JLG 1200SJP Service And Maintenance Manual
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JLG 1200SJP Service And Maintenance Manual

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Service and Maintenance Manual
Models
1200SJP
1350SJP
PN - 3121142
April 22, 2019 - Rev V
GB
AS/NZS

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Summary of Contents for JLG 1200SJP

  • Page 1 Service and Maintenance Manual Models 1200SJP 1350SJP PN - 3121142 April 22, 2019 - Rev V AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • 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 - June 5, 2002 Revised B - January 15, 2003 Revised C - May 23, 2003 Revised D - August 30, 2004 Revised E - January 12, 2006 Revised F - July 12, 2006 Revised G - November 30, 2006 Revised...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 Do NOT Do the Following When Welding on JLG Equipment....... .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.16 Drive Hub - Reggiana Riduttori (SN 134389 to Present) ..........3-60 Symbol Nomenclature .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.30 Deutz Engine - TD2.9L4 ................3-129 Glow Plugs .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.11 Hose Routing Procedure ................4-70 4.12 Wire Rope .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. FFWR and TFFT Methods..............5-52 Adjustable Stud End Assembly .
  • Page 11 To Connect the JLG Control System Analyzer........
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Lubrication and Maintenance Diagram ............. 1-6 1-2.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-49. Swing Drive - Motor and Brake Disassembly (SN 0300201016 through 0300254466, SN B300002238 to Present)........3-78 3-50.
  • Page 15 Load Pin Removal Tool, JLG PN 4846765 ........
  • Page 16 Platform Valve Identification - JLG PN 4641266 ........
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-62. Function Pump, Pressure and Flow Control - Sheet 1 ..........5-108 5-63.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-29. CANbus Connections - Sheet 1 of 5..............6-143 6-30.
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-39. Electrical Schematic - Sheet 1 of 17 ..............7-33 7-40.
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. Capacities ..................1-1 Tire Specifications .
  • Page 21 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 ........5-41 5-26 British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 .
  • Page 22 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 23: Specifications

    Idle Engine RPM 1200 Foam Fill Poly urethane HD (55 Durometer) Foam Mid Engine RPM 1800 Max Tire Load 1200SJP 25,000 lbs. (11,340 kg) High Engine RPM 2475 1350SJP 26,250 lbs. (11,907 kg) Max Tire Load (Non-Marking Tire) Deutz TCD 2.9 @6 km/h 33,000 lbs.

  • Page 24: Deutz Tcd 2.9 Guoiii

    Max High Engine RPM 2600 Stowed Height 10 ft. (3.04 m) Min Low Engine RPM Stowed Length (Transport Mode) 1200SJP 34 ft. 11in. (10.64 m) High RPM set 2500 ±50 RPM 1350SJP 38 ft. 11in. (11.86 m) Low RPM set 1200 ±...

  • Page 25: Torque Requirements

    F. (-7 degrees C.), JLG Industries recommends the use of Mobil DTE13. 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 viscosi- ties.

  • Page 26: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.7 MAJOR COMPONENT WEIGHTS Table 1-15. Mobil EAL H 46 Specs Table 1-17. Component Weights Type Synthetic Biodegradable ISO Viscosity Grade Component Pounds Kilograms Specific Gravity .910 Tire & Wheel (Foam Filled) Pour Point -49°F (-45°C) Tire &...

  • Page 27: Pressure Settings

    SECTION 1 - SPECIFICATIONS 1.8 PRESSURE SETTINGS Table 1-18. Pressure Settings Circuit Function Pump, High 3400 234.4 Function Pump, Low 20.6 Drive, Pre-Set 5000 344.7 Lift Up 2750 189.6 Lift Down 1500 103.4 Swing 1500 103.4 Tele Out 3000 206.8 Telescope In 3200 220.6...
  • Page 28 SECTION 1 - SPECIFICATIONS 10,11 Figure 1-1. Lubrication and Maintenance Diagram 3121142...

