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance extended and Mid/Lower Boom stowed, (See Figure 3- 22.), using a magnetic base dial indicator, measure and 1. With the boom positioned over the side of the machine, record the distance between the swing bearing and the Upper Boom horizontal with telescope fully turntable.

  • Page 71: Replacement Of Swing Bearing

    Use a suitable con- tainer to retain any residual hydraulic fluid. Cap lines JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8 BEARING NUTS and ports. AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS.

  • Page 72: Swing Bearing Torquing Sequence

    SECTION 3 - CHASSIS & TURNTABLE k. Apply a light coating of JLG Threadlocker PN 0100019 to the new bearing bolts and install IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED through the turntable and inner race of bearing.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 3121714 3-33...
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 3-34 3121714...

  • Page 75: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Adjusting End Play Install with JLG Threadlocker - 190 ft. lbs. (260 Nm). 1. Remove end plate. 2. Measure and record total thickness of existing shim Checking Worm Gear End Play pack.

  • Page 76: Swing Components

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-27. Swing Components 3-36 3121714...

  • Page 77: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING MOTOR Figure 3-28. Swing Motor - Cutaway 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. 3121714 3-37...

  • Page 78: Swing Motor Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufac- turers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

  • Page 79: Swing Motor - Exploded View

    SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used 2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used 3. Seal Ring 8.

  • Page 80: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- 1. Place the motor in a soft jawed vice, with coupling shaft nents read this entire section. It provides important infor- (12) pointed down and the vise jaws clamping firmly on mation on parts and procedures you will need to know to the sides of the housing (18) mounting flange or port...
  • Page 81 SECTION 3 - CHASSIS & 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 necessary.
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove seal 8. Remove manifold (7) and inspect for cracks surface scor- ring from commutator, using an air hose to blow air into ing, brinelling or spalling. Replace manifold if any of ring groove until seal ring is lifted out and discard seal these conditions exist.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 9. Remove rotor set (8) and wearplate (9), together to 10. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 retain the rotor set in its assembled form, maintaining degrees apart) and a roller vane centerline are on the the same rotor vane to stator contact surfaces.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 12. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bear- ing. Crocus cloth or fine emery paper may be used. 13.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 15. Remove thrust bearing (15) and thrust washer (14). 18. Inspect housing (18) assembly for cracks, the machined Inspect for wear, brinelling, corrosion and a full comple- surfaces for nicks, burrs, brinelling or corrosion. Remove ment of retained rollers.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the motor is com- 20. If the bearings, bushing or thrust washers must be pleted. replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) with- out damaging the housing.

  • Page 87: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly with the press base and the bearing/ bushing is not cocked when pressing a bearing/bushing into the housing. Replace all seals and seal rings with new ones each time you reassemble the motor unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing (18) 6. Assemble thrust washer (14) then thrust bearing (15) outer bearing counterbore. The dirt and water seal (20) that was removed from the motor. must be pressed in until its’...
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- 9. Apply a small amount of clean grease to a new seal ring tant grease has been applied to the lower (outer) hous- (4) and insert it into the housing (18) seal ring groove.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: It may be necessary to turn one alignment stud out of the alignment studs onto the housing (18). housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs and 18. Assemble a new seal ring (3) flat side up, into commuta- drive link (10) and onto the rotor set. Be sure the correct tor (5) and assemble commutator over the end of drive manifold surface is against the rotor set.
  • Page 92 SECTION 3 - CHASSIS & 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 compo- nents into place with a final torque of 25-30 ft.

  • Page 93: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor stator and vanes that cannot be read- ily assembled by hand can be assembled by the following procedures.

  • Page 94: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction A disassembled rotor set (8) that cannot be readily assem- IF THE STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS) THAN STATOR bled by hand and has a two piece stator can be assembled HALF (8D) THE STATOR VANES (8C) OR (8E)OF THE SAME LENGTH (HEIGHT) AS by the following procedures.

  • Page 95: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.7 BATTERY MAINTENANCE AND CHARGING Optional On Board Generator Battery Maintenance, Quarterly 1. Open battery compartment cover to allow access to bat- EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY. tery terminals and vent caps.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 3-56 3121714...

  • Page 97: Battery Charger

    SECTION 3 - CHASSIS & TURNTABLE 3.8 BATTERY CHARGER Operating Instructions JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTENSION CORD, FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.

  • Page 98: Maintenance Instructions

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Instructions Battery Charger Fault Codes If a fault occurred during charging, the red "Fault" LED will 1. For flooded lead-acid batteries, regularly check water flash with a code corresponding to the error. Refer to the levels of each battery cell after charging and add dis- table following for the flash codes and their removal.

  • Page 99: Battery Charger (E450A/Aj)

    SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-31. Battery Charger (E450A/AJ) 3121714 3-59...

  • Page 100: Battery Charger (M450Aj)

    SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-32. Battery Charger (M450AJ) 3-60 3121714...
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is not Indicates the battery failed to charge within the allowed connected or that the AC voltage is too low. It could also time.

  • Page 102: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    1. Remove excessive AC loads from inverter if installed. NOTE: Contact JLG if your specific battery model is not listed. 2. Try to clear the fault by unplugging the AC, waiting 30 seconds and reconnecting the ac power.

  • Page 103: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.9 GENERATOR Dynamo and Dynamo Voltage Regulator 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.

  • Page 104: Generator

    SECTION 3 - CHASSIS & TURNTABLE 1. Glow Plug Relay 4. Temperature Sensor 2. Fuel Control Relay 5. Voltage Regulator 3. Start Control Relay 6. Alternator 4. Fuel Solenoid 7. Starter 5. Fuel Pump 8. Starter Solenoid 6. Low Oil Pressure Switch 9.

  • Page 105: Start Battery

    SECTION 3 - CHASSIS & TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead-acid start battery (not supplied 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.

  • Page 106: Fuel Control Relay

    SECTION 3 - CHASSIS & TURNTABLE Fuel Control Relay Glow Plug Control Relay The glow plug control relay energizes the glow plug. It is The fuel control relay energizes the hold coil of the fuel energized by the engine/generator controller, pin J2-27. solenoid.

  • Page 107: Fuel Pump

    SECTION 3 - CHASSIS & 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.

  • Page 108: Alternator Output Current Sensor

    SECTION 3 - CHASSIS & TURNTABLE engine temperature shutdown 248°F (120°C) for the engine. The signal is also used in determining if the air glow plug should be energized. The engine oil temperature sensor is connected to the engine/generator controller at pins J2-8 and J2-19. The engine oil temperature sensor is located on the left side of the engine.

  • Page 109: Warnings And Safety Precautions

    SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Controller Interface Pin Assignments System Settings FUNCTION CALL TO START SETTINGS + Output voltage Low battery voltage call to start level 48.0 VDC Speed sensing + 5V Low battery voltage remove call to start level 54.0 VDC Output current sense Low temperature call to start level...

  • Page 110: Rbs Start

    SECTION 3 - CHASSIS & TURNTABLE RBS Start RBS shutdown Call to start Manual 48V DC applied to the input Call to start removed Manually Inhibit run input applied Automatic 1 Low battery voltage (below 48VDC) Automati- 1 Battery voltage above 54VDC and cally: finish charging current below 30ADC 2 Low engine temperature (below 5°C)

  • Page 111: Rbs Alarms And Flash Codes

    SECTION 3 - CHASSIS & 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 3-6. RBS Alarms and Flash Codes Flash Code Problem RBS Condition Below 7psi...

  • Page 112: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-7. Troubleshooting Flash Code Problem Solution Unit Off / Disabled (engine will not crank) Check position of selector switch. Verify that the inhibit run is released. Check the warning LED. Remedy fault if present and restart the RBS. Check the start battery voltage.

  • Page 113: Apu Engine Start Battery Boosting

    SECTION 3 - CHASSIS & TURNTABLE APU Engine Start Battery Boosting Always connect the POSITIVE (+) of the booster battery to DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID LEVEL IN THE the POSITIVE (+) of the APU start battery, and the NEGATIVE BATTERY.

  • Page 114: Supplementary Fuse For Apu

    • - Weather proof fuse holder - JLG PN 2400081 • - AGC1, 1 Amp fuse - JLG PN 2400080 • - 45 cm of #16 AWG wire - JLG PN 4920019 • - 2 X insulated butt splice connectors - JLG PN 4460035 •...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE 4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. 6. Re-install the harness with the new fuse in place. 5.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-76 3121714...

  • Page 117: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM PLATFORM 4. Remove the bolts and locknuts securing the support to the rotator. Support Removal Figure 4-1. Location of Components Platform Support 5. Using a suitable brass drift and hammer, remove the rotator shaft, then remove the support from the rotator.

  • Page 118: Support Installation

    2. Install the rotator center bolt. 6. Connect the electrical cables to the platform control console. 3. Apply JLG Threadlocker PN 0100011 to the bolts and locknuts securing the support to the rotator and install the bolts and locknuts. 4. Torque the nut on the rotator center bolt to 250-270 ft.

  • Page 119: Platform Support Torque Values

    NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Torque to 40 ft. lbs. (55 Nm) JLG Thread locker (#0100011) Torque to 250-270 ft. lbs. (339-366 Nm) Check torque every 150 hours of operation Figure 4-2.

