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JLG 530LRT Service And Maintenance Manual
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JLG 530LRT Service And Maintenance Manual

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Service and Maintenance Manual
Model
530LRT
SN E200000676 to Present,
Including 1200030223
3121781
September 03, 2018 - Rev A
AS/NZS

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Summary of Contents for JLG 530LRT

  • Page 1 Service and Maintenance Manual Model 530LRT SN E200000676 to Present, Including 1200030223 3121781 September 03, 2018 - Rev A AS/NZS...
  • Page 3 • Remove all rings, watches and jewelry when perform- ing any maintenance. MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUS- TRIES, INC. IS A SAFETY VIOLATION. • Do not wear long hair unrestrained, or loose-fitting clothing and neckties which are apt to become caught The specific precautions to be observed during mainte- on or entangled in equipment.
  • Page 4 INTRODUCTION REVISION LOG Original Issue A - September 03, 2018 3121781...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................. . a Hydraulic System Safety .

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Lubrication and Servicing ............2-6 Lubrication and Information .

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Drive Motor (Sauer)............... 3-20 Description .

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Cylinders - Theory of Operation ............4-1 Valves - Theory of Operation .

  • Page 9: Table Of Contents

    Connecting the JLG Control System Analyzer........

  • Page 10: Table Of Contents

    TABLE OF CONTENTS Calibration ................6-6 Procedure .

  • Page 11: Table Of Contents

    TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location ..............1-3 1-2.

  • Page 12: Table Of Contents

    TABLE OF CONTENTS 3-40. Right Side - Hydraulic/Fuel Compartment Covers......... . 3-49 3-41.

  • Page 13: Table Of Contents

    TABLE OF CONTENTS 4-40. Lift Cylinder Valve Cartridge Torque Values ..........4-80 4-41.
  • Page 14 TABLE OF CONTENTS This page left blank intentionally 3121781...
  • Page 15 TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ..............1-1 7500W Generator Specifications.
  • Page 16 TABLE OF CONTENTS 4-19 Metric Flat Face Port (MFF) - L Series - Table 2 of 3 ......... 4-33 4-20 Metric Flat Face Port (MFF) - L Series - Table 3 of 3 .

  • Page 17: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS SPECIFICATIONS Table 1-1. Operating Specifications Model 530LRT Operating Specifications Outside Turning Radius 19.76 ft. (6.023 m) Table 1-1. Operating Specifications Gross Vehicle Weight Dual Fuel/Diesel - Model 530LRT ANSI/ANSI Export/CSA/CE Maximum Occupants w/ One Extension: 17,000 lb.

  • Page 18: Dimensional Data

    Table 1-6. Tire Specifications Table 1-4. Dimensional Data Foam Fill Tire Wheel Nut Size Rating Assembly Rating Torque 530LRT 12 x 16.5 90 PSI @ Wheelbase 117 in. (297 cm) 170 ft. lb. Foam Filled (Non-Mark- 8,000 lb. (3700 kg) -...

  • Page 19: Serial Number Locations

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

  • Page 20: Hydraulic Pressure Settings

    Viscosity Index at 65°C (150°F) 22cST(106SUS) HYDRAULIC PRESSURE SETTINGS Viscosity Index Table 1-16. Main Control Valve Relief Settings Table 1-13. Mobil EAL 224H Description 530LRT Type Biodegradable Vegetable Oil Main Relief 2700 psi (186 bar) ISO Viscosity Grade 32/46 Steer Relief...

  • Page 21: Engine Specifications

    SECTION 1 - SPECIFICATIONS ENGINE SPECIFICATIONS Table 1-20. Kubota (WG972-GL-E4 - Dual Fuel) Emissions U.S. EPA Phase 3 and CARB SSI Table 1-18. Kubota Diesel (D1305-E4B - T4F) Fuel Type: Gasoline - 87 Octane minium Emissions CARB and EPA Tier 4 Final - Ethanol/Gas Mix-10% max.

  • Page 22: Platform Height/Tilt Limit Settings

    Table 1-21, Maximum Cutout Height. Table 1-21. Maximum Cutout Height Model High Drive Cutout 530LRT 14 ft (4.26 m) Tilt Alarm - An alarm sounds and a warning light is illu- minated when the machine is operated on a slope that exceeds the values in Table 1-22, Tilt Cutout Settings.

  • Page 23: Hydraulic Oil Operating Temperature Specifications

    SECTION 1 - SPECIFICATIONS 4150740_B_Hydraulic Figure 1-2. Hydraulic Oil Operating Temperature Specifications 1001204714_A_Dual Fuel Figure 1-3. Engine Oil Operating Temperature Specifications - Kubota (Dual Fuel Engine) 3121781...

  • Page 24: Engine Oil Operating Temperature Specifications - Kubota (Diesel Engine)

    SECTION 1 - SPECIFICATIONS 1001120075_C_Diesel Figure 1-4. Engine Oil Operating Temperature Specifications - Kubota (Diesel Engine) 3121781...

  • Page 25: Torque Charts

    SECTION 1 - SPECIFICATIONS TORQUE CHARTS Figure 1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121781...

  • Page 26: Torque Chart - Sheet 2 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-10 3121781...

  • Page 27: Torque Chart - Sheet 3 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121781 1-11...

  • Page 28: Torque Chart - Sheet 4 Of 5 - (Metric Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-12 3121781...

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

    SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121781 1-13...
  • Page 30 SECTION 1 - SPECIFICATIONS NOTES: 1-14 3121781...

  • Page 31: Machine Preparation, Inspection, And Maintenance

    Technician as a person who has successfully completed It is important to establish and conform to a compre- the JLG Service Training School for the subject JLG prod- hensive inspection and preventive maintenance pro- uct model. Reference the machine Service and Mainte- gram.

  • Page 32: Preventive Maintenance And Inspection Schedule

    20. No loose connections, corrosion, or abrasions. NOTE: This machine requires periodic safety and mainte- 21. Verify. nance inspections by a JLG Dealer. A decal located 22. Perform. on the frame affords a place to record (stamp) inspection dates. Notify dealer if inspection is over- 23.
  • Page 33 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule INTERVAL PRE-DELIVERY (a) ANNUAL (c) AREA ON MACHINE OR FREQUENT (b) (YEARLY) INSPECTION INSPECTION FUNCTIONS/CONTROLS Platform Controls 5, 6, 7 5, 6, 7 Ground Controls 5, 6 5, 6 Function Control, Guards, or Detents Function Enable System 5, 8...

  • Page 34: Footnotes

    Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Notify JLG of change in Machine Ownership Replace Annually - JLG P/N - 70005423. Replace when system performance is degraded. *** Every two years, drain and remove hydraulic oil reservoir, clean pick-up screen, refill with fresh hydraulic fluid.

  • Page 35: Service And Guidelines

    SECTION 2 - GENERAL SERVICE AND GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, General complete the procedural steps in sequence. Do not par- tially disassemble or assemble one part, then start on The following information is provided to assist you in another.

  • Page 36: Hydraulic Lines And Electrical Wiring

    SECTION 2 - GENERAL 2. Unless specific torque requirements are given within LUBRICATION AND INFORMATION the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accor- Hydraulic System dance with recommended shop practices. (See Torque Chart Section 1.) 1.