  • Page 29: Lubrication And Maintenance

    SECTION 1 - SPECIFICATIONS 1.9 LUBRICATION AND MAINTENANCE 2. Swing Gearbox a. Swing Gearbox 0300201016 through NOTE: The following numbers correspond to those in Figure 1-1., 0300254466, SN B300002238 to Present) Lubrication and Maintenance Diagram. Table 1-19. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350°...
  • Page 30 SECTION 1 - SPECIFICATIONS 3. Swing Brake NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. a. Swing Brake (SN 0300201016 through 0300254466, SN B300002238 to Present) 4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128) Lube Point(s) - Level/Fill Plug Capacity - 0.5 liters (1/2 full) Lube - EPGL...
  • Page 31 SECTION 1 - SPECIFICATIONS C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to 7. Hydraulic Oil Present) FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Level/Fill Plug Capacity - 0.5 quarts (0.5 liters) ± 10% Lube - EPGL Interval - Change after first 150 hours then every 1200 hours of operation...
  • Page 32 SECTION 1 - SPECIFICATIONS 9. A. Oil Change w/Filter - Deutz 2011 MINIMUM OIL LEVEL MAXIMUM OIL LEVEL MINIMUM LEVEL, OIL HOT MAXIMUM LEVEL, OIL HOT Lube Point(s) - Fill Cap/Spin-on Element Capacity - 5 Quarts (4.5 L) Cooling System 11 Quarts (10.5 L) w/Filter MINIMUM LEVEL, 16 Quarts (15 L) Total Capacity...
  • Page 33 SECTION 1 - SPECIFICATIONS 12. Fuel Pre-Filter TCD2.9 B. Fuel Filter - Deutz TCD2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation. 13. Radiator Coolant TCD2.9 Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation.
  • Page 34 SECTION 1 - SPECIFICATIONS 14. A. Air Filter - Deutz 2011 15. Platform Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as Interval - Change after first 50 hours and then every year indicated by the condition indicator.
  • Page 35 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121142 1-13...
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-14 3121142...
  • Page 37 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121142 1-15...
  • Page 38 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-16 3121142...
  • Page 39 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121142 1-17...
  • Page 40 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 41: General

    Service Technician as a person who has successfully com- this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG product model. Reference the machine Service and Mainte- Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor- mance of this inspection.

  • Page 42: 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 43: 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 44: Lubrication

    When recommended lubricants are not avail- able, consult your local supplier for an equivalent that meets 2. JLG recommends Mobilfluid 424 hydraulic oil, which has or exceeds the specifications listed. an SAE viscosity of 10W-30 and a viscosity index of 152.

  • Page 45: 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 46: Pins And Composite Bearing Repair Guidelines

    • Ground only to structure being welded. a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG b. Cracked or damaged liner backing. c. Bearings that have moved or spun in their housing.
  • Page 47 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent 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 Extend/Retract Chain or Cable Systems...
  • Page 48 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent 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 Swing Brakes...
  • Page 49 Function Test of All Systems 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change 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 50 SECTION 2 - GENERAL 1001159163 B Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 3121142...
  • Page 51 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 52: Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the air the mounting stud holes in the wheels. pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. The proper procedure for attaching wheels is as follows: 1.

  • Page 53: Extending Axles

    SECTION 3 - CHASSIS & TURNTABLE 3.2 EXTENDING AXLES NOTE: For more detailed information concerning system adjust- ment and operation, refer to Section 6 - JLG Control Sys- The Axle Extension System allows each of the four axles to be tem.

  • Page 54: Drive System

    NOTE: For more detailed information concerning system adjust- ment and operation, refer to Section 6 - JLG Control Sys- tem. Figure 3-3. Crab Steer Mode...