  • Page 120: Rotator And Slave Cylinder Removal

    SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR AND SLAVE CYLINDER REMOVAL Installation 1. Using a suitable lifting equipment, adequately support Removal main boom weight along entire length. 1. Using a suitable lifting equipment, adequately support 2. Supporting the slave cylinder, Using a suitable brass main boom weight along entire length.

  • Page 121: Main Boom Powertrack (E/M450Aj)

    SECTION 4 - BOOM & PLATFORM 4.3 MAIN BOOM POWERTRACK (E/M450AJ) Installation NOTE: The Main Boom weighs approximately 590lbs. (268kg). Removal 1. Disconnect wiring harness connectors located in main 1. Using suitable lifting equipment, adequately support upright. Powertrack weight along entire length. 2.

  • Page 122: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM 4.4 BOOM MAINTENANCE Removal a. 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. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

  • Page 123: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Inspection 1. Inspect boom pivot pin for wear, scoring or other dam- 1. Loosen jam nuts on aft end of fly boom wear pad adjust- age, and for tapering or ovality. Replace pin as neces- ment and loosen adjustments.

  • Page 124: Installation

    SECTION 4 - BOOM & PLATFORM 11. Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring. 12. Align bolt holes at aft end of base boom section with telescope cylinder port block.

  • Page 125: Wear Pads

    2. Replace wear pads when worn to thickness shown machines that are used in excessively dirty environments. below. 1. JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom.

  • Page 126: Boom Limit Switches

    SECTION 4 - BOOM & PLATFORM THE FOLLOWING ANGLES ARE USED TO SET THE UPPER LIMIT SWITCH IF IT IS AN AJ MODEL THE JIB IS TO BE COMPLETELY LOWERED MAKE SURE THE LOWER BOOM IS COMPLETELY LOWERED ALL ANGLES ARE TAKEN FROM THE MIDDLE OF THE UPPER BOOM 0˚...

  • Page 127: Platform Components And Attaching Hardware (M450A & E450A)

    SECTION 4 - BOOM & PLATFORM Figure 4-5. Platform Components and Attaching Hardware (M450A & E450A) 3121714 4-11...

  • Page 128: Articulating Jib Boom

    SECTION 4 - BOOM & PLATFORM 4.8 ARTICULATING JIB BOOM Inspection NOTE: When inspecting pins and bearings refer to Section Removal 2, Pins and Composite Bearing Repair Guidelines. 1. For platform/support removal see platform/support 1. Inspect articulating fly boom pivot pin for wear, scoring, removal diagram.

  • Page 129: Boom Synchronizing Procedure

    SECTION 4 - BOOM & PLATFORM 3. Align bottom tubes with attach holes in rotator support. 4.9 BOOM SYNCHRONIZING PROCEDURE Using a soft head mallet, install rotator support pin #5 into articulating jib boom and secure with mounting NOTE: If the Lower Boom assembly does not fully lower: hardware.

  • Page 130: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.11 ROTARY ACTUATOR Tools Required for Assembly/Disassembly there are Upon assembly and disassembly of the actuator Theory Of Operation basic tools required. The tools and their intended func- tions are as follows: The rotary actuator is a simple mechanism that uses the slid- ing spline operating concept to convert linear piston motion 1.

  • Page 131: Rotary Actuator (Exploded View)

    SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.

  • Page 132: Rotator- Assembly Drawing

    SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing 3. Piston Sleeve 106.1. Port Plug 204.

  • Page 133: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 4. Install the end cap (4) removal tools provided with the Helac seal kit. 1. Remove the capscrews (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.
  • Page 134 SECTION 4 - BOOM & PLATFORM 7. Remove the stop tube if included. The stop tube is an 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and pis- available option to limit the rotation of the actuator. ton.
  • Page 135 SECTION 4 - BOOM & PLATFORM 12. To remove the piston (3) use a rubber mallet and a plas- 15. Remove the wear guides (302) from the end cap (4) and tic mandrel so the piston is no damaged. shaft (2). 13.

  • Page 136: Inspection

    SECTION 4 - BOOM & PLATFORM 18. Remove the wiper seal (304.1) from its groove in the end Inspection cap (4) and shaft (2). 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting. Carefully inspect all criti- cal areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.

  • Page 137: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular 1. Gather all the components and tools into one location motion.
  • Page 138 SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using a 8. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the hous- circular motion.
  • Page 139 SECTION 4 - BOOM & PLATFORM 10. Looking from the opposite end of the housing (1) you 13. Install 2 bolts in the threaded holes in the flange. Using a bar, rotate the shaft in a clockwise direction until the can see if your timing marks are lining up.
  • Page 140 SECTION 4 - BOOM & PLATFORM 16. Install the O-ring (204) and backup ring (207) into the 19. Place the lock pins (109) provided in the Helac seal kit in inner seal groove on the end cap (4). the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.

  • Page 141: Installing Counterbalance Valve

    If possible 3. The bolts that come with the valve are grade 8 bolts. test this using hydraulic hand pump or electric test. New bolts should be installed with a new valve. JLG Figure 4-9. Rotator Counterbalance Valve 3121714...

  • Page 142: Greasing Thrust Washers

    SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on 6. After the actuator is assembled but before it is put into a hydraulic test bench. The breakaway pressure — the pres- service, the thrust washer area must be packed with sure at which the shaft begins to rotate —...

  • Page 143: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 2. With an operator in the platform, open both bleed nip- ples 1/4 turn. Hydraulically rotate the platform to the After installation of the actuator on the equipment, it is impor- end of rotation (either clockwise or counterclockwise), tant that all safety devices such as tie rods or safety cables are and maintain hydraulic pressure.

  • Page 144: Troubleshooting

    SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 4. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.

  • Page 145: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.12 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the pow- ertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be differ- ent.
  • Page 146 SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together 4. insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled must be removed.
  • Page 147 SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet out 6. Using a flat head screwdriver between the links, twist by using a center punch with a hammer. the screwdriver and pull the links apart. NOTE: It 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.

  • Page 148: Installing A New Link

    SECTION 4 - BOOM & 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. 4-32 3121714...
  • Page 149 SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new link 3. After the new link is installed in the powertrack the and slide the peanut end of the track section into it. A round half-shears will not fit properly in the peanut cut- screwdriver may be necessary to do this.
  • Page 150 SECTION 4 - BOOM & PLATFORM In this position the round half-shears will rotate into the 6. Push pin through center hole then slide washer on pin. peanut cut outs. 5. The parts shown below will be used to connect the new link to the powertrack.
  • Page 151 SECTION 4 - BOOM & PLATFORM NOTE: When installing snap rings make sure they are 7. Install the snap ring in the groove on the pin. Repeat the seated in pin groove and closed properly. pin installation steps for all center holes that have the rivets removed.
  • Page 152 SECTION 4 - BOOM & PLATFORM NOTE: Maximum tightening torque is 18-20 in-lbs. 9. Pull up on the other end of the round bar and slide the new poly roller onto the bar. 4-36 3121714...

  • Page 153: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM 10. Install a new 8-32 x 0.500 self threading screw on the Replacing Fixed End Brackets other side. 1. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
  • Page 154 SECTION 4 - BOOM & PLATFORM NOTE: When installing snap rings make sure they are 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. seated in pin groove and closed properly. CLOSED SNAP RING 3. Take the new bracket and install bracket center pin and snap ring.

  • Page 155: Replacing Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets 2. Take new bracket and install center pin with snap ring. 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.
  • Page 156 SECTION 4 - BOOM & PLATFORM NOTE: When installing snap rings make sure they are 3. Install radius pins into their original locations and install seated in pin groove and closed properly. snap rings. Repeat with other moving end if replacing as well.

  • Page 157: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.13 SKYGUARD Function Test SKYGUARD ONLY Operation Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2). When the SkyGuard sensor is activated, functions in use at From the Platform Control Console in an area free from obstruc- the time of actuation will reverse or cutout.

  • Page 158: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains OPEN while the Sky- Guard sensor is actively engaged, it is possible the sensor has If SkyGuard does not function when the sensor is engaged, failed and should be replaced immediately.

  • Page 159: Basic Hydraulic Information & Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 160: Dip Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.

  • Page 161: Hydraulic Connection Assembly And Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512 TORQUE SPECIFICATION Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.

  • Page 162: Straight Thread Types, Port Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Straight Thread Types, Port Connections Flange Connection Types ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162 MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162 6149, DIN 3852 Figure 5-10.

  • Page 163: Assembly And Torque Specifications

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.

  • Page 164: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for American Standard Pipe MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR ALIGNMENT. Thread Tapered (NPTF) Connections. 1. Inspect components to ensure male and female port 5.

  • Page 165: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for British Standard Pipe MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR ALIGNMENT. Thread Tapered (BSPT) Connections 1. Inspect components to ensure male and female port 5.

  • Page 166: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - 1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.

  • Page 167: Flare (Jic) Thread - Steel

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...

  • Page 168: Flare (Jic) Thread - Aluminum/Brass

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 169 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-11...

  • Page 170: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings 4. Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass 1. Inspect the flare for obvious visual squareness and con- while using the Double Wrench Method outlined in this centricity issues with the tube OD.

  • Page 171: Flare (Sae) - Steel

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Turns From Thread Size ØA* ØB* [Ft-Lb] [N-m] Finger Tight Dash Size (TFFT)** (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 1/4 to 1/2 5/8-18...

  • Page 172: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.

  • Page 173: O-Ring Face Seal (Orfs) - Aluminum/Brass

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in) (mm)

  • Page 174: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.

  • Page 175: Din 24° Cone (Mbtl & Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-9. DIN 24° Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...