  • Page 37: Changing Hydraulic Oil

    Avoid mixing rotate vertically into position. (See Figure 2-1.) petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually. 2. Rotate the rod keeper plate and release the safety prop actuator rod at the front of the machine.

  • Page 38: General Maintenance Tips

    SECTION 2 - GENERAL restored back to its stowed position. Lock the actua- General Maintenance Tips tor rod in place with the keeper plate till next use. NOTE: Be sure to lubricate like items on each side of machine. TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTE- NOTE: Recommended lubricating intervals are based on NANCE REQUIRING PLATFORM TO BE ELEVATED.

  • Page 39: Fuel Tank

    SECTION 2 - GENERAL Fuel Tank Hydraulic Oil Tank • Lube Point - Fill Cap/Fill Level • Lube - HO - API service classification GL-3, Refer- • Fuel - Diesel or Gasoline (Per Engine Type - Refer- ence - Figure 1-2., Hydraulic Oil Operating Temper- ence Decal on Machine) ature Specifications •...

  • Page 40: Oil Change With Filter

    SECTION 2 - GENERAL Oil Change with Filter Fuel/Water Separator Filter (Diesel) - Kubota Figure 2-4. Kubota Dual Fuel (WG972-GL-E4) NOTE: Exhaust system shown removed for illustrative pur- poses only. NOTE: Mounted inside engine cabinet on right-rear cabi- net wall behind battery and exhaust pipe. •...

  • Page 41: Fuel Filter (Gas) - Kubota

    SECTION 2 - GENERAL Fuel Filter (Gas) - Kubota Engine Coolant NOTE: Mounted inside fuel/hydraulic cabinet on left-rear cabinet wall behind fuel tank. MAF06110 • Lube Point(s) - Replaceable Element • Lube Point - Fill Cap/Fill Level • Interval - Every 6 months or 300 hours of opera- •...

  • Page 42: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. Pinned joints should be disassembled and inspected if Platform Drift the following occurs: Measure the drift of the platform to the ground.

  • Page 43: Operating Characteristics

    The air pressure for pneumatic tires must be equal to end of stroke on any of the cylinders you cannot lift the air pressure that is stenciled on the side of the JLG the machine. product or rim decal for safe and proper operational characteristics.

  • Page 44: Wheel Replacement

    If Tighten the lug nuts to the proper torque to prevent not using a JLG approved replacement tire, we recom- wheels from coming loose. Use a torque wrench to mend that replacement tires have the following charac- tighten the fasteners.

  • Page 45: Drive Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Drive Assembly 1. Tire & Rim 2. Lugnut 3. Drive Hub 4. Bolt 5. Washer 6. Drive Motor (Sauer) 7. Gasket 8. Bolt 9. Washer 10. Nut NOTE: Rear axle shown. Figure 3-1. Drive Assembly (Fairfield/Sauer) INSTALLATION REMOVAL 1.

  • Page 46: Drive Hub (Fairfield)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS DRIVE HUB (FAIRFIELD) The following steps describe the proper procedure for tightening and torquing bolts or socket head cap screws in a bolt circle. Roll and Leak Testing 1. Tighten (but do not torque) bolt "A" until snug. Always roll and leak test Drive-Hubs after assembly to 2.

  • Page 47: Drive Hub (Cross-Section)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1. Hub-Spindle Sub-Assembly 2. Internal Gear A. Cover C. Spring A. Spindle 3. Carrier Sub-Assembly B. Cover Cap D. Spacer A. Carrier Housing B. Seal C. Bolt 8. Input Gear B. Thrust Washer C.

  • Page 48: Drive Hub

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 6H 6G Figure 3-3. Drive Hub 3121781...
  • Page 49 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTE: Refer to Figure 3-3., Drive Hub. Table 3-2. Drive Hub Part Description Item # Description Table 3-2. Drive Hub Part Description Sun Gear Item # Description Thrust Washer Spindle/Housing Assembly Bolt Spindle Dowell Pin Seal...

  • Page 50: Main Disassembly For Drive Hub

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Disassembly for Drive Hub 17. At this point the main disassembly for drive hub is complete. NOTE: Refer to Figure 3-2. for part location and listing. Hub-Spindle Disassembly 1. Turn hub (1G) over onto its side. Remove coupling NOTE: Start with large end of hub facing up, large end of (14) from the wide end of spindle (1A).

  • Page 51: Cover Disassembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Cover Disassembly Carrier Assembly 1. Remove the two bolts (6C) holding disconnect cap 1. Apply grease to the inside of one cluster gear (3F) (6D) to cover (6A). and line one half of cluster gear with 16 needle roll- ers (3C).
  • Page 52 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Set carrier housing (3A) sideways on a table. Insert a 7. Following the cluster gear, place one more thrust planet shaft (3E), roll pin hole last, into one of the washer (3B) onto planet shaft (3E) through the oppo- planet shaft holes from roll-pin-holed side of carrier site planet shaft hole in carrier housing (3A).

  • Page 53: Cover Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover cap (6B) onto cover (6A), aligning the pipe plug hole in the cover cap over the pipe plug hole in the cover. 1.

  • Page 54: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7. With the large end down, place the disconnect cap 10. Apply a light coat of “Never-Seize” to pipe plug (6H) (6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover hole in the disconnect cap over the pipe plug hole in (6A).
  • Page 55 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Apply a light coat of “Never-Seize” to two pipe plugs 6. Press seal (1B) into the small end of hub (1G). (1J) and tighten them into the two pipe plug holes in the side of the hub (1G).

  • Page 56: Main Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTE: Make sure the retaining ring is securely seated in the Main Assembly groove. 10. Place retaining ring (1I) over the spacer onto spindle (1A) in hub (1G). BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING 1.
  • Page 57 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Place thrust washer (11) around spindle (1A) so it 7. Place other spacer (7D) onto the smooth end of input rests on the bottom of the internal gear (2). shaft (7A). 5.

  • Page 58: Cluster Gear Punch Marks

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 10. Place thrust spacer (9) onto input shaft (7). NOTE: You may lift the ring gear off the hub to align the shoulder bolt holes. The ring gear and carrier are installed together only to keep the punch marks on the carrier in place.
  • Page 59 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTE: The o-ring may be stretched or pinched together to 19. Place shoulder bolts (13) into the four shoulder bolt holes in cover (6) and tighten by hand. make it fit the counterbore exactly. 20.
  • Page 60 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Torque the shoulder bolts (13) 18 to 25 ft. lb. (25 to 34 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for 2 Nm). Torque bolts (12) 18 to 25 ft. lb. (25 to 34 Nm). to 3 minutes.

  • Page 61: Tool List

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E) 6.625" (168.3 mm) The following specialized tools are used to assemble this unit. The tool diagrams included in this manual are 0.125" (3.1 mm) 6"...

  • Page 62: Drive Motor (Sauer)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS DRIVE MOTOR (SAUER) Shaft Seal Replacement Description REMOVAL 1. Remove the snap ring (1) retaining the shaft seal and The drive motors are low to medium power, two-posi- support washer. tion axial piston motors incorporating an integral servo piston.

  • Page 63: Loop Flushing Valve

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS INSPECT THE COMPONENTS 4. Using pliers, remove centering springs (7, 8, and 9). Inspect the new seal, the motor housing seal bore, and 5. Remove spring retaining washers (10 and 11). the sealing area on the shaft for rust, wear, and contami- 6.