  • Page 55: Drive/Steering Speed Control

    NOTE: For more detailed information concerning system adjust- driving position. This occurs roughly when the boom is swung ment and operation, refer to Section 6 - JLG Control Sys- past a rear tire. When the turntable is in the normal drive posi- tem.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Chassis Component Location - Sheet 1 of 2 3121142...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear) 2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear) 3. Steer Valve (Front) 11. Chassis Module 4. Axle Lockout Valve 12.
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE Figure 3-7. Turntable and Boom Component Location - Sheet 1 of 2 3121142...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Platform Control Valve 23. Headlight 2. Jib Stow Switch 24. Deutz EMR2 Module 3. Platform Level Sensor (Secondary - Left) 25. 110V / 220V Generator 4. Tail Lights 26. Generator Control Box 5. Skypower Generator 27.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE D E T A IL A * AXLE STOP SHIMMING PROCEDURE: ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM.
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 11,12,B ,G 11,12,A ,G 11,12,C ,G D E T A IL A 11,12,D ,G 11,12,E ,G 11,12,F ,G A - Assemble to Axle Box Mid Plate; Typical 8 Places D E T A IL B B- Assemble to Top Plate of Axle Boxes;...
  • Page 62 SEE DETAIL A SEE DETAIL B -ASSEMBLE TO TOP PLATE OF AXLE WELDMENT -TYP 4 PLACES, 4 AXLES -TORQUE GRADE 8 PER JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM 14 OR 15) TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT 1001173913-H MAE35920H Figure 3-11.
  • Page 63 BOX MID PLATE -TYP 4 PLACES, 2 AXLE BOXES TYP 8 PLACES, -TORQUE GRADE 8 PER 2 AXLE BOXES JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM 15, 16, OR 17) TO ENSURE 1/2" 1/16" THREAD ENGAGEMNET PLUG (4) 1/2-13 TAPPED HOLES...
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL A AXLE STOP SHIMMING PROCEDURE: 1) ALL 4 WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2) SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM.
  • Page 65 PLATES OF AXLE BOXES TYP 8 PLACES, 2 AXLE BOXES -ASSEMBLE TO TOP PLATE OF AXLE WELDMENT -TYP 4 PLACES, 4 AXLES -TORQUE GRADE 8 PER JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM 52 OR 53) TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT...
  • Page 66 SEE DETAIL B -ASSEMBLE TO TOP PLATE OF AXLE WELDMENT -TYP 4 PLACES, 4 AXLES AXLE AND AXLE BOX FRONT PLATES -TORQUE GRADE 8 PER JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM #15 OR #16) TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT 1001173914-I MAE35940I Figure 3-15.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE -ASSEMBLE TO TOP PLATE OF AXLE BOXES -TYP 4 PLACES, 2 AXLE BOXES -TORQUE GRADE 8 PER JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM #16, #17, OR #18) TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT ASSEMBLE TO SIDE PLATES...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Axle Loctite Application 3-18 3121142...
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes Apply JLG Threadlocker PN 0100011 Apply JLG Threadlocker PN 0100019 Apply Loctite #222 Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut Spindle Steer Cylinder Pivot Pin Angle Sensor Assembly...

  • Page 70: Oscillating Axle System

    NOTE: For more detailed information concerning system adjust- form (on high engine) feather drive. Activate drive fully. ment and operation, refer to Section 6 - JLG Control Sys- 5. Close the bleeder when there is a steady stream of oil tem.

  • Page 71: Oscillating Axle Lockout Test

    12" [30.4 cm] on the1350SJP or 24" 13. Have an assistant check to see that right front wheel [60.9 cm] on the 1200SJP) and drive is selected. remains locked in position off of ground. 14. Retract the boom back in to the transport position. Acti- vate drive and the lockout cylinders should release.

  • Page 72: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.11 WHEEL DRIVE ASSEMBLY 2. Remove hardware securing wheel and remove wheel assembly. Removal 3. Using suitable lifting device lift the wheel assembly and place in a suitable area. NOTE: The drive motor can be removed through the axle flange as part of the wheel drive assembly or they can be removed Installation separately through the bottom of the frame while leaving...

  • Page 73: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE HUB Installation 1. Use suitable lifting device to support the drive hub. Removal NOTE: The drive hub weighs approximately 267 lbs. (121 kg). 1. Place machine on the firm level surface. 2. Install the drive hub to the machine. 2.

  • Page 74: Removal

    SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE MOTOR Installation 1. Use suitable lifting device to support the drive motor. Removal NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg). 1. Place machine on the firm level surface. 2. Install the drive motor to the drive hub. 2.
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE MAE37590B 1. Bolt 9. Snap ring 17. Cylinder Piston 25. Gasket 33. Snap ring 2. End cap motor 10. Spring Retainer 18. Piston Ring 26. Plug 34. Snap ring 3. Locating pin 11. Spring 19.

  • Page 76: Disassembly

    18. The second stage planetary gears (1) must be changed as a complete set of four and JLG recommends changing 2. Remove all bolts holding the motor and Remove motor the sun gear (3) along with this set of planets.