  • Page 176: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2. Remove the locknut from the bulkhead assembly. 3.

  • Page 177: Bulkhead Fittings (Bh) - Inch

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12 Torque...

  • Page 178: Bulkhead Fittings (Bh) - Metric

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5...
  • Page 179 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-21...

  • Page 180: Assembly Instructions For O-Ring Boss (Orb) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Tables 5-17, O-RING BOSS (ORB) while using the Double Fittings Wrench Method. 1. Inspect components to ensure that male and female NOTE: The table headings identify the straight thread O-ring port port threads are free of rust, splits, dirt, foreign matter, or and the type on the other side of the fitting.

  • Page 181: O-Ring Boss (Orb) - Table 1 Of 6

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb)

  • Page 182: O-Ring Boss (Orb) - Table 2 Of 6

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)

  • Page 183: O-Ring Boss (Orb) - Table 3 Of 6

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF)

  • Page 184: O-Ring Boss (Orb) - Table 4 Of 6

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)

  • Page 185: O-Ring Boss (Orb) - Table 5 Of 6

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque Thread Size ØA* Ft-Lb or (in-lb) [N-m] MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33)

  • Page 186: O-Ring Boss (Orb) - Table 6 Of 6

    1.19 30.10 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on 1 5/8-12 1.63 41.30 JLG applications. Consult specific service procedure if encountered. 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION...
  • Page 187 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-29...

  • Page 188: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Metric Flat Face Port (MFF) - L Metric (MFF) Fittings Series and Table 5-21, Table 5-22, Table 5-23, Metric Flat Face Port (MFF) - S Series while using the Double 1.

  • Page 189: Metric Flat Face Port (Mff) - L Series - Table 1 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...

  • Page 190: Metric Flat Face Port (Mff) - L Series - Table 2 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...

  • Page 191: Metric Flat Face Port (Mff) - L Series - Table 3 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...

  • Page 192: Metric Flat Face Port (Mff) - S Series - Table 1 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...

  • Page 193: Metric Flat Face Port (Mff) - S Series - Table 2 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...

  • Page 194: Metric Flat Face Port (Mff) - S Series - Table 3 Of 3

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...
  • Page 195 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-37...

  • Page 196: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24, Metric Pipe Parallel O-ring Boss (MPP) while using the Port Assembly Stud Ends Double Wrench Method.

  • Page 197: Metric Pipe Parallel O-Ring Boss (Mpp)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 198: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, British Standard Parallel Pipe Port (BSPP) Fittings (BSPP) - L Series and Table 5-28, Table 5-29, Table 5-30, British Standard Parallel Pipe Port (BSPP) - S Series while 1.

  • Page 199: British Standard Parallel Pipe Port (Bspp) - L Series - Table 1 Of 3

    G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121714 5-41...

  • Page 200: British Standard Parallel Pipe Port (Bspp) - L Series - Table 2 Of 3

    G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-42 3121714...

  • Page 201: British Standard Parallel Pipe Port (Bspp) - L Series - Table 3 Of 3

    G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121714 5-43...

  • Page 202: British Standard Parallel Pipe Port (Bspp) - S Series - Table 1 Of 3

    G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-44 3121714...

  • Page 203: British Standard Parallel Pipe Port (Bspp) - S Series - Table 2 Of 3

    G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121714 5-45...

  • Page 204: British Standard Parallel Pipe Port (Bspp) - S Series - Table 3 Of 3

    Service Manual. G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-46 3121714...
  • Page 205 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-47...

  • Page 206: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See O-ring Installation (Replacement) for O-ring installa- tion instructions.

  • Page 207: Flange Code (Fl61 & Fl62) -Inch Fasteners

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws Flange Size...

  • Page 208: Flange Code (Fl61 & Fl62) - Metric Fasteners

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws CLASS 10.9 Screws...

  • Page 209: Double Wrench Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Double Wrench Method improper joint load and leads to leaks. For hose connections, the ‘layline’ printed on the hose is a good indicator of proper To prevent undesired hose or connector rotation, two hose installation.

  • Page 210: Ffwr And Tfft Methods

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: 1. Tighten the swivel nut to the mating fitting until no lat- 1.

  • Page 211: O-Ring Installation (Replacement)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads dur- ing replacement or installation.

  • Page 212: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.3 HYDRAULIC CYLINDERS 5. Using a spanner wrench, unscrew the cylinder head from the barrel. Platform Level (Slave) Cylinder (E450Aonly) 6. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.

  • Page 213: Platform Level (Slave) Cylinder (E450A Only)

    11. O-ring 15. O-ring 19. Plug 3. Head 8. O-ring 12. Backup Ring 16. O-ring 20. Plug 4. Piston 9. Retainer 13. Wiper Seal 17. Bushing 21. Counterbalance Valve 5. Plug Figure 5-17. Platform Level (Slave) Cylinder (E450A only) 3121714 5-55...
  • Page 214 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 215: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 216: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than cable cylinder head gland groove.

  • Page 217: Platform Level (Slave) Cylinder E/M450Aj

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Platform Level (Slave) Cylinder E/M450AJ 5. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 218 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft. lbs. (70 Nm) ** Torque to 442 ft. lbs. (600 Nm) *** Torque to 7 ft. lbs.(10 Nm) **** Torque to 11 ft. lbs. (15Nm) 1001140279-A 1. Barrel 5.

  • Page 219: Platform Level (Slave) Cylinder - E/M450Aj (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 19** * Torque to 50-55 ft. lbs. (68-75 Nm) * *Torque to 7 ft. lbs. (10 Nm) 1001230304-A MAE32700A 1. Barrel 6. Piston Seal 11. Rod Seal 16. Counterbalance Valve 2. Rod 7.
  • Page 220 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 221: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 222: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Remove the cylinder rod from the holding fixture. cable cylinder head gland groove. Install the new retain- 11.

  • Page 223: Jib Lift Cylinder (E/M 450Aj Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Jib Lift Cylinder (E/M 450AJ Only) 5. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.

  • Page 224: Jib Lift Cylinder (Sn 0300208529 To Present, Sn B300001429 Through B300002486)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft. lbs. (70 Nm) ** Torque to 11 ft. lbs. (15 Nm) 1001140280 A 1. Barrel 6. Bushing 11. Retainer 16. O-ring 21. Piston Seal 2. Rod 7. Counterbalance Valve 12.

  • Page 225: Jib Lift Cylinder (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 19** 7*** 7*** * Torque to 7 ft. lbs. (10 Nm) ** Torque to 34-38 ft. lbs. (46-52 Nm) *** Torque to 50-55 ft. lbs. (68-75 Nm) 1001230305-A MAE32710A 1. Barrel 5. Bushing 9.
  • Page 226 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 227: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 228: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Remove the cylinder rod from the holding fixture. cable cylinder head gland groove. Install the new retain- 12.

  • Page 229: Lower Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lower Lift Cylinder 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-51. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 230: Cylinder Head Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Unscrew cylinder head with hook spanner wrench. 7. With the barrel clamped securely, apply pressure to the Refer Figure 5-52. & Figure 5-53. rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

  • Page 231: Lower Lift Cylinder - E450A (Sn 0300235601 Through 0300239755 E450Aj/M450Aj (Sn 0300208529 Through 0300239252, Sn B300001429 Through B300002461)

    7. Tube Spacer 11. Setscrew 15. Wear Ring 19. Bushing 4. Piston 8. Cartridge Valve 12. Piston Seal 16. O-ring Figure 5-51. Lower Lift Cylinder - E450A (SN 0300235601 through 0300239755), E450AJ/M450AJ (SN 0300208529 through 0300239252, SN B300001429 through B300002461) 3121714 5-73...

  • Page 232: Lower Lift Cylinder - E450A (Sn 0300239756 To Present)

    18. Cartridge Valve 3. Head 7. Backup Ring 11. O-ring 15. Steel Ball 19. Plug 4. Wiper Seal 8. Wear Ring 12. Piston 16. Setscrew 20. Bushing Figure 5-52. Lower Lift Cylinder - E450A (SN 0300239756 to Present) 5-74 3121714...
  • Page 233 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10*** * Torque to 30-35 ft. lbs. (41-47 Nm) ** Torque to 398 ft. lbs. (539 Nm) *** Torque to 11 ft. lbs. (15 Nm) 1001228035-A MAE32750A 1. Barrel 5. Head 9. Cartridge Valve 13.

  • Page 234: Lower Lift Cylinder - E450Aj/M450Aj (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7*** * Torque to 30-35 ft. lbs. (41- 47 Nm) ** Torque to 498- 608 ft. lbs. (675 - 825 Nm) *** Torque to 597- 730 ft. lbs. (810 - 990 Nm) 1001230300-A MAE32760A 1.
  • Page 235 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 236: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 237: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- b. Install the setscrew and ball on the piston and cable cylinder head gland groove. Install the new wear attach the piston on the rod.

  • Page 238: Mid Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Mid Lift Cylinder 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-66. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 239: Cylinder Head Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Unscrew cylinder head with hook spanner wrench. 7. With the barrel clamped securely, apply pressure to the Refer Figure 5-67. rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 5-64.
  • Page 240 16. Wear Ring 20. Wiper Seal 4. Piston 9. Cartridge Valve 13. Wear Ring 17. O-ring 21. Bushing 5. Head Figure 5-66. Mid Lift Cylinder - E450A (SN 0300235601 through 0300239755), E450AJ/M450AJ (SN 0300208529 through 0300239252, SN B300001429 through B300002461) 5-82 3121714...
  • Page 241 11. Plug 15. Piston Seal 19. Backup Ring 4. Piston 8. Spacer 12. Plug 16. O-ring 20. Rod Seal Figure 5-67. Mid Lift Cylinder - E450A (SN 0300239756 to Present), E450AJ/M450AJ (SN 0300239253 to Present, SN B300002462 through B300002486) 3121714 5-83...