  • Page 64: Troubleshooting

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply to oil supply to the motor.

  • Page 65: Disassembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced.

  • Page 66: End Cap

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring 28. Rear Shaft Bearing Figure 3-10. End Cap 29. Minimum Angle Stop 13. Using an 8 mm internal hex wrench, remove the end- 30.

  • Page 67: Cylinder Kit

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34). Discard the seal. To avoid damaging the shaft during seal removal, install a large sheet metal screw into the chuck of a slide hammer.

  • Page 68: Swash Plate & Servo Piston

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings 44. Piston 49. Retaining Ring Figure 3-15. Swash Plate & Servo Piston 45. Slipper Retainer 50. Block Spring Washer 46.

  • Page 69: Inspection

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 28. Turn the block over. Using a press, apply pressure on SLIPPERS the block spring washer (50) to compress the block Inspect the running surface of the slippers. Replace any spring. Compress the spring enough to safely piston assemblies with scored or excessively rounded remove the spiral retaining ring (51).
  • Page 70 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS BALL GUIDE AND SLIPPER RETAINER tion. Replace swashplate if the difference in thickness from one side to the other exceeds specification. Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat.

  • Page 71: Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SERVO PISTON AND MINIMUM ANGLE STOP Assembly Inspect the minimum angle stop, servo piston head, and 1. Install new O-ring (1) and piston seal (2) to the servo servo piston ball-socket for damage or excessive wear. piston (3).

  • Page 72: Cylinder Kit Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Install the inner block spring washer (4), block spring 6. Install the journal bearings (13) into the housing (5), and outer washer (6) into the cylinder block. seats. Use assembly grease to keep the bearings Using a press, compress the block spring enough to seated during assembly.

  • Page 73: Shaft And Front Bearing

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated. bearing onto shaft with lettering facing out. Lubri- Install the cylinder kit (19) onto the shaft. Install with cate bearing rollers.
  • Page 74 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Press the rear shaft bearing (22) into the endcap. 15. Install the endcap (25) onto the housing with the Install the bearing with letters facing out. Press until endcap screws (26). Check to ensure the endcap will bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above properly seat onto the housing without interference.

  • Page 75: Shaft Seal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing. a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and motor.

  • Page 76: Initial Start-Up Procedures

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 20. Install orifice poppet (30). Initial Start-Up Procedures Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage 11/16 in incurred during shipping.

  • Page 77: Axle Installation

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS AXLE INSTALLATION Front Axle Assembly (Fixed) MAF03740 1. Front Axle 5. Pin Keeper and Screw 8. Stop Block Pad Bracket 11. Nuts 2. Pivot Pin 6. Stop Block Pad 9. Hex Head Screws 12.

  • Page 78: Front Axle Assembly (Oscillating)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Front Axle Assembly (Oscillating) MAF03750 1. Front Axle 5. Pin Keeper and Screw 8. Hex Head Screws 11. Spacers 2. Pivot Pin 6. Wear Pad 9. Osc. Axle Tilt Sensor 12. Mounting Bolts/Wash- Bracket ers/Nuts 3.

  • Page 79: Steering Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Steering Assembly 1. Steer Cylinder Assembly 6. Cyl. Attach Screws 11. Hex Flange Bolt 2. Tie-Rod Link 7. Washer 12. Tapered Kingpin Pin 3. Pivot Pins 8. Spindle Assembly 13. Hex Nut 4.

  • Page 80: Axle Lockout Cylinder

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Axle Lockout Cylinder 1. Axle Lockout Cylinder 2. Bolt 3. Washers Figure 3-31. Axle Lockout Cylinder REMOVAL INSTALLATION 1. Disable machine operation. 1. Attach cylinder to frame using four bolts (2) and washers (3).

  • Page 81: Leveling Jacks

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS LEVELING JACKS Cylinder Removal 1. Cover 2. Bolt 3. Flat washer 4. Tinnerman Nut 5. Jack Cover Attach Bracket 6. Bolt 7. Nut/Washer 8. Leveling Jack Cylinder 9. Bolt 10. Nut/Washer MAF04230 Figure 3-32.

  • Page 82: Assembly Removal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Assembly Removal NOTE: Applies to both front and rear of machine. MAF04240 1. Leveling Jacks Assembly 3. Bolt 5. Nut 2. Hydraulic Lines/Electrical Wiring 4. Washers (Hardened) 6. Doubler Plate Figure 3-32. Leveling Jacks Assembly REMOVAL INSTALLATION 1.

  • Page 83: Platform

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS PLATFORM 1. Platform 2. Scissor Arms 3. Slide Block 4. Bolt 5. Locknut 6. Pin 7. Spacer Tube 8. Bolt 9. Locknut 10. Pin Keeper 11. Pin MAF03770 Figure 3-33. Platform Removal 4.

  • Page 84: Platform Control Station

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Control Station MAF04160 1. Mounting Bracket 5. Wiring Harness Connec- 9. Select Switch/Guard 13. Engine Start Switch 2. Control Box Plate 10. Stop Switch 14. Horn Switch 6. Function Decal 3. Joystick Controller 11.

  • Page 85: Joystick Controller

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Joystick Controller Figure 3-35. Joystick Controller Table 3-9. Joystick Specifications Table 3-10. Joystick Plug Loading Chart Type Single Axis (Y Axis Only) Terminal Color Function Input Voltage Handle COM Current Consumption 10mA @ 12VDC VIOLET Trigger N.O.

  • Page 86: Scissor Arms

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SCISSOR ARMS Scissor Arm Assembly Removal Lift Cylinder Removal NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST REMOVAL PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY. REMOVAL NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY.

  • Page 87: Scissor Arm - Hose And Wiring Routing

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS MAF04270 NOTE: See Figure 3-37. and Figure 3-38. for letter detail views. Route hoses/wiring through wire rod on arm, behind safety prop. Figure 3-36. Scissor Arm - Hose and Wiring Routing. 3121781 3-45...

  • Page 88: Scissor Arm Component Assembly 1 Of 2

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS DETAIL E DETAIL A DETAIL F DETAIL B DETAIL G DETAIL C DETAIL H DETAIL D MAF03780 NOTE: Detail H - Do not overtighten safety rod keeper plate, it must rotate freely. Detail A, C, D, F, G, and H - Apply Loctite #242 to threads.

  • Page 89: Scissor Arm Component Assembly 2 Of 2

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS DETAIL P DETAIL J DETAIL U DETAIL K DETAIL L DETAIL R DETAIL N DETAIL M DETAIL S DETAIL T MAF04150 NOTE: Coat all pins (Detail: B, J, K, L, M, and V) with moly paste lubricant (example: Loctite #51049) before assembly. Figure 3-38.

  • Page 90: Side Compartment Covers

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SIDE COMPARTMENT COVERS MAF04330 Figure 3-39. Left Side - Engine Compartment Covers 1. Engine Main Compartment Cover 4. Ladder Assembly 7. Engine Exhaust Tube 2. Front Engine Door 5. Door Latch Assembly 8.