  • Page 77: Assembly Of First Stage Planetary Assembly (7)

    SECTION 3 - CHASSIS & TURNTABLE Assembly of First Stage Planetary Assembly (7) 6. Before installation of motor, CHECK THAT THERE IS 1-2 mm OF CLEARANCE BETWEEN THE MOTOR SPLINE 1. Pre-freeze planet pins (5) and install into planet carrier SHAFT SHOULDER AND THE COUPLER (62).
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 3-28 3121142...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE 3121142 3-29...

  • Page 80: Drive Hub - Bonfiglioli (Sn 100128 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.15 DRIVE HUB - BONFIGLIOLI (SN 100128 TO Installation of the Wheel Drive on the Machine PRESENT) 1. Clean the mating surfaces from oils or paint and fit the wheel drive on the machine frame. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs.

  • Page 81: General Information

    SECTION 3 - CHASSIS & TURNTABLE 5. Make sure that the oil temperature does not exceed Connecting the Brake values listed previously. The gearbox is fitted with a negative multi disk safety brake with hydraulic control release (parking brake). For information After having finished running-in the gearbox, follow the steps regarding the characteristics of the brake refer to the installa- given below.
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5......Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..Brake port Figure 3-26. Hub Assembly 3-32 3121142...

  • Page 83: Gearbox Disengagement

    SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade Ambient temperature -20°C / +30°C +10°C / +45°C Oil viscosity SAE 80W/90 SAE 85W/140 Manufacturer Oil Brand SHELL SPIRAX HD SPIRAX HD AGIP ROTRA MP ROTRA MP...
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 3. Take out the cap nut (5). THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. 4. Turn the cap nut (5) upside down. As result the pin (3) will be pushed inside in order to permit disengagement of the gearbox.

  • Page 85: Maintenance Information

    SECTION 3 - CHASSIS & TURNTABLE 6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade- quate solution.

  • Page 86: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting The following table is provided to help locate problems in the gearbox. Table 3-6. Troubleshooting Symptom Causes Remedies External oil leakage: From the lifetime seal a)Lifetime seal damaged a)Replace lifetime seal From the end cover a)O-ring seal damaged a)Replace O-ring seals From the plugs...
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for (31) and turn the screw until it compresses the springs the reassembly. (45).
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring 2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring 3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39). 11.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the splined shaft (14). 14. Place the disengagement shaft kit (15) inside the special tool (6689960240). 17. Remove the special tool and remove the spring (13) and the washers (12).
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male hex head wrench. 20. Remove the pin (3). 23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the end cover (7).
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17). (7). 29. Remove the 2nd reduction assembly (18). 26. Remove the 1st stage sun gear (10). 30.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE 31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier 3rd reduction (20). (ATZ.09.016.0) on the ring nut (22). 32. Remove the spacer (21) from their seats in the pins of 35.

  • Page 94: Inspection Of Parts

    SECTION 3 - CHASSIS & TURNTABLE 37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29) flanged hub (31) from the gearbox housing (23). from the flanged hub (31). 38.

  • Page 95: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate seals to make reassembly easier.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 4. Using the same tool (6689960300), assemble the 2nd 7. Apply grease TECNOLUBE SEAL GS730 on the seal ring half seal (29) on the flanged hub (31). (30). 5. Carefully clean the metallic faces of the lifetime seal (29) and lube the surfaces with oil.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 9. By using a press and a metallic stopper, push the gear- 11. By using the mutiplier (ATZ.09.016.0), tighten the ring box housing (23) against the shoulder on the flanged nut (22), using a torque wrench with an input multiplier hub (31) until assembling of the unit is complete.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 13. Assemble correctly the spacers (21) on the pins of the 16. By using pliers, assemble the circlips (19) in the flanged flanged hub (31). hub pin seats (31). 17. Assemble the 2nd reduction assembly (18). 14.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble the 1st reduction assembly (16). 22. Place the end cover (7) on the gearbox housing (23). 20. Insert the 1st stage sun gear (10). 23. Tighten the 10 socket head screws M10x25 (1),grade 12,9, by a torque wrench at 62.7 ft.lbs.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 25. Assemble the O-ring seal (2) into its seat in the end 28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. cover (7). (25 Nm). 29. Insert the 1st washer (12) in the splined shaft (14). 26.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 31. Insert the splined shaft (14) in the equipment 34. By using pliers, assemble the elastic ring (11) into its seat (6689960240). in the splined shaft (14). 32. Insert the 2nd washer (12) correctly in the splined shaft (14).
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE 36. By using pliers assemble the circlip (36) into its seat in 39. Then insert an internally toothed steel disc (32). Repeat the brake shaft (35). the operation until all 5 sintered bronze discs and 4 steel discs have been assembled.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 42. Insert the spacer (39) inside the flanged hub (31), paying 44. Lube the seal seats into the flanged hub (31) and assem- attention not to damage the seals already fitted. ble the O-ring seal (42) and the backup ring (43). 43.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 45. Insert the brake piston (44) inside the flanged hub (31), 47. Insert the springs (45) into the holes in the brake piston paying attention not to damage the seals already fitted. (44) marked previously. 48.