  • Page 242: Mid Lift Cylinder - E450Aj/M450Aj (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 30-35 ft. lbs. (41-47 Nm) 1001230301-A MAE32730A 1. Barrel 5. Spacer 9. Rod Seal 13. O-ring 17. Backup Ring 21. Plug 2. Rod 6. Locking Piece 10. Piston Seal 14.
  • Page 243 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 244: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 245: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- b. Install locknut onto the piston and attach the piston cable cylinder head gland groove. Install the new wear on the rod.

  • Page 246: Upper Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Upper Lift Cylinder 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-80. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 247: Cylinder Head Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Unscrew cylinder head with hook spanner wrench. 7. With the barrel clamped securely, apply pressure to the Refer Figure 5-81. and Figure 5-82. rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.
  • Page 248 7. Spacer 11. Setscrew 15. O-ring 19. Wiper Seal 4. Piston 8. Bushing 12. Setscrew 16. Wear Ring Figure 5-80. Upper Lift Cylinder - E450A (SN 0300235601 through 0300239755), E450AJ/M450AJ (SN 0300208529 through 0300239755, SN B300001429 through B300002486) 5-90 3121714...

  • Page 249: Upper Lift Cylinder - E450A (Sn 0300239756 To Present)

    10. Plug 14. Piston Seal 18. Rod Seal 3. Retainer 7. Spacer 11. Setscrew 15. O-ring 19. Wiper Seal 4. Piston 8. Bushing 12. Setscrew 16. Wear Ring Figure 5-81. Upper Lift Cylinder - E450A (SN 0300239756 to Present) 3121714 5-91...

  • Page 250: Upper Lift Cylinder - E450Aj/M450Aj (Sn 0300239756 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 9*** 11** * Torque to 199 ft. lbs. (270 Nm) ** Torque to 4 ft. lbs. (5 Nm) *** Torque to 30-35 ft. lbs. (41-47 Nm) 1001228016-A MAE32850A 1. Barrel 5. Head 9.

  • Page 251: Upper Lift Cylinder - E450Aj/M450Aj (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 20** 20** * Torque to 30-35 ft. lbs. (41-48 Nm) ** Torque to 34-38 ft. lbs. (46-52 Nm) 1001230299-A MAE32740A 1. Barrel 5. Spacer 9. Rod Seal 13. O-ring 17. Wear Ring 2.
  • Page 252 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 253: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 254: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 12. Remove the cylinder rod from the holding fixture. cable cylinder head gland groove. Install the new wear 13.

  • Page 255: Master Cylinder (E450A Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder (E450A only) 4. Using a spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY 5. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.

  • Page 256: Master Cylinder (E450A Only)

    9. Spacer 13. Wiper Seal 2. Rod 6. Piston Seal 10. O-ring 14. O-ring 3. Head 7. O-ring 11. Backup Ring 15. O-ring 4. Piston 8. Retainer 12. Rod Seal 16. Bushing Figure 5-92. Master Cylinder (E450A only) 5-98 3121714...
  • Page 257 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 258: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 259: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 260: Master Cylinder E/M450Aj

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder E/M450AJ 4. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.

  • Page 261: Master Cylinder E/M450Aj (Sn 0300208529 To Present, Sn B300001429 Through B300002486)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque gland to 442 ft. lbs. (600 Nm) 1001140278 A 1. Barrel 5. Bushing 9. O-ring 13. O-ring 2. Rod 6. O-ring 10. Rod Seal 14. Wear Ring 3. Head 7. Retaining Ring 11.

  • Page 262: Master Cylinder E/M450Aj (Sn B3000024867 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 442.5 ft. lbs. (600 Nm) 1001230303-A MAE32870A 1. Barrel 5. Bushing 9. O-ring 13. O-ring 2. Rod 6. O-ring 10. Rod Seal 14. Wear Ring 3. Piston 7. Wear Ring 11.
  • Page 263 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 264: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 265: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. Install a new retaining diameter groove.

  • Page 266: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Cylinder 4. Using a hook spanner, loosen and remove spanner nut from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.

  • Page 267: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque gland to 200-250 ft. lbs. (271-339 Nm) 1683591 B 1. Wiper 6. Backup Ring 10. Tube 14. O-ring 2. Spanner Nut 7. O-ring 11. Piston 15. O-ring 3. Retaining Ring 8.
  • Page 268 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 269: Rod Seal Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder retaining ring into the applicable cylinder guide gland seal kit is used. See your JLG Parts Manual. groove. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 270: Piston Seal Kit Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 12. Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, the O.D. of the piston is recommended to install the HEAD, AND PISTON.

  • Page 271: Telescope Cylinder (E450A Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder (E450A only) 5. Mark cylinder head and barrel with a center punch for easy realignment. Unscrew the cylinder cap from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 272: Telescope Cylinder (E450A Only)

    4. Head 10. End Cap 16. O-ring 21. Fitting 26. Wear Pad 5. Spacer 11. Locknut 17. Backup Ring 22. Cap Fitting 27. JLG Thread Locker 6. Counterbalance Valve 12. Wear Ring Figure 5-122. Telescope Cylinder (E450A only) 5-114 3121714...
  • Page 273 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 274: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 275: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new cap seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 276: Telescope Cylinder E/M450Aj

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder E/M450AJ 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-133. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 277: Cylinder Rod Support

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 6. Attach a suitable pulling device to the cylinder rod end. 7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.

  • Page 278: Telescope Cylinder - E/M450Aj (Sn 0300208529 To Present, Sn B300001429 Through B300002486)

    9. End Cap 14. O-ring 19. Wiper Seal 24. Fitting 5. Spacer 10. Locknut 15. Wear Ring 20. JLG Thread Locker 25. Cap Fitting Figure 5-133. Telescope Cylinder - E/M450AJ (SN 0300208529 to Present, SN B300001429 through B300002486) 5-120 3121714...

  • Page 279: Telescope Cylinder - E450Aj/M450Aj (Sn B300002487 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 9*** 9*** * Torque to 15 ft. lbs. (21 Nm) **Torque to 10-11 ft. lbs. (14-15 Nm) ***Torque to 34-37 ft. lbs. (46-50 Nm) 1001230302-A MAE32880A 1. Barrel 5. Spacer 9. Fitting 13.
  • Page 280 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.

  • Page 281: Composite Bearing Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 282: Wiper Seal Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new cap seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 283: Components Boom

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-141. Components Boom 3121714 5-125...

  • Page 284: Cylinder Removal And Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.4 CYLINDER REMOVAL AND INSTALLATION Main Boom Lift Cylinder Installation NOTE: Coat I.D. of bushings with specified lubricant prior to Main Boom Lift Cylinder Removal installing pins. NOTE: The Main Boom weighs approximately 450lbs. (204kg). NOTE: The Main Boom Lift Cylinder weighs approximately 97 lbs.

  • Page 285: Mid Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Mid Boom Lift Cylinder Removal Mid Boom Lift Cylinder Installation NOTE: The Upright weighs approximately 92 lbs. (42kg) and Main NOTE: Coat I.D. of bushings with specified lubricant prior to Boom weighs approximately 450lbs. (204kg). installing pins.

  • Page 286: Lower Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lower Boom Lift Cylinder Removal Lower Boom Lift Cylinder Installation NOTE: The Lower Lift Cylinder weighs approximately 130lbs. NOTE: Coat I.D. of bushings with specified lubricant prior to (59kg). installing pins. 1. Place machine on flat and level surface. Place the Main NOTE: The Lower Lift Cylinder weighs approximately 130lbs.

  • Page 287: Main Boom Telescope Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Removal 10. Using another lifting device, support the rod end of the cylinder and remove the cylinder from the boom assem- bly. 1. Place machine on flat and level surface, with Main Boom in the horizontal position.

  • Page 288: Pressure Setting Procedures

    5.6 PRESSURE SETTING PROCEDURES PROCEDURE NOTE: Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the NOTE: Bleeding procedure should only be necessary if machine until hydraulic system has warmed to normal rebuilding or replacing lift cylinder.

  • Page 289: Platform Level Up Relief

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Platform Level Up Relief Platform Level Down Relief 1. Install the pressure gauge at the "B2" port on the back of 1. Install the pressure gauge at the "B1" port on the back of the Main Control Valve, activate and bottom out Plat- the Main Control Valve, activate and bottom out Plat- form Level Up.

  • Page 290: Steer Relief

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Relief 4. Adjust the releveling pressure relief to the value given in Figure 5-151., Main Valve Pressure Adjustment. Turning 1. With pressure gauge at “G” port on steer/brake valve, clockwise increases the pressure and turning counter- activate and bottom out Steer Left or Right.

  • Page 291: Hydraulic Component Location

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS JIB VALVE RELEVELING VALVE MAIN CONTROL VALVE HYBRID JIB VALVE STEER VALVE MAE32890 Figure 5-147. Hydraulic Component Location 3121714 5-133...

  • Page 292: Steer Valve Pressure Adjustment

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS STEER RELIEF Figure 5-148. Steer Valve Pressure Adjustment 5-134 3121714...