  • Page 91: Right Side - Hydraulic/Fuel Compartment Covers

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS MAF04170 Figure 3-40. Right Side - Hydraulic/Fuel Compartment Covers 1. Hydraulic/Fuel Main Compartment Cover 4. Ladder Assembly 6. Door Hinge Assembly 2. Hydraulic Tank Door 5. Door Latch Assembly 7. Bracket Ladder Support 3.

  • Page 92: Cover Removal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Cover Removal 3.10 GROUND CONTROL STATION NOTE: Procedures apply to both left and right side compart- Control Station Removal ment hoods. 1. Elevate the platform to a height where, when removed and lifted, the compartment covers clear the underside of the platform.

  • Page 93: Ground Control Station Components

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Ground Control Station Components MAF04180 1. Ground Control Box 4. Chassis Tilt Sensor 2. Lid 5. Machine Harness Connectors 3. Circuit Board Figure 3-42. Ground Control Station Components DISASSEMBLY ASSEMBLY 1. Disconnect the harnesses from the ground control 1.

  • Page 94: Options Control Module

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Options Control Module The Options Control Module provides additional machine harness connections for additional machine components such as the Leveling Jacks and LSS control system. If determined faulty, this module is only replaceable and not service- able.

  • Page 95: Battery

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.11 BATTERY INSTALLATION 1. Place battery in the seat. Negative battery terminal (2) should be closest to outside of machine. 2. Secure battery in place with the hold-down bracket, bolt, nut and washers (4). 3.
  • Page 96 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.12 FUEL TANK MAF04220 1. Fuel Tank 4. Fuel Feed/Return and Vent Lines 2. Tank Drain (on bottom of tank) 5. Tank Mounting Bolts/Nuts and Washers 3. Tank Sending Unit Figure 3-45. Fuel Tank Installation REMOVAL INSTALLATION 1.

  • Page 97: Hydraulic Tank

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.13 HYDRAULIC TANK 1. Hydraulic Tank 3. Tank Mounting Bolts/Nuts and Washers 2. Tank Drain Figure 3-46. Hydraulic Tank Removal REMOVAL INSTALLATION 1. Follow Removal Steps in reverse. NOTE: It is recommended to remove the side compartment 2.

  • Page 98: Kubota Engine

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.14 KUBOTA ENGINE NOTE: When servicing components on the back side of the engine, remove the tray (2) and ladder (3), bolts, nuts and washers to swing the engine tray out for better Engine Tray - Swing Out access (as shown below).

  • Page 99: Dual Fuel/Lpg System

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Dual Fuel/LPG System 6. Do not store LPG tanks near heat or open flame. For complete instructions on the storage of LPG fuels, refer to ANSI/NFPA 58 & 505 or applicable standards. IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP.

  • Page 100: Generator (If Equipped)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Generator (if equipped) MAF03540 1. Generator 4. Drive Pulley 2. Belt Tensioner 5. Bracket Assembly 3. Drive Belt Figure 3-49. AC Generator Installation Table 3-11. AC Generator Specifications DESCRIPTION 7500 KW 4000 KW ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ING.

  • Page 101: Exhaust System

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust System MAF04450 MAF04440 Dual Fuel - Gas/LPG Diesel Figure 3-50. Exhaust System (Kubota Engine) 1. Tail Pipe 4. Mounting Bracket 1. Muffler 3. Mounting Bracket 2. O2 Sensor 5. Gasket 2. Gasket 3.

  • Page 102: Air Cleaner System

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Cleaner System MAF04470 MAF04460 Dual Fuel - Gas/LPG Diesel Figure 3-51. Air Cleaner System (Kobota Engine) 1. Inlet Hose 5. Intake Pipe 1. Inlet Hose 5. Intake Pipe 2. Clamp 6. Clamp 2.

  • Page 103: Radiator

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Radiator Figure 3-52. Radiator Installation (All Engines) 1. Radiator Mounting Plate 4. Fan Shroud Assembly 2. Mounting Plate Lower Support 5. Engine Tray 3. Radiator Assembly 6. Radiator Petcock Location 5. Re-check that all connections, hoses, etc. are discon- nected and remove complete radiator mounting plate (1) assembly from the engine tray.

  • Page 104: Engine Electrical Component Locations

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Electrical Component Locations 1. Dual Fuel Engine 2. ECM Module Figure 3-53. Duel Fuel Engine - Control Module Location FC274 RL13 PWR RELAY ETV RELAY FUSE FC273 RL11 FC271 RL12 ALT FUSE LP SELECT RL STRT FUSE PWR RELAY...

  • Page 105: Diesel Engine Compartment - Electrical Component Locations (T4F And Ce)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS FC257 FC267 HOLD RL 2 SPD HOLD GLOW FUSE RELAY PLUGS FUSE FC258 FC260 FC259 STRT START 2 SPD PULL ALT EXCITE PULL RL FUSE RELAY RELAY RELAY FUSE FUSE RELAY TO OIL PRESSURE SENSOR TO STARTER SOLENOID CONNECTOR...

  • Page 106: Hydraulic Pump Installation

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Hydraulic Pump Installation 1. Tandem Gear Pump 3. Axial Hi 45 Pump 2. O-Ring 4. Pump Coupling Figure 3-56. Hydraulic Pump Assembly INSTALLATION 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- NOTE: Apply grease to internal splines of pump coupling (1) ING.

  • Page 107: Pump Coupling Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pump Coupling Assembly 1. Coupler Housing 3. Engine Flywheel/Coupler Mounting Plate 2. Pump Coupler 4. Starter Bolts Figure 3-57. Pump Coupling Assembly (All Engines) INSTALLATION 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- NOTE: Apply Loctite®...

  • Page 108: Engine Removal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1. Kubota Engine 4. Engine Isolator Mount 2. Engine Lifting Lugs 5. Swinging Engine Tray 3. Left/Right Side Engine Mounting Brackets Figure 3-58. Engine Removal (All Engines) REMOVAL 1. Disable machine operation. Disconnect battery posi- ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- tive (+) terminal.
  • Page 109 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 2. Remove platform ladder and brackets, exhaust sys- tem, air cleaner system, hydraulic pumps and radia- tor cooling system, as necessary. 3. Disconnect, cap and label all hoses connected to engine (1). Disconnect and label all electrical wiring connected to engine.
  • Page 110 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTES: 3-68 3121781...

  • Page 111: Cylinders - Theory Of Operation

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 4. BASIC HYDRAULIC INFORMATION & SCHEMATICS CYLINDERS - THEORY OF OPERATION alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or Cylinders are of the double acting type. The steer sys- fitting.

  • Page 112: Cylinders With Single Counterbalance Valve

    If leakage continues at a rate of 6-8 drops 5. Raise machine platform above stowed position per minute or more, the counterbalance valve is approximately 14 ft (4.26 m) on the 530LRT. defective and must be replaced. 6. Carefully drive the machine back off the block and 4.

  • Page 113: Right Side Wheel Test

    Pre-Fill of the Drive Pump Housing Without HOC 5. Raise machine platform above stowed position These types of pumps should never be dry started. approximately 14 ft (4.26 m) on the 530LRT. Pre-fill the pump as follows: 6. Carefully drive the machine back off the block and ramp.

  • Page 114: Drive Pump Start-Up Procedure

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS DRIVE PUMP START-UP PROCEDURE MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START-UP. Once charge pressure has been established, increase THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PERFORMED WHEN speed to normal operating RPM. Charge pressure STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN should be approximately 220 psi (15.5 bar) minimum.