  • Page 105: Final Test And Reinstallation

    SECTION 3 - CHASSIS & TURNTABLE 49. Install the special tool (6689960310) on the flanged hub Final Test and Reinstallation (31) and turn the screw until it compresses the springs Check the product by remounting it to the machine. (45). Check the function of the drive hub following all the checks shown in Startup and Running In.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Figure 3-30. Drive Hub Special Tools - Sheet 1 of 4 3-56 3121142...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE Figure 3-31. Drive Hub Special Tools - Sheet 2 of 4 3121142 3-57...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Figure 3-32. Drive Hub Special Tools - Sheet 3 of 4 3-58 3121142...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE Figure 3-33. Drive Hub Special Tools - Sheet 4 of 4 3121142 3-59...

  • Page 110: Drive Hub - Reggiana Riduttori (Sn 134389 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.16 DRIVE HUB - REGGIANA RIDUTTORI (SN 134389 8. Wrench for M6, M8, M10 socket head screws and 1/4"G plug. TO PRESENT) 9. Socket wrench for M6 hexagonal screw. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE Ø210 Ø130 Ø30 M- 1321 LOCTITE 2701 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-36. Bearing Spacer Mountng CO16117 Figure 3-37. Assembly Diagram 1 3121142 3-61...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE M- 1316 M- 1020 M- 1317 M- 1317 N° 4 M- 1317 216.5 Ø11 Ø230 10x45° M- 1316 Ø17 M- 1317 M- 1317 Figure 3-40. Anti-rotation Block M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-38.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-42. Assembly Diagram 2 3121142 3-63...
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE M- 1546 M- 1548 Ø105 Ø93.5 Ø48 +0.1 Ø20 Ø46 +0.2 Ø8.5 Ø13.5 Ø40.5 Ø46 M- 1547 Ø39.5 Ø20 -0.1 VTCEI M8X16 n°1 Figure 3-43. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 3-64 3121142...

  • Page 115: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly 3. Release the screws from the release cover and pull the pin out. 1. Remove the plugs and pour the lubricant in a container. 4. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE 3-66 3121142...
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 3121142 3-67...
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE 6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also the planetary ring without damaging the O-Ring. remove the 3/16" balls. 7. Remove the release joint together with the spring. 10.

  • Page 119: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 12. Disassemble the Ø160 inner snap ring and pull the Assembly spring holder spacer out. Remove the springs and using a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are piston out of the spindle.
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE 4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner the brake discs making sure to centre them on the spin- track.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE 9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on lowing order: the spindle thread by the M6 holes of the ring nut. 10.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE 13. Fit the bearings onto the 3rd stage planetary gears and 15. Place the hub onto the support making the two holes using a spacer mounting mount everything on the spin- coincide for tightening the M10x25 flathead socket dle pins.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor ably greased and lock it with the shimming ring. Lubri- coupling flange S-D LC/KC. Mount the flange on the cate the bearings.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-46. Swing System (SN 0300201016 through 0300254466, SN B300002238 to Present) 3-74 3121142...
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE MAE36280 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-47. Swing System (SN 0300254467 to Present) 3121142 3-75...