  • Page 293: Steer Valve Component

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS STEER RELIEF Figure 5-149. Steer Valve Component 3121714 5-135...

  • Page 294: Steer Valve Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2, B 1, A 1001177364-G MAE32360G Table 5-33. Cartridge Torque Values Table 5-34. Coil Torque Values Ft. Lbs. Ft. Lbs. 35-40 47-54 10-12 13-16 25-30 34-41 Figure 5-150. Steer Valve Torque Specification 5-136 3121714...

  • Page 295: Main Valve Pressure Adjustment

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS RELEVELING VALVE RELEVELING RELIEF ADJUST TO 2200 psi (151.7 Bar) UPPER LIFT DOWN RELIEF ADJUST TO 800 psi (55.15 Bar) LOWER LIFT DOWN RELIEF ADJUST TO 2600 psi (179.26 Bar) TELESCOPE RELIEF ADJUST TO 3000 psi (206.84 Bar) PLATFORM LEVEL RELIEF...

  • Page 296: Main Valve Components

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS EMERGENCY DESCENT HAND PUMP RELEVELING VALVE BYPASS UNLOADING RELIEF RELEVELING RELIEF FLOW REGULATOR MAIN LIFT UP AND DOWN VALVE TOWER LIFT UP AND DOWN VALVE EMERGENCY DESCENT VALVE TELESCOPE IN VALVE PLATFORM ROTATE VALVE SWING ARREST VALVE...

  • Page 297: Main Control Valve Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2, A 1, B 1, B 1, C 1, A 1, A 2, A 1001180554-F 1, B MAE32320F Table 5-35. Cartridge Torque Values Table 5-36. Coil Torque Values Ft. Lbs. Ft. Lbs. 10-12 13-16 7-10...

  • Page 298: Releveling Valve Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001097777-B MAE32330B Table 5-37. Cartridge Torque Values Ft. Lbs. Figure 5-154. Releveling Valve Torque Specification 5-140 3121714...

  • Page 299: Cartridge Torque Values

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1, A 1001097775-C MAE32380C Table 5-38. Cartridge Torque Values Table 5-39. Coil Torque Values Ft. Lbs. Ft. Lbs. Figure 5-155. Jib Valve Torque Specification (SN 0300208529 through 0300233452, SN B300001429 through B300002532) 3121714 5-141...

  • Page 300: Jib Valve Torque Specification (Sn 0300233452 To Present, Sn B300002533 To Present)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001216920-C MAE32370C Table 5-40. Cartridge Torque Values Ft. Lbs. Figure 5-156. Jib Valve Torque Specification (SN 0300233452 to Present, SN B300002533 to Present) 5-142 3121714...
  • Page 301 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-143...

  • Page 302: Sn B300001429 Through B300002532) - Sheet 1 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 303: Sn B300001429 Through B300002532) - Sheet 2 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT...

  • Page 304: Sn B300001429 Through B300002532) - Sheet 3 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY JIB VALVE ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 305: Sn B300001429 Through B300002532) - Sheet 4 Of 7

    JIB VALVE E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT LOWER LIFT...

  • Page 306: Sn B300001429 Through B300002532) - Sheet 5 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 307: Sn B300001429 Through B300002532) - Sheet 6 Of 7

    E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN JIB VALVE ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT JIB CYLINDER...

  • Page 308: Sn B300001429 Through B300002532) - Sheet 7 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS COMPONENT LIST 1. PROPORTIONAL FLOW REGULATOR, PRESSURE COMPENSATED, PV70-3001B-0-N-12DW 2. 2-POS, 2-WAY POPPET VALVE, NORMALLY OPEN, SV08-21-0-N-12DW (BYPASS UNLOADING) 3. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (LOWER LIFT) 4. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (UPPER LIFT) 5.
  • Page 309 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This page left blank intentionally 3121714 5-151...

  • Page 310: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 1 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 311: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 2 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT...

  • Page 312: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 3 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR JIB VALVE .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 313: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 4 Of 7

    JIB VALVE E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT LOWER LIFT...

  • Page 314: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 5 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 JIB VALVE .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...

  • Page 315: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 6 Of 7

    E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN JIB VALVE ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT JIB CYLINDER...

  • Page 316: Hydraulic Schematic (Sn 0300233452 To Present, Sn B300002533 To Present) - Sheet 7 Of 7

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS COMPONENT LIST 1. PROPORTIONAL FLOW REGULATOR, PRESSURE COMPENSATED, PV70-3001B-0-N-12DW 2. 2-POS, 2-WAY POPPET VALVE, NORMALLY OPEN, SV08-21-0-N-12DW (BYPASS UNLOADING) 3. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (LOWER LIFT) 4. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (UPPER LIFT) 5.

  • Page 317: Jlg Control System

    The JLG designed Control System is a 48 volt based motor con- NOTE: Each module has a label with the JLG part number and a trol unit installed on the boom lift. serial number which contains a date code.

  • Page 318: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer With the machine power on and the analyzer connected prop- Connect the four pin end of the cable supplied with the erly, the analyzer will display the following:...

  • Page 319: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: DRIVE BOOM HELP SYSTEM DIAGNOSTICS DATALOG SYSTEM TEST VERSIONS ACCESS LEVEL PERSONALITIES MACHINE SETUP Pressing ENTER with any of the above displayed menus, LEVEL VEHICLE (level 1 only) will display additional sub-menus within the selected menu.

  • Page 320: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 321: Machine Setup

    Not available at password level 2 ENTER confirms that vehicle is currently level, and zeroes the tilt sensor measurements There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK...

  • Page 322: Analyzer Abbreviations

    SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING ACCEL ACCELERATE GROUND ACTIVE GREEN ANALOG DIGITAL CONVERTER COUNT GROUND MODULE AMB. AMBIENT HOURS ANGLE HARDWARE AUXILIARY HWFS HARDWARE FAILSAFE BOOM CONTROL SYSTEM...
  • Page 323 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP...

  • Page 324: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 325 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number TILT: 5 DEGREES+CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also disallows the tower lift up, drive, telescope ANSI USA, out and lift up.
  • Page 326 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number LOAD SYSTEM: NO: No load sensor installed. * Only visible under certain WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps(5 sec ON, 2 sec OFF).
  • Page 327 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number CHARGER INTERLOCK: DRIVE ONLY: Drive function is disabled when battery charger is plugged in. CUTOUT ALL: Drive and bottom function is disabled when battery charger is plugged in.

  • Page 328: Machine Configuration Programming Settings

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings E450 E450 Display Units Model Number Market Alert Beacon Batteries Temp Cutout Wheel Drive Tilt Charger Interlock Ground Alarm Plat Lvl Ovr Cut BOLD TEXT indicates the default setting.

  • Page 329: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5s to 5.0s 2.0s...
  • Page 330 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS BOOM LIFT ACCELeration 0.1 to 5.0s 2.5s DECELeration 0.1 to 5.0s 2.5s MINimum UP speed 1 to 15% MAXimum UP speed 36 to 80% CREEP maximum UP speed...
  • Page 331 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS CREEP maximum DOWN speed 16 to 35% JIB SWING ACCELeration 0.1 to 5.0s 2.0s DECELeration 0.1 to 5.0s 1.0s MINimum LEFT speed 1 to 15% MAXimum LEFT speed...
  • Page 332 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS Telescope OUT 61 to 100% Jib UP 41 to 80% Jib DOWN 41 to 80% Jib SWING 41 to 75% Platform LEVEL 36 to 80% Platform ROTATE...

  • Page 333: Analyzer Software P1.4 - Sheet 1 Of 5

    SECTION 6 - JLG CONTROL SYSTEM ANAL YZER MENU STRUCTURE MENU : HELP : (001) HELP : PRESS ENTER SYSTEM OK LOG : *(XXXXX) X : XXXXXXXXXXXXXX DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : MENU : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS...

  • Page 334: Analyzer Software P1.4 - Sheet 2 Of 5

    SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : TRACTION VOLTAGE/CUR OPER CONTROLS OPTIONS PLATFORM LOAD CAN STATISTICS SYSTEM INPUTS RIGHT MOTOR BATTERY SOC JOYSTICK DRIVE H&T LIGHTS SW...

  • Page 335: Analyzer Software P1.4 - Sheet 3 Of 5

    SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : CAN STATISTICS DEBUG UGM I/O CALIBRATION DATA DATALOG VERSIONS PLATFORM LOAD CAN1 STATISTICS DEBUG DIAG UGM TILT X DATALOG TIME DATALOG CYCLES ON XXXXH XXM SOFTWARD XX.XX...

  • Page 336: Analyzer Software P1.4 - Sheet 4 Of 5

    SECTION 6 - JLG CONTROL SYSTEM FROM MENU : OPERATOR ACCESS MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES DRIVE STEER SWING TOWER LIFT LIFT TELESCOPE DRIVE MAX SPEED STEER SWING TOWER LIFT...

  • Page 337: Analyzer Software P1.4 - Sheet 5 Of 5

    SECTION 6 - JLG CONTROL SYSTEM FROM MENU : PERSONALITIES MENU: MODEL MARKET BATTERIES TILT GROUND ALARM MACHINE SETUP E400 ANSI USA 310AH FLOOD 5 DEGREES JIB SWING SKYGUARD SOFTTOUCH H & T LIGHTS LOAD SYSTEM FUNCTION CUTOUT DISPLAY UNITS...