  • Page 115: Hydraulic Component Start-Up Procedures & Recommendations

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC COMPONENT START-UP that the pump is not being asked to draw an inlet vacuum higher than it is capable of. PROCEDURES & RECOMMENDATIONS Be certain to fill the pump and/or motor housing with From a hydrostatic component standpoint, the goal at clean hydraulic fluid prior to start up.
  • Page 116 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABIL- ITY TO CONTROL THE MACHINE. Shut down the engine and connect the external control input signal. Also reconnect the machine function(s), if disconnected earlier. Start the engine, checking to be certain the pump remains in neutral.

  • Page 117: Hydraulic Connection Assembly And Torque Specification

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.8 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 4-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 4-1.

  • Page 118: Straight Thread Types, Port Connections

    SECTION 4 - 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 4-9.

  • Page 119: Assembly And Torque Specifications

    SECTION 4 - 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 120: Connections

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN- MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR Thread Tapered (NPTF) Connections. ALIGNMENT.

  • Page 121: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 4 - 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 5. Rotate male fitting the number of turns per Table 4-2, 1.

  • Page 122: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 4-3, 37° Flare (JIC)Thread - Steel or Table 4-4, 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 123 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-3. 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 124 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-4. 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 125: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 4-5, 45° Flare (SAE) - Steel and Table 4-6, 45° Flare (SAE) - Aluminum/Brass while using 1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
  • Page 126 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Thread ØA* ØB* [ft. lb.] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16...

  • Page 127: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-ring Face Seal (ORFS) 5. Torque nut to value listed in Table 4-7, O-ring Face Seal (ORFS) - Steel or Table 4-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
  • Page 128 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Size ØA* ØB* [ft. lb.] [N-m] Dash Swivel & Tube Nuts Size Hose Ends (UNF) (in) (mm) (in)

  • Page 129: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 4 - 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 130 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-9. DIN 24°Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without o-ring) Torque Flats from Thread M Tube O.D. ØA* ØB* ØD* Wrench Size [ft. lb.] [N-m] Resistance (mm)

  • Page 131: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 4 - 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 132 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-10. 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...
  • Page 133 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Tube Thread M Size 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...

  • Page 134: Assembly Instructions For O-Ring Boss (Orb) Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 4-12 through Table 4-17 while using the Double Wrench Fittings Method. 1. Inspect components to ensure that male and female a.
  • Page 135 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-12. 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 Thread Size ØA* Torque MATERIAL Dash Size (UNF)
  • Page 136 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31...
  • Page 137 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 138 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
  • Page 139 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52 (55)
  • Page 140 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 141: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 4-18, Table 4-19, Table 4-20, Table 4-21, Table 4-22, or Table 4- Metric (MFF) Fittings 23 while using the Double Wrench Method.
  • Page 142 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-18. 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 143 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-19. 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 144 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-20. 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 145 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-21. 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 146 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-22. 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 STUD TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 147 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-23. 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 S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...

  • Page 148: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 4-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the 1.
  • Page 149 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-24. 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 M...

  • Page 150: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 4-25, Table 4-26, Table 4-27, Table 4-28, Table 4-29, or Table 4- (BSPP) Fittings 30 while using the Double Wrench Method. 1.
  • Page 151 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 3121781 4-41...
  • Page 152 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 4-42 3121781...
  • Page 153 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 3121781 4-43...
  • Page 154 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 4-44 3121781...
  • Page 155 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 3121781 4-45...
  • Page 156 Refer to the specific procedure in this G 3/4A Service Manual. G 1A G 1-1/4A 30 G 1-1/2A 38 * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 4-46 3121781...

  • Page 157: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 4 - 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. Install o-ring as per “O-ring Installation (Replacement)” . 3.
  • Page 158 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with GRADE 5 Fastener Torque for Flanges Equipped with GRADE 8 Bolt Inch Screws...
  • Page 159 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with CLASS Fastener Torque for Flanges Equipped with CLASS Bolt Inch Flange 8.8 Screws...

  • Page 160: Double Wrench Method

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.

  • Page 161: Ffwr And Tfft Methods

    SECTION 4 - 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 162: O-Ring Installation (Replacement)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 4-13. 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 Care must be taken when installing o-rings over threads dur- the threads prior to installation.

  • Page 163: Hydraulic Valves

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC VALVES 1. Main Valve 4. Oscillating Axle Lock-Out Valve (If Equipped) 2. Flow Divider Valve 5. Hydraulic Tank 3. Leveling Jack Valve Figure 4-14. Hydraulic Compartment Control Valves REMOVAL INSTALLATION 1. Disconnect, cap and label all hydraulic hoses and any 1.

  • Page 164: Main Hydraulic Valve

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Hydraulic Valve 17, 11 7, 14, 12 3, 15, 13 2, 15 1,15, 15 5, 16 4, 16 OPTIONAL LOCATION SLOT FOR MACHINING SET UP 1001234828-B MAF04050B Figure 4-15. Main Valve Port Identification See Table 4-34 on page 4-55 4-54 3121781...
  • Page 165 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-33. Main Valve Port Identification See Figure 4-15. on page 4-54 Port Functionality To Port To Lift Cylinder Lift Cylinder To Lift Cylinder Lift Cylinder Main RT Valve (Left Side) T - Outrigger Valve Main RT Valve (Left Side) Outlet - Tandem Gear Pump Main RT Valve (Left Side)

  • Page 166: Flow Divider Valve

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Flow Divider Valve 5,OR1 1001234828-B MAF04310B Figure 4-16. Flow Divider Valve 4-56 3121781...

  • Page 167: Leveling Jack Directional Valve

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Leveling Jack Directional Valve OUTRIGGER CYLINDERS THERMAL RELIEF S2, 2 RESET NON ADJUSTABLE OUTRIGGER CYLINDER EXTEND PRESSURE VALVE OUTRIGGER CYLINDERS EXTEND TANK VALVE S3, 4 S1, 1 OUTRIGGER CYLINDERS RETRACT VALVE 1001217108-C MAF04350C Figure 4-17.

  • Page 168: Leveling Jack Valves

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-36. Leveling Jack Directional Valve Torque Specs See Figure 4-17. on page 4-57 Component Functionality Torque Leveling Jack Cylinders Retract Valve 18.5 - 22 ft. lb. (25-30 Nm) Leveling Jack Cylinders Extend Tank Valve 28 - 33 ft.

  • Page 169: Pressure Relief Valve - Setting Procedures

    “trim” function. pressures. JLG Industries Inc. also recommends the use c. Next, fully retract leveling jacks. Repeat this of a calibrated gauge. Pressure readings are acceptable cycle four more times to bleed all air from cir- if they are within ±...

  • Page 170: Gear Pump

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.10 GEAR PUMP 1. Inlet Port from Hydraulic Tank, 1-15/16-12 SAE STD 2. Outlet Ports, 7/8-14 SAE STD THD - SAE #10 ORB THD - SAE #16 ORB Figure 4-19. Tandem Gear Pump Table 4-39.

  • Page 171: Gear Pump Priming

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Gear Pump Priming The gear pump is mounted with the suction hose up. Air trapped in this area can cause an air lock on start up. during this period, the pump is running dry, which can cause gear wear, which affects the volumetric efficiency of the pump.