  • Page 126: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING DRIVE 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 127: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36) and remove fittings from Brake (26) and Motor Control 1. Place unit on bench with the motor end up. Valve (32).

  • Page 128: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor (10). 1. With unit resting on bench with Motor (10) end up, 4. Remove Brake (26) from Main Torque-Hub Assembly loosen Hex Bolts (29) and remove Lift Lugs (28) from the and dump oil out of Brake (26).

  • Page 129: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15) from between Input Cover (6) and Carrier (3A) Subas- 1. With the unit resting on the Output Shaft (Pinion) (1A), sembly. remove the eight Bolts (17), four Shoulder Bolts (18) and 7.

  • Page 130: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G). 5. Invert the Housing (1G) and remove the Lip Seal (1B) if 1. Using retaining ring pliers, remove Retaining Ring (1I) not already removed when Output Shaft (1A) was from groove in Output Shaft (1A) and discard.

  • Page 131: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust Washers (3H) and the two Thrust Washers (3B) out of the 1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).

  • Page 132: Hub-Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly Carrier Sub-Assembly NOTE: Refer to Figure 3-51., Swing Drive - Hub Shaft Disassembly NOTE: Refer to Figure 3-52., Swing Drive - Carrier Disassembly (SN (SN 0300201016 through 0300254466, SN B300002238 to 0300201016 through 0300254466, SN B300002238 to Pres- Present).

  • Page 133: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh with the Internal Gear (2) and Input Gear (13). On the NOTE: Refer to Figure 3-50., Swing Drive - Main Disassembly (SN Ring Gear (4) locate the hole marked "X", or punch 0300201016 through 0300254466, SN B300002238 to Pres-...

  • Page 134: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-49., Swing Drive - Motor and Brake Disas- NOTE: Refer to Figure 3-48., Swing Drive - Motor Control Valve Dis- sembly (SN 0300201016 through 0300254466, SN assembly (SN 0300201016 through 0300254466, SN B300002238 to Present).
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE 1001228488-B MAE37600B Figure 3-53. Swing Motor (SN 0300254467 to Present)- Sheet 1 of 2 3-86 3121142...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring 2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover 3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw 4. Bearing 14.

  • Page 137: Swing Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING BRAKE HYDRAULIC/MECHANICAL To check brake release, connect an appropriate hydraulic pres- Pre-Installation Checks sure supply set to the required level up to a maximum of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. MECHANICAL Check, That in the handling prior to assembly, the mounting Remove hydraulic supply from brake, checking to ensure that...

  • Page 138: Installation

    SECTION 3 - CHASSIS & TURNTABLE Installation 5. Remove 2-off dowel pins (19). Position 1-off gasket (5) over male pilot on brake housing (4). 6. Remove springs (8). Take note of quantity and orienta- Locate brake shaft (1) and secure brake in position using 2-off tion of springs.
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 2. Apply ring of Loctite 641 or equivalent adhesive to full 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or circumference of housing (2) bearing recess adjacent to equivalent) silicone grease and assemble together with shoulder.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 8. Cylinder 15. O-Ring 2. Housing 9. Piston 16. Backing Ring 3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring 4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring 5.

  • Page 141: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.19 SWING MOTOR Disassembly and inspection 1. Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing 2. End Cover 8C. Vane 16. Seal 3. Seal Ring-Commutator 8D. Stator Half 17. Backup Washer 4. Seal Ring 9. Wear Plate 18. Housing 5.
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into ing the internal orifice plug, are free of contamination.
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disas- sembly for service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur- link for cracks and worn or damaged splines.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is ment of retained rollers.
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE 21. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of the two thrust washers (14) and thrust bearing (15).

  • Page 148: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15) the coupling shaft bore down, clamping against the that was removed from the Torqlink™. mounting flange.
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID.
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the original rotor-drive link spline contact.
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 19. If shuttle valve components items #21, were removed 17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one onto the manifold.
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight.

  • Page 155: One Piece Stator Construction

    6. Remove the two assembled bolts (1) if used to retain sta- tor and wear plate. 7. Tighten the jam nut (shown below) with JLG Thread- locker PN 0100019. 3-106 3121142...