  • Page 338: Machine Orientation When Performing Test

    SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN PERFORMING Main lift: Main Lift in stowed position Tower Lift in stowed position, Telescope Retracted. Main Lift Up, record time. Main TEST Lift Down, record time. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode;...

  • Page 339: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM Test Notes 6.4 FUNCTION SPEED Stop watch should be started with the function move- ment, not with actuation of joystick and switch. Table 6-5. Function Speeds Drive speeds should be set to the values below regard- less of the tire size.

  • Page 340: Control Module Location - Sheet 1 Of 2

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONTROL MODULE Figure 6-7. Control Module Location - Sheet 1 of 2 6-24 3121714...

  • Page 341: Control Module Location - Sheet 2 Of 2

    SECTION 6 - JLG CONTROL SYSTEM GENERATOR CONTROL MODULE GROUND CONTROL MODULE Figure 6-8. Control Module Location - Sheet 2 of 2 3121714 6-25...

  • Page 342: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-9. Analyzer Connecting Points 6-26 3121714...

  • Page 343: Power Module - Lh

    SECTION 6 - JLG CONTROL SYSTEM 1001192212 D Figure 6-10. Power Module - LH 3121714 6-27...

  • Page 344: Power Module - Rh

    SECTION 6 - JLG CONTROL SYSTEM CONNECTOR 1001178339 E Figure 6-11. Power Module - RH 6-28 3121714...

  • Page 345: Ground Control Module - Sheet 1 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Connector Function Type UNUSED DIGITAL OUTPUT ALERT BEACON POWER DIGITAL OUTPUT UNUSED DIGITAL OUTPUT ALERT BEACON GROUND GROUND INPUT UNUSED GROUND INPUT UNUSED DIGITAL OUTPUT UNUSED DIGITAL OUTPUT UNUSED (GROUND) GROUND INPUT UNUSED (GROUND)

  • Page 346: Ground Control Module - Sheet 2 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Connector Function Type PLATFORM EMS DIGITAL INPUT PLATFORM MODE DIGITAL INPUT GROUND MODE DIGITAL INPUT UPPER BOOM ELEVATION SWITCH ANALOG INPUT UNUSED VOLTAGE OUTPUT CAN1 TERMINATOR TERM LOWER BOOM ELEVATION SWITCH ANALOG INPUT UNUSED...

  • Page 347: Ground Control Module - Sheet 3 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Connector Function Type MODULE GROUND / GROUND FROM BATTERY GROUND OUTPUT MODULE POWER / GROUND EMS VBAT INPUT (Black) GROUND TO PLATFORM MODULE GROUND INPUT POWER TO PLATFORM MODULE / GROUND EMS OUT TO PLATFORM...

  • Page 348: Platform Module - Sheet 1 Of 2

    SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION UNALLOCATED (JIB RT) DIGITAL INPUT UNALLOCATED (JIB LT) DIGITAL INPUT UNUSED (BATTERY VOLTAGE) BATTERY VOLTAGE DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT UNALLOCATED (BASKET STOW SWITCH) DIGITAL INPUT CHASSIS TILTED INDICATOR...

  • Page 349: Platform Module - Sheet 2 Of 2

    SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION LIFT / SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE LIFT CENTER TAP ANALOG INPUT LIFT SIGNAL ANALOG INPUT SWING SIGNAL ANALOG INPUT NATURAL SWING CENTER TAP ANALOG INPUT UNUSED ANALOG INPUT LIFT / SWING JOYSTICK RETURN...

  • Page 350: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Help Descriptions and Fault Flash Codes Table 6-6. Machine Setup Descriptions Table 6-7. JLG Control System Flash Codes MODEL NUMBER Displays/adjusts machine model NOTE: all Code Description personalities reset to default when model number is altered...

  • Page 351: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected.
  • Page 352 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Descriptions and Fault Flash Codes Flash code 2/2 indicates problems with drive & steer selection. DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range, or the wiper is wire-off.
  • Page 353 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Descriptions and Fault Flash Codes 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 pre- vent vehicle roll on the grade.
  • Page 354 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Help Descriptions and Fault Flash Codes CANbus FAILURE: GROUND MODULE The power module is receiving from the platform module but not the ground module. This should not be possible! CANbus FAILURE: PLATFORM MODULE The power module is receiving from the ground module but not the platform module.
  • Page 355 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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 did not complete because traction point A is not safe, or the hardware failsafe is perma- nently tripped.

  • Page 356: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure arrow keys move between items in the same level. The In the following structure descriptions, an intended item is or DOWN arrow keys alter a value if allowed. selected by pressing ENTER ;...
  • Page 357 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLAT LVL DEMAND UP/DOWN XXX%/CREEP Direction and percentage of input command (or CREEP if applicable)
  • Page 358 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) SYSTEM INPUTS BOOM ELEV SW OPEN/CLOSED State of Boom Elevation Switch #1...
  • Page 359 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) VOLTAGE/CUR BATTERY SOC XXX%/DISCHARGED/DEEP DISCHARGED UGM calculated battery State-of-Charge; display percentage unless...
  • Page 360 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) JIB LIFT UP SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input...
  • Page 361 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLATFORM LOAD PLATFORM LOAD STATE: OK/OVER LOAD LSS Status...

  • Page 362: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM System Self Test operator to close the lower lift up switch. When the con- troller sees that the lower lift up switch has been closed, The system self test is utilized to locate typical problems. See it will move on to the next input, lower lift down LLD.

  • Page 363: System Test Messages

    SECTION 6 - JLG CONTROL SYSTEM Table 6-11. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run while running certain “critical” checks are made. CHECK GROUND/ PLATFORM SELECT The analyzer must be connected to the active control station to run the system test...
  • Page 364 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer PLATFORM RT VALVE SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay) PLATFORM LEVEL UP...
  • Page 365 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP TELE IN OPEN or CLOSED (advanced test after switch toggles) CL TELE OUT OPEN or CLOSED (advanced test after switch toggles)
  • Page 366 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP JIB DOWN OPEN or CLOSED (advanced test after switch toggles) CL JIB SWING LEFT OPEN or CLOSED (advanced test after switch toggles)

  • Page 367: Calibrating Steer

    SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATING STEER 8. Use the arrow keys to reach STEER SENSOR. The screen will read: When calibrating steering, each individual wheel must be cali- brated in order to make the tire and wheel parallel with the frame.
  • Page 368 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 14. Hit Enter. The screen will read: 15. The display will read Left Steer Maximum value. 11. Activate the steer control until the tire and wheel are straight in relationship with the chassis, then leave off 16.

  • Page 369: Calibrating Tilt Sensor

    SECTION 6 - JLG CONTROL SYSTEM 6.6 CALIBRATING TILT SENSOR 9. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 10. Use the arrow keys to reach TILT SENSOR. The screen will read: A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE- FOLLOWING PROCEDURE IS PERFORMED.
  • Page 370 SECTION 6 - JLG CONTROL SYSTEM 11. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 14. Upon completing swing calibration, swing turntable 12. When prompted, swing turntable 180° to opposite end 180° back to the stowed position.

  • Page 371: Calibrating Load Sensing

    SECTION 6 - JLG CONTROL SYSTEM 6.7 CALIBRATING LOAD SENSING 8. Use the arrow keys to reach LOAD SENSING. The screen will read: NOTE: Calibration sub-menu LOAD SENSING is visible only if MACHINE SET-UP sub-menu LOAD SYSTEM is selected to 1.
  • Page 372 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 12. Hit Enter. The screen will read: 11. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 6-56 3121714...
  • Page 373 SECTION 6 - JLG CONTROL SYSTEM 14. Hit Enter. The screen will read: 15. After few seconds, the screen will read: 16. Hit ESC twice to go back to CALIBRATIONS. 3121714 6-57...

  • Page 374: Lss System

    SECTION 6 - JLG CONTROL SYSTEM 6.8 LSS SYSTEM The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR: ture.

  • Page 375: Diagnostic Menu

    SECTION 6 - JLG CONTROL SYSTEM Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus. To access a sub-menu, press the The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT Load Sensing System.

  • Page 376: Calibration Procedure

    System to record its’ weight during calibration. This includes all tools, debris, and customer-installed devices. 2. Plug the JLG Analyzer into the Machine at the Ground Station and enter Service Access Password 33271. 3. The platform should be approximately level for calibra- tion.

  • Page 377: Accessory Weights

    80 lb (36 kg) Work Surface 20 lb (9 kg) NOTE: Not all Accessories are available on every JLG model. Some Accessory combinations are prohibited due to excessive weight and/or load restriction. If any installed JLG Accessories are labeled with weight decals but are not listed in the table above, include their weight when entering the ACC WEIGHT value.
  • Page 378 SECTION 6 - JLG CONTROL SYSTEM 9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg).

  • Page 379: Skyglazier Capacity Reductions

    SECTION 6 - JLG CONTROL SYSTEM 12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-15. Pipe Rack Capacity Reductions PLATFORM OVRLD ENTER . The control system will default to an esti- Capacity...
  • Page 380 SECTION 6 - JLG CONTROL SYSTEM 14. Press ENTER . If calibration is successful, the screen will read: 6-64 3121714...

  • Page 381: Testing & Evaluation

    (fully functional and the Load Sensing System’s Overload stowed) for safety. Plug the JLG Analyzer into the control Visual and Audible Warnings are not active. Simulate an system connection and proceed to the DIAGNOSTICS, Overload by unplugging the Shear Beam Load Cell.