  • Page 172: Axial Hi 45 Pump

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.11 AXIAL HI 45 PUMP MAF06320 1. Case Drain Port L2 (SAE#12) 5. Charge Pressure Filtration Port 9. Port A (SAE#16) (to inlet on filter) 2. Deutsch DT04-2P Connector 10. Charge Pump Suction Port 6.

  • Page 173: Axial Hi 45 Pump - Cross Section View

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF06330 1. Electric Displacement Control 6. Shaft 11. Charge Pump 2. Swashplate Feedback Pin 7. Front Bearing 12. Rear Bearing 3. Piston 8. Swashplate Bearing 13. Valve Plate 4. Slipper 9. Swashplate 14.

  • Page 174: General Repair Instructions

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS General Repair Instructions Start-Up Procedure Follow this procedure when starting-up a new pump REMOVAL installation or when restarting an installation in which the pump has been removed and re-installed on the machine. Ensure pump has been thoroughly tested on a test stand before installing on a machine.

  • Page 175: Removing The Pump

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS nected, plug each open port, to ensure that dirt and contamination do not get into the pump. AFTER START-UP, THE FLUID LEVEL IN THE RESERVOIR MAY DROP 3. Remove the pump and its auxiliary pump (if applica- DUE TO SYSTEM COMPONENTS FILLING.

  • Page 176: Electric Control Module

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Electric Control Module D050 (3X) 4 mm 4 ft.lbs. (5 Nm) D250 D025A 5 mm 10 ft.lbs. D025A D050 (3X) Torque sequence 4 mm D084 4 ft.lbs. (5 Nm) D150 F100 (2X) 3 mm 1.8 ft.lbs.

  • Page 177: Shaft Seal, Roller Bearing & Shaft Replacement

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Shaft Seal, Roller Bearing & Shaft Replacement (+0.12mm) or 0.0028 in (-0.72 mm) of the inside lip of the carrier: see illustration. NOTE: The shaft assembly is serviceable without disassem- Positioning seal in seal carrier bling the pump.
  • Page 178 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS INSPECTION Charge pump removal/installation 1. Inspect the components for wear, scratches or pit- ting. Carefully inspect the valve and pressure-bal- ance plates. Scratches on these components will K400 cause a loss of charge pressure. If any component 8 mm shows signs of wear, scratching or pitting, replace it.

  • Page 179: Charge Check/Hprv

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Charge Check/HPRV Charge Pressure Relief Valve Replace the charge pressure relief valve (V10) as a com- REMOVAL plete unit. Do not attempt to repair the internal compo- 1. Using a 22 mm hex wrench, remove the HPRVs (L100/ nents of the valve.

  • Page 180: Pressure Limiter Valve Replacement

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Pressure Limiter Valve Replacement 4.12 CHARGE PUMP FILTER NOTE: Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual components. REMOVAL 1. Using a 14 mm wrench, remove the pressure limiter valves (L300/L400).

  • Page 181: Cylinder Repair

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.13 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fix- ture. NOTE: The following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 182: Cleaning And Inspection

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 13. Remove the bushing from the piston. 7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable. Figure 4-27. Tapered Bushing Removal EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER 14.
  • Page 183 17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cyl- inder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly. 3121781...

  • Page 184: Wiper Seal Installation

    11. Assemble the tapered bushing loosely into the pis- ton and insert JLG capscrews (not vendor capscrews) 7. If applicable, correctly place new seals and guide through the drilled holes in the bushing and into the lock rings in the outer piston diameter groove.

  • Page 185: Tapered Bushing Installation

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR- REL SURFACES. 18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder.
  • Page 186 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BAR- REL SURFACES. 27. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder.

  • Page 187: Cylinder Assemblies

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.14 CYLINDER ASSEMBLIES Steer Cylinder 1. Barrel 2. Rod 3. Head - Torque to 434 ft. lb. (588 Nm) 4. Wiper 5. Road Seal 6. Back-up Ring 7. Dry Bearing 8. O-Ring 9.

  • Page 188: Lift Cylinder (Lower)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: SEE SCISSORS ARMS ASSEMBLY FOR CARTRIDGE VALVES LOCATED IN VALVE BLOCK. DO NOT PUT CYLINDER INTO SERVICE WITHOUT CARTRIDGE VALVE INSTALLED Lift Cylinder (Lower) 1. Barrel 2. Rod 3. Head - Torque to 332 ft.

  • Page 189: Lift Cylinder (Upper)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: SEE SCISSORS ARMS ASSEMBLY FOR CARTRIDGE VALVES LOCATED IN VALVE BLOCK. DO NOT PUT CYLINDER INTO SERVICE WITHOUT CARTRIDGE VALVE INSTALLED Lift Cylinder (Upper) 1. Barrel 2. Rod 3. Head - Torque to 332 ft. lb. (450 Nm) 4.

  • Page 190: Lift Cylinder Valve Cartridge Torque Values

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS LOWER CYLINDER UPPER CYLINDER MAF04390 Item Torque 33 -37 ft. lb. (45 - 50 Nm) 3 - 4.5 ft. lb. (4 - 6 Nm) 18.5 - 22 ft. lb. (25 - 30 Nm) 5 - 7 ft.

  • Page 191: Oscillating Axle Cylinder

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1. Barrel 2. Rod 3. Wiper Seal 4. Wear Ring 5. Rod Seal 6. Wear Ring 7. CounterBalance Valve 8. Bleeder Valve 9. Pilot Port 10. Valve Port NOTE: Torque item #7 to 22 ft. lb. (30 Nm) THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF THE BLEEDER VALVE IS LOOSENED.

  • Page 192: Leveling Jack Cylinder

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1. Head 2. Barrel 3. Rod 4. Jack Plate 5. Ring, Lock 6. Ring, Wear 7. Ring, Washer 8. Ring, Retaining 9. O-Ring 10. Screw 11. Capscrew 12. Seal 13. WIper 14. Ring, Back-Up 15.

  • Page 193: Leveling Jack Torques

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF04300 Item Description Torque Solenoid Directional Valve 18.4 to 22.1 ft. lb. (25-30 Nm) Straight Fitting 16.2 ft. lb. (22 Nm) Straight Fitting 40 ft. lb. (54.2 Nm) Figure 4-42. Leveling Jack Torques 3121781 4-83...

  • Page 194: Oscillating Axle Cylinder Bleeding Procedure

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Oscillating Axle Cylinder Bleeding Procedure 1. Oscillating Axle Cylinder 2. Bleeder Valve Figure 4-43. Oscillating Axle Cylinder Bleeding 1. Start the engine. NOTE: A fast stream of oil will exhaust the air out of the hoses and cylinder better than a slow stream of oil.

  • Page 195: Hydraulic Schematics

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.15 HYDRAULIC SCHEMATICS Figure 4-44. Hydraulic Schematic 3121781 4-85...

  • Page 196: Hydraulic Schematic

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS OPTION: AXLE LOCKOUT VALVE RAM LOCKOUT CYLINDERS R2P2W R2P3W (4500 PSI) (4500 PSI) L2P2W L2P3W FROM PORT 11 TRACTION MANIFOLD FROM PORT M3 DRIVE PUMP SHEET 2 1001232921-B MAF03730B Figure 4-45. Hydraulic Schematic 4-86 3121781...