  • Page 156: Procedure For Setting Gear Backlash

    1. Set backlash to 0.010" to 0.015" using the following pro- cedure. 2. Place shim (JLG PN 4071041) between pinion and bear- ing on the bearing high spot. The bearing high spot should be stamped with an "X" on the surface below the teeth and marked with yellow paint in the tooth space.

  • Page 157: Swing Drive Lubrication

    SECTION 3 - CHASSIS & TURNTABLE 7. Torque the setscrew to 50 foot-pounds (68 Nm). MAE37630 Gearbox Fill Port Gearbox Drain Port 8. Torque the capscrews shown in step 5 to 660 foot- Figure 3-61. Swing Drive Ports (SN0300254467 to Present) pounds (896 Nm).

  • Page 158: Swing Bearing

    NOTE: This check is designed to replace the existing bearing bolt the 0.0015” feeler gauge between the bolt head and torque checks on JLG Lifts in service. This check must be hardened washer at the arrow indicated position. performed after the first 50 hours of machine operation c.
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE BO O M F U LL Y E LE V A T E D D IA L IN D IC A T O R F E E LE R G A U G E M E A S U R IN G P O IN T M E A S U R IN G P O IN T Figure 3-63.
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE 3121142 3-111...

  • Page 161: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE 3. If the measurement is greater than 0.094 in. (2.387 mm), the swing bearing should be replaced. 4. If the measurement is less than 0.094 in. (2.387 mm), and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the fol- lowing: a.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE 3121142 3-113...

  • Page 163: Swing Bearing Installation

    (marked with yellow paint) is towards the centerline of the swing drive (as close as the bolt pattern will allow). JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS- CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER- ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.

  • Page 164: Swing Bearing Torque Values

    Safety Solvent 13 on the new bearing bolts. Then 10. Install the rotary coupling retaining yoke brackets, apply apply a light coating of JLG Threadlocker PN 0100019 to a light coating of JLG Threadlocker 0100011 to the the new bearing bolts, and install the bolts and washers attaching bolts and secure the yoke to the turntable through the frame and outer race of the bearing.

  • Page 165: Swing Speed Proportioning

    NOTE: For more detailed information concerning system adjust- NOTE: For more detailed information concerning system adjust- ment and operation, refer to Section 6 - JLG Control Sys- ment and operation, refer to Section 6 - JLG Control Sys- tem.

  • Page 166: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.25 ROTARY COUPLING 6. Reassemble O-ring (4). 7. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F Use the following procedure to for installing the seal kit. (149° C). 1. Remove snap ring (7) from end. 8.
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE Center Body Seal Seal Thrust Ring Housing Snap Ring O-ring Figure 3-69. Rotary Coupling Cutaway 3-118 3121142...
  • Page 168 SECTION 3 - CHASSIS & TURNTABLE JLG Threadlocker PN 0100011 5B. Rotary Circuit Contactor Bolt Locknut Bolt Not Used Swivel Bracket Flatwasher Rotary Coupling & Collector Ring Assembly 5A. Rotary Coupling Figure 3-70. Rotary Coupling Installation 3121142 3-119...
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE Figure 3-71. Rotary Coupling Port Location 3-120 3121142...

  • Page 170: Generator

    SECTION 3 - CHASSIS & TURNTABLE Every 500 hours Table 3-7. Coupling Port Information Table Every 500 hours of operation, service the generator brushes and slip rings. Hostile environments may require more fre- Operating Proof Port Port quent service. Description Pressure Pressure Outlets...

  • Page 171: Overload Protection

    SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings Refer to Figure 3-72., Inspecting Generator Brushes, Replacing STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings. BREAKER. INSPECTING BRUSH POSITION The circuit breaker protects the generator windings from over- Inspect brush alignment with slip rings.
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-72. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3121142 3-123...

  • Page 173: Auxiliary Power System

    SECTION 3 - CHASSIS & TURNTABLE 3.27 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres- sure to the lift cylinder allowing gravity to lower the boom. The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to of moving the boom in the event of primary power loss.
  • Page 174 SECTION 3 - CHASSIS & TURNTABLE H Y D R A U LIC O IL T A N K H E A T E R C A BLE BA TT E R Y H E A T E R C A B LE BA TT E R Y H E A T E R C A B LE B A T T E R Y R E F A U X P U M P...

  • Page 175: Cold Weather