  • Page 382: Troubleshooting

    Inspect wiring where damage to the channel is apparent. out the influence of vibration or wind). 3. The Load Cell was not assembled properly during installation. Examine the sensor’ s reading using the JLG Analyzer. Proceed to the DIAG- There are large variations in Platform Load NOSTICS, CELL, LOAD displays and determine if the readings are reasonable.

  • Page 383: Resetting The Msso System

    SECTION 6 - JLG CONTROL SYSTEM 6.9 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read: 1. Use the following procedure to reset the MSSO system. 2. Position the Platform/Ground select switch to the desired position.
  • Page 384 SECTION 6 - JLG CONTROL SYSTEM 12. Press Enter . The screen will read: 13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu.

  • Page 385: Diagnostic Trouble Codes

    SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution EVERYTHING OK The UGM determines that platform station (EVERY- Occurrence of active DTC TING OK) OR ground station (GROUND MODE OK) is selected and no system faults exist, including Power Module check;...
  • Page 386 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution BATTERY CHARGE LOW Battery SOC < 10% Battery SOC > Discharged; speed restrictions removed after controls ini- tialized TORQUE CUTBACK - EXCESSIVE TILT...
  • Page 387 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution L/S JOY. OUT OF RANGE HIGH The PM detects that the Lift or Swing joystick sig- The PM detects that the lift/swing center tap nal voltage >...
  • Page 388 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution FUNCTION PROBLEM - DOS OVERRIDE PERMA- The machine is in Platform mode and the Drive Ori- Drive Orientation input = LOW while the...
  • Page 389 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution AMBIENT TEMPERATURE SENSOR - OUT OF System is in platform mode; Ambient Temperature sensor reading > -50 °C RANGE LOW MACHINE SETUP ->...
  • Page 390 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution PLATFORM LEVEL PREVENTED – ABOVE ELEVA- UGM has determined that all of the following con- Not all of the trigger conditions are met...
  • Page 391 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution PLATFORM LEVEL UP VALVE - SHORT TO The UGM detects a short to ground at the platform Power cycle GROUND...
  • Page 392 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution TOWER LIFT DOWN VALVE - OPEN CIRCUIT The UGM detects an open circuit supporting the UGM no longer detects open circuit;...
  • Page 393 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution FLOW CONTROL VALVE - SHORT TO BATTERY The UGM detects a short to 12V battery at this out- Power cycle...
  • Page 394 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT MOTOR TOO HOT - PLEASE WAIT The UGM determines that the drive motor temper- Power Module no longer report fault and UGM ature reported by the PM >...
  • Page 395 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution MAIN CONTACTOR / REAR RIGHT BRAKE At Startup, the Master Traction Module detects an Power cycle RETURN - SHORT TO BATTERY overcurrent condition on pin A12, indicating a short between B+ and the Main Contactor.
  • Page 396 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution PUMP MOTOR OUTPUT - OUT OF RANGE HIGH Master Traction Module detects that the pump Power cycle motor voltage output is higher than expected (Pump Vmn High;...
  • Page 397 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT MOTOR - ROTATION OPPOSITE CON- Associated Power Module detects that the motor is Power cycle TROL rotating in the direction opposite of the com-...
  • Page 398 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution LSS READING UNDER WEIGHT MACHINE SETUP -> LOAD SYSTEM ≠ NO; The load Not all of the trigger conditions are met; full func-...
  • Page 399 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution GROUND SENSOR REF VOLTAGE OUT OF RANGE The UGM has detected reference voltage is out of Power cycle range: 2.3V < Reference Voltage <...
  • Page 400 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT MODULE - EEPROM FAILURE Applicable Power Module determines at Startup Power cycle that an internal EEPROM error exists or UGM fails to...
  • Page 401 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR RIGHT MODULE - WATCHDOG2 RESET Applicable Power Module determines that Power cycle Watchdog2 failure/reset has occurred REAR RIGHT MODULE - RAM FAILURE...
  • Page 402 SECTION 6 - JLG CONTROL SYSTEM Table 6-17. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution FUNCTIONS LOCKED OUT – REAR RIGHT MOD- The UGM software version type is ‘P’ The UGM has Not all of the trigger conditions are met...

  • Page 403: Basic Electrical Information & Electrical Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERAL Polarity Getting a negative Voltage or current reading when expecting This section contains basic electrical information and sche- a positive reading frequently means the leads are reversed. matics to be used for locating and correcting most of the oper- Check what reading is expected, the location of the signal and ating problems which may develop.

  • Page 404: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing. • Circuit power must be turned OFF before testing conti- Figure 7-2.

  • Page 405: Current Measurement

    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 prox- imity switch, also referred to as a "prox switch". Inductive prox- imity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch.

  • Page 406: Automatic Switches

    JLG PN 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. 4. Place sensing face of switch on the object to be sensed by the switch.

  • Page 407: Installation Of Dielectric Grease

    After assembly, install a seal plug (JLG 5. Pierce one of the unused wire seals prior to assembly if #4460905) in that location to prevent moisture ingress.

  • Page 408: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS AMP Mate-N-Lok This connector system is widely used inside enclosures for general-purpose interconnect. Follow the installation instruc- tions. Figure 7-6. Use of Seal Plugs DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions.
  • Page 409 The EMR2 engine control the dielectric grease (replacement of female contacts module from Deutz employs this connector system (for exam- required). The JLG Load Sensing System and 1250AJP Rotary ple). Angle Sensors are examples of components with the M12 con- nector system.

  • Page 410: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.5 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as-shipped, Applying Silicone Dielectric Compound to AMP position (See Figure 7-7.). Proceed as follows: Connectors Silicone Dielectric Compound must be used on the AMP con- nections for the following reasons: •...

  • Page 411: Connector Assembly Figure 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 412: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 6.

  • Page 413: Connector Installation

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-13. Connector Installation 3121714 7-11...

  • Page 414: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 5. Remove wedgelock using needle nose pliers or a hook 1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 415: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp 11. With rear insert toward you, snap appropriate size barrel.

  • Page 416: Wiring Harness Connector Lables

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.7 WIRING HARNESS CONNECTOR LABLES Table 7-1. Wiring Harness Connector Labels Components Category Label Connector Labels Audible Alarms Connectors between harnesses are identified by the prefix "X" Horns and a sequentially assigned number. An optional suffix (letters Battery Batteries &...
  • Page 417 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Table 7-1. Wiring Harness Connector Labels Components Category Label Other Switches Disconnect Foot HVAC Park brake Pump pot Push Shifter Turn signal Relay 5 Pin 4 Pin Contactor Power module Rocker Switch Sensor Angle Fuel...
  • Page 418 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-16 3121714...

  • Page 419: Platform Console Harness - Sheet 2 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-21. Platform Console Harness - Sheet 2 of 4 3121714 7-17...

  • Page 420: Platform Console Harness - Sheet 3 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-22. Platform Console Harness - Sheet 3 of 4 7-18 3121714...

  • Page 421: Platform Console Harness - Sheet 4 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-23. Platform Console Harness - Sheet 4 of 4 3121714 7-19...
  • Page 422 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-20 3121714...
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  • Page 424 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-22 3121714...

  • Page 425: Load Sensing System Harness - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS T391 Figure 7-26. Load Sensing System Harness - Sheet 2 of 2 3121714 7-23...
  • Page 426 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-24 3121714...

  • Page 427: Main Valve Harness - Sheet 2 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-28. Main Valve Harness - Sheet 2 of 3 3121714 7-25...

  • Page 428: Main Valve Harness - Sheet 3 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-29. Main Valve Harness - Sheet 3 of 3 7-26 3121714...
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  • Page 430 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-28 3121714...

  • Page 431: Turntable Harness - Sheet 2 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-31. Turntable Harness - Sheet 2 of 3 3121714 7-29...

  • Page 432: Turntable Harness - Sheet 3 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-32. Turntable Harness - Sheet 3 of 3 7-30 3121714...
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  • Page 434 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-32 3121714...

  • Page 435: Ground Control Panel Harness - Sheet 2 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-34. Ground Control Panel Harness - Sheet 2 of 3 3121714 7-33...

  • Page 436: Ground Control Panel Harness - Sheet 3 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-35. Ground Control Panel Harness - Sheet 3 of 3 7-34 3121714...
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  • Page 438 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-36 3121714...

  • Page 439: Chassis Traction Harness - Sheet 2 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-37. Chassis Traction Harness - Sheet 2 of 4 3121714 7-37...

  • Page 440: Chassis Traction Harness - Sheet 3 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-38. Chassis Traction Harness - Sheet 3 of 4 7-38 3121714...

  • Page 441: Chassis Traction Harness - Sheet 4 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-39. Chassis Traction Harness - Sheet 4 of 4 3121714 7-39...
  • Page 442 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-40 3121714...
  • Page 443 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS This page left blank intentionally 3121714 7-41...
  • Page 444 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-42 3121714...

  • Page 445: Chassis Steer/Brake Harness - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-42. Chassis Steer/Brake Harness - Sheet 2 of 2 3121714 7-43...
  • Page 446 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-44 3121714...

  • Page 447: Chassis Head /Tail Light Harness - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-44. Chassis Head /Tail Light Harness - Sheet 2 of 2 3121714 7-45...
  • Page 448 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-46 3121714...
  • Page 449 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121714 7-47...
  • Page 450 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-48 3121714...