  • Page 197: Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub To return home or access Level, and item menus previous menu Left &...

  • Page 198: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM NOTE: The cable has a four pin connector at each end; the If you press ENTER, at the HELP:PRESS ENTER display, cable cannot be connected backwards. and a fault is present during power up, the analyzer dis- play will scroll the fault across the screen.

  • Page 199: Changing The Access Level Of The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM menus while in access level 2. Remember, you may Once the correct password is displayed, press ENTER. always cancel a selected menu item by pressing the ESC The access level should display the following, if the pass- key.

  • Page 200: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Once you have gained access to level 1, and a personal-...
  • Page 201 ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTI- LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM- PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFOR- INCHES (30.5 CM) AWAY FROM THESE COMPONENTS.

  • Page 202: Analyzer Menu Flow Charts

    SECTION 5 - JLG CONTROL SYSTEM Analyzer Menu Flow Charts 3121781...
  • Page 203 SECTION 5 - JLG CONTROL SYSTEM 3121781...
  • Page 204 SECTION 5 - JLG CONTROL SYSTEM 3121781...

  • Page 205: Diagnostic Troubleshooting Codes (Dtc's) And Flash Codes Description

    SECTION 5 - JLG CONTROL SYSTEM DIAGNOSTIC TROUBLESHOOTING CODES (DTC’S) AND FLASH CODES DESCRIPTION Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code "Everything Ok" • No issues detected "Driving At Cutback - Above Elevation"...
  • Page 206 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code 2 3 "Ground Lift Up/down Active Together" • Ground lift up and lift down inputs both closed. The control system prevents lifting and lowering.
  • Page 207 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code 2239 2 2 "Function Locked Out - Joystick Calibration Faulty" • Joystick calibration is not valid. The control system prevents any func- tion selects.
  • Page 208 > 100 inches AND < 350 inches AND Model = 330LRT > 120 inches AND < 450 inches AND Model = 430LRT > 140 inches AND < 600 inches AND Model = 530LRT Lift Up/LJ Flow Control (530LRT) or Lift Flow Control (330/430LRT) Command >...
  • Page 209 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code 3524 3 5 "Rear Left Leveling Jack Short To Battery" • The Rear Left Leveling Jack is shorted to battery.
  • Page 210 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code 33751 3 3 "Upper Lift Down Valve - Short to Ground" • The HIM has detected a STG on the Upper Lift Down Valve output and...
  • Page 211 • MACHINE SETUP ->AXLE = OSCILLATING AND MODEL = 330/430LRT and MARKET = CE MACHINE SETUP MODEL = 530LRT and AXLE = OSCILLATING Ground module has lost communication with the oscillating axle tilt sensor (0xC3) via CANbus for greater than or equal to 250ms .
  • Page 212 MACHINE SETUP ->AXLE = OSCILLATING AND MODEL = 330/430LRT and MARKET = CE MACHINE SETUP MODEL = 530LRT and AXLE = OSCILLATING. 8114 8 1 "Arm Stack Tilt Sensor Out Of Range" • The Arm Stack Tilt Sensor Raw Arm Angle reading is < -90 degrees...
  • Page 213 SECTION 5 - JLG CONTROL SYSTEM Table 5-1. DTC and Flash Code Descriptions Flash Description Item Check List Code Code 9 9 "LSS Watchdog Reset" • LOAD CFG = LOAD PINS and LOAD != NO LSS Module reports watchdog reset fault 0x40 9 9 "LSS EEPROM Error"...

  • Page 214: Chassis Tilt Sensor Installation

    SECTION 5 - JLG CONTROL SYSTEM CHASSIS TILT SENSOR INSTALLATION MAF04530 MAF04250 1. Chassis Tilt Sensor 5. Stand-off Insulators 1. Ground Control Box 2. Chassis Tilt Sensor 2. Sensor Mount 6. Washers Assembly 3. Screws 7. Screws 4. Washers 8. Harness Connector Figure 5-6.

  • Page 215: Location Of Additional Sensors

    SECTION 5 - JLG CONTROL SYSTEM LOCATION OF ADDITIONAL SENSORS MAF04000 1. Oscillating Axle Tilt Sensor 3. Rotary Angle (Elevation) Sensor 2. Arm Stack Tilt Sensor Figure 5-8. Chassis Sensor Locations 3121781 5-19...

  • Page 216: Calibration Procedures

    SECTION 5 - JLG CONTROL SYSTEM CALIBRATION PROCEDURES Some possible reasons that the tilt sensor will not cali- brate are: Chassis Tilt Sensor Calibration a. The surface the machine is sitting on is off level by a few degrees (flat doesn’t imply level; park- (Item 1, Figure 5-7.)

  • Page 217: Oscillating Axle Tilt Sensor

    SECTION 5 - JLG CONTROL SYSTEM Oscillating Axle Tilt Sensor SERVICE MODE PROCEDURES (Item 4, Figure 5-8.) ECM Override (Dual Fuel Only) 1. Place machine on level surface This service menu may be utilized when ECM CAN communication is lost on a machine equipped with 2.

  • Page 218: Eeprom Reset

    SECTION 5 - JLG CONTROL SYSTEM EEPROM Reset Allow Leveling Jack Retract This procedure clears all the machine's calibrations and This mode allows a service technician to retract the lev- returns the machine personalities and set-up to default eling jacks when an active DTC prevents normal leveling settings.

  • Page 219: Machine Configuration And Programming Settings

    SECTION 5 - JLG CONTROL SYSTEM MACHINE CONFIGURATION AND PROGRAMMING SETTINGS The Machine Configuration Programming must be completed before any Personality settings (Table 5-5) can be changed. Changing the Personality settings first and then changing the Model of the Machine Configuration will cause the Personality settings to return to default values.
  • Page 220 SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Configuration Programming Information Configuration Digit Setting Description Default Number AXLE CONFIG: FIXED - The machine is not equipped with an oscillating axle. OSCILLATING - The machine is equipped with an oscillating axle.
  • Page 221 SECTION 5 - JLG CONTROL SYSTEM Table 5-5. Machine Model Personality Adjustment Model Default Values Adjustment Adjustment Range 530LRT DRIVE Accel 0.1 - 5.0 (sec) Decel 0.1 - 3.0 (sec) Min Forward 500 - 800 mA Hi Drv Fwd 1000 - 1800 mA...
  • Page 222 SECTION 5 - JLG CONTROL SYSTEM Table 5-5. Machine Model Personality Adjustment Model Default Values Adjustment Adjustment Range 530LRT TEMP CUTOUT Cutout Set -30 - 0 (C) 1001241349_A NOTE: These settings may be changed in order to achieve optimal performance.

  • Page 223: Connecting The Jlg Control System Analyzer

    NOTE: The cable has a four-pin connector at each end of When accessing the Help Menu, the JLG Analyzer will the cable; The cable cannot be connected back- display EVERYTHING OK if the platform is not over- wards.

  • Page 224: Diagnostic Menu

    SECTION 6 - LSS SETUP/CALIBRATION/SERVICE DIAGNOSTIC MENU NOTE: The Diagnostic, Load menu is not available when the LSS is not enabled. (Machine Setup, Load is set to 0=Not Installed NOTE: If necessary refer to Section 5 - Analyzer Menu Flow Charts.