  • Page 451: Generator Ign Harness - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X617 Figure 7-48. Generator IGN Harness - Sheet 2 of 2 3121714 7-49...
  • Page 452 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-50 3121714...

  • Page 453: Skyguard Harness Sheet - 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X506 Figure 7-50. SkyGuard Harness Sheet - 2 of 2 3121714 7-51...
  • Page 454 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-52 3121714...

  • Page 455: Soft Touch Harness - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X7B-12 Figure 7-52. Soft Touch Harness - Sheet 2 of 2 3121714 7-53...
  • Page 456 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-54 3121714...

  • Page 457: Platform Console Harness With Skyguard And 1 Cell Lss - Sheet 2 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS This page left blank intentionally. Figure 7-54. Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 2 of 4 3121714 7-55...

  • Page 458: Platform Console Harness With Skyguard And 1 Cell Lss - Sheet 3 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-55. Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 3 of 4 7-56 3121714...

  • Page 459: Platform Console Harness With Skyguard And 1 Cell Lss - Sheet 4 Of 4

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-56. Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 4 of 4 3121714 7-57...
  • Page 460 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-58 3121714...

  • Page 461: Electrical Schematic - Sheet 1 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS SHEET 2: PLATFORM CONSOLE CONSOLE HARNESS PLATFORM BEACON SHEET 3: PLATFORM AND BOOM COMPONENTS SHEET 4: TURNTABLE, AND UGM WIRING MAIN VALVE HARNESS TURNTABLE HARNESS SHEET 5: GROUND CONTROL WIRING GROUND PANEL HARNESS SHEET 6: CHASSIS WIRING TRACTION HARNESS...

  • Page 462: Electrical Schematic - Sheet 2 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SW305 WHT 120-1 TORQUE/SPEED MODE YEL 5-14-1 WHT 120-2 AWDA MAN SW06 YEL 5-14-1 WHT 29-0 TWR LFT UP WHT 29-30 TWR LFT DN YEL 5-14-2 SW09 WHT 13-0 MAIN TELE IN YEL 5-14-2 WHT 14-0 MAIN TELE OUT YEL 5-14-3...

  • Page 463: Electrical Schematic - Sheet 3 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS WHT 124-2 SKYG INPUT#2 WHT 124-5 SOFTT YEL 3-8 PLAT IGN 12AWG BLK 1-5 PLAT GND 12AWG WHT 1-551 JUMPER 15 POS WHT 131-1 FOOT SWITCH WHT 3-16 FOOTSWITCH MATE-N-LOK GRN 131-2 FOOT PEDAL FC-7 S830 BLK 14AWG...

  • Page 464: Electrical Schematic - Sheet 4 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS LSS MODULE (OPTIONAL) *LOCATED UNDER CONSOLE BOX* GENERIC FOOT SWITCH TO SHEET 2 15 POS MATE-N-LOK IN CONSOLE T394 WHT 1-28 LSS GND T395 WHT 3-20 LSS PWR TO SHEET 2 T391 15 POS YEL TP CAN CABLE...

  • Page 465: Electrical Schematic - Sheet 5 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS X50A RED 12AWG BLK 12AWG SHIELD BLK 18AWG RED 18AWG TO TURNTABLE BLU 18AWG HARNESS ORG 18AWG YEL 18AWG TO SHEET 4 BRN 18AWG BLU/BLK 18AWG BLK/WHT 12AWG ORG 12AWG YEL/BLK 18AWG RED/BLK 18AWG ORN/BLK 18AWG ALL WIRES ARE 18AWG UNLESS OTHERWISE NOTED...

  • Page 466: Electrical Schematic - Sheet 6 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ANALYZER PORT HV13 BLK 4-13-2 RTN WHT 13-0-3 TELE IN BLK 4-13 RTN HV14 BLK 4-13-1 RTN WHT 14-0-3 TELE OUT HV21 WHT 38-5-1 CURNT FBACK BLK 300-2 ALERT GND WHT 21-0-1 SWG LFT WHT 300-1 ALERT PWR HV22 WHT 38-5-2 CURNT FBACK...

  • Page 467: Electrical Schematic - Sheet 7 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS TO MDI Sheet_5-[2,D] Sheet_5-[2,D] MS423-3 YEL CAN1 HI GRN CAN1 LO MS423-2 YEL CAN1 HI GRN CAN1 LO MS423-1 X4-A GRN CAN1 LO YEL CAN1 HI BLK 4-0-1 INSTR GND 12GXL YEL 5-10-1-1 SWITCHED PWR 12GXL WHT 8-3 GENSET ENABLE SW Sheet_8-[6,G]...

  • Page 468: Electrical Schematic - Sheet 8 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENSET LED LT START PLATFORM ROTATE PLATFORM LEVEL SIDESWING JIB LIFT MAIN LIFT TOWER LIFT CO66-J4 WHT 26-0-1 PLAT LVL DN WHT 25-0-1 PLAT LVL UP WHT 23-0-1 PLAT ROT LFT WHT 24-0-1 PLAT ROT RHT WHT 27-0-1 JIB UP WHT 28-0-1 JIB DN...

  • Page 469: Electrical Schematic - Sheet 9 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SIDESWING JIB LIFT MAIN LIFT TOWER LIFT SWING TELESCOPE ENABLE GD139 WHT METER PWR BLK METER GND GRN CAN1 LO YEL CAN1 HI WHT 5-11-1 IGN PLAT SW100-1 YEL 2-26 IGN SW100-B YEL 5-10-6 IGN GMODE KEY SWITCH...

  • Page 470: Electrical Schematic - Sheet 10 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CHASSIS TO TURNTABLE HARNESS TO TURNTABLE HARNESS YEL CAN2 HI SHLD 85-1 SHIELD YEL CAN2 HI S551 Sheet_4-[8,B] GRN 84-1 CAN2 LOW GRN CAN2 LO Sheet_4-[8,B] MS-4 YEL 83-1 CAN2 HIGH YEL CAN2 HI GRN CAN2 LO S552...

  • Page 471: Electrical Schematic - Sheet 11 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ATTACHED TO RIGHT CONTROLLER MOUNTING PLATE X600 STEER SENSOR ZAPI #1 RIGHT (MASTER) CO4-J1-RL RED BRAKE1-IN-2 SHIELD 18/3 CABLE X599A RED EPDM 4 AWG WHT 200 RT BRK WHT 201-1 STR SNR RED 18/3 CABLE RED BRAKE1-IN IP408...

  • Page 472: Electrical Schematic - Sheet 12 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CONNECTS TO TH2-2 ON SHEET 6 A4 RED GENERATOR B+ 4EPDM X637 BLK GENERATOR B- 4EPDM CONNECTS TO TH3-1 ON SHEET 6 D1 X638 EC363B- EC363B+ UA103 UA131 48VDC UA108 DYNAMO GENERATOR ENGINE SCHEMATIC VR110 UA112...

  • Page 473: Electrical Schematic - Sheet 13 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS EC363B+ X658 48VDC PLUGS IN TO X617 PAGE 8 H8 EC104 SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOID MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP. ENGINE OIL TEMP SPEED SENSING INPUT RS232 +12V CONN-2...

  • Page 474: Electrical Schematic - Sheet 14 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERIC GENERIC RR LT FR LT TO SHEET 4 A3 WHT 88-2 LIGHTING X596B RL266 WHT 88-2 LIGHTING WHT 1-22-5 GND WHT 3-12-4 LIGHT 16AWG BLK 5-1 FUSE 12AWG WHT 3-12-2 LIGHT 16AWG S267 WHT 3-12 LIGHT PWR 12AWG WHT 3-12-1 LIGHT 16AWG...

  • Page 475: Electrical Schematic - Sheet 15 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERIC X617 FR LT WHT 8-6 WHT 8-7 PLUGS IN TO X658 WHT 8-8 GEN DISTRESS PWR PAGE 7 G7 WHT 8-5 GEN DISTRESS GND WHT 8-4-2 IGN 48VOLT CONNECTS TO X598A S620 WHT 8-4-1 IGN 48VOLT WHT 8-4-2 IGN 48VOLT...

  • Page 476: Electrical Schematic - Sheet 16 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SW305 WHT 120-1 TORQUE/SPEED MODE YEL 5-14-1 WHT 120-2 AWDA MAN SW06 YEL 5-14-1 WHT 29-0 TWR LFT UP WHT 29-30 TWR LFT DN WHT 5-14-2 SW09 WHT 13-0 MAIN TELE IN WHT 3-8 PLAT IGN 12AWG WHT 5-14-2 WHT 1-5 PLAT GND 12AWG...

  • Page 477: Electrical Schematic - Sheet 17 Of 18

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS FC-8 BLK 14AWG BLK 14AWG WHT 3-18-1 SKYG PWR 5A SKYG FUSE WHT 1-36 SKYG GND SHEET 10 WHT 3-18-2 SOFTT SENSE 20AWG WHT 124-1 SKYG INPUT#1 20AWG WHT 124-2 SKYG INPUT#2 20AWG WHT 124-5 SOFTT 20AWG WHT 124-5-1 SOFTT OUT 20AWG WHT 3-8 PLAT IGN 12AWG...

  • Page 478: Gen 2 Plat Interface Harness

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HARNESS,GEN 2 PLAT INTERFACE HARNESS,GEN 2 PLAT INTERFACE PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR RELAY #1 RELAY #1 RELAY #2 RELAY #2 S191 S191 S192 S192 WHT P2 WHT P2...
  • Page 480 3121714 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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