  • Page 225: Machine Setup Menu

    SECTION 6 - LSS SETUP/CALIBRATION/SERVICE MACHINE SETUP MENU CALIBRATION MENU The LOAD submenu within the machine setup menu is The Load submenu within the Calibration Menu is used used to configure the LSS. To access the Machine Setup, to zero the Empty Platform weight. Load menu, use the Left and Right arrow keys to select To access the Calibration Load Menu, use the LEFT and MACHINE SETUP from the Top Level Menu.

  • Page 226: Service

    SECTION 6 - LSS SETUP/CALIBRATION/SERVICE Pressing the ENTER key will confirm that the platform is If the empty platform weight is less than minimum cali- empty (except for factory-installed options outside the bration value, the calibration attempt will be unsuccess- Rated Load).

  • Page 227: Description

    SECTION 6 - LSS SETUP/CALIBRATION/SERVICE SERVICE Description The system consists of the LSS Module, four Shear Pin Load Cells (sensors), Wire Harness, and various brackets and fas- teners. The LSS Module is mounted beneath the platform on a bracket. The Shear Pin Load Cells mount between the platform and the arm structure in such a way that all support force for the platform is applied through them (for mea- surement).

  • Page 228: Calibration

    Refer to the Troubleshooting section of this manual if the Load Sensing System fails to meet these guidelines. 1. Plug the JLG Analyzer into the LSS Module on the Host Control System and enter the Access Level 1 1. Plug the JLG Analyzer into the Host Control System.
  • Page 229 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE 6. Confirm Load Sensing System Performance with Cali- brated Weights. Operate the vehicle from Ground Control and place the platform in the fully stowed position for safety. Place 120% of the machines rated load in the center of the platform and ensure that the overload visual and audible warnings are active.
  • Page 230 3. There is a short circuit on the pre-regulated supply for the JLG Analyzer present on J2-1. Unplug J2’s connector and observe whether the module begins to function. If so, examine the Analyzer harness for defect.
  • Page 231 (this is normal). (±1kg) (without the influence of vibration 2. Wiring leading to one of the Shear Pin Load Cells is damaged. Examine each sensor’s reading using the JLG Analyzer. or wind).
  • Page 232 2. The signal between the LSS Module and the Host Control System is shorted. The Platform Module’s J1-20 is an input, and it connected to the J1-5 output on the LSS Module To examine the status of this signal, plug the JLG Ana- lyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the DIAGNOSTICS, SYS- TEM, LOAD display.
  • Page 233 Figure 6-2. LSS Module Load Cell Connector Communication (J1 - Black) Pinout (J5, J6, J7, J8) SIGNAL DESCRIPTION APWR Pre-Regulated Supply for JLG Analyzer (Analyzer Pin 1; approx. 12V) RS-232 for JLG Analyzer (Analyzer Pin 3) TRP1 120 Ohm CANbus Terminator CANH-1...
  • Page 234 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE ANALYZER CONNECTOR PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 1 PIN 2 PIN 11 PIN 12 PIN 5 PIN 6 PIN 7 PIN 8...

  • Page 235: General

    TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH Finding a negative voltage or current reading when AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- expecting a positive reading frequently means the leads TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A are reversed.

  • Page 236: Voltage Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 7-1. Voltage Measurement (DC) Figure 7-2. Resistance Measurement • If meter is not auto ranging, set it to the correct • First test meter and leads by touching leads together. range (See multimeter’s operation manual) Resistance should read a short circuit (very low resis- tance)

  • Page 237: Continuity Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC) • Some meters require a separate button press to • Set up the meter for the expected current range enable audible continuity testing •...

  • Page 238: Continuity Measurement Over Long Distances

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances 1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is When trying to determine continuity of a harness or not completely isolated disconnect battery terminals wire, longer than the reach of standard instrument also, as a precaution.

  • Page 239: Applying Silicone Dielectric Compound To Electrical Connections

    NOTE: Curing-type sealants might also be used to prevent short- ing and would be less messy, but would make future pin JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- removal more difficult. RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.

  • Page 240: Deutsch Hd, Dt, Dtm, Drc Series

    If trapped air prevents the connector from latching, pierce one of the unused wire seals. After assembly, install a seal plug (JLG #4460905) in that location to prevent moisture ingress. Note that seal plugs may be installed by the wire harness man-...

  • Page 241: Din Connectors

    Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required). The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con- nector system.

  • Page 242: Engine Control Unit Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Engine Control unit connectors MIL-C-5015 SPEC Connector’s Many times, these types of connectors use back-seals for mois- Crown Connector Inc’s recommendation is to not use dielec- ture integrity. However, the low-force contacts cannot displace tric grease for this series connector.

  • Page 243: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS APPLYING SILICONE DIELECTRIC COMPOUND around male and female pins on the inside of the connector after the mating of the housing to the TO AMP CONNECTORS header. This is easily achieved by using a syringe to fill the header with silicone dielectric compound, to a Silicone Dielectric Compound must be used on the AMP point just above the top of the male pins inside the...
  • Page 244 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as- shipped, position (See Figure 7-10. Connector Assembly (1 of 4)). Proceed as follows: Figure 7-11. Connector Assembly (2 of 4) Figure 7-10.
  • Page 245 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half 1. Insert a 4.8 mm (3/16”) wide screwdriver blade turn (1/4 turn in each direction), gently pull the wire between the mating seal and one of the red wedge until the contact is removed.

  • Page 246: Service - Voltage Reading

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

  • Page 247: Working With Deutsch Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-17. DT/DTP Contact Removal Figure 7-16. DT/DTP Contact Installation 1. Remove wedgelock using needle nose pliers or a hook shaped wire to pull wedge straight out. 1.

  • Page 248: Hd30/Hdp20 Series Assembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-18. HD/HDP Contact Installation Figure 7-20. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact 1. With rear insert toward you, snap appropriate size crimp barrel.

  • Page 249: Switches

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a “prox switch”. 1. De-energize the circuit. Inductive proximity switches are actuated only by fer- 2.

  • Page 250: Automatic Switches

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches Switch Wiring - Low Side, High Side If the switch is actuated automatically, by temperature When controlling a load, a switch can be wired between or pressure for example, find a way to manually actuate the positive side of the power source and the load.

  • Page 251: Electrical Schematics

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS 530LRT ELECTRICAL SCHEMATIC SHEET 2: GROUND CONTROL HARNESS,GROUND MODULE HARNESS,GROUND CONTROL BOX SHEET 3: CHASSIS, ARM STACK & OPTIONS HARNESS,CHASSIS WIRING CABLE,ARM STACK CABLE,ARM STACK CABLE,ARM STACK HARNESS,CHASSIS WIRING CABLE,ARM STACK,UPR AUX...
  • Page 252 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 7-18 3121781...
  • Page 253 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 3121781 7-19...
  • Page 254 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 7-20 3121781...
  • Page 255 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 3121781 7-21...
  • Page 256 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 7-22 3121781...
  • Page 257 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 3121781 7-23...
  • Page 258 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 7-24 3121781...
  • Page 259 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 3121781 7-25...
  • Page 260 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic 7-26 3121781...
  • Page 262 3121781 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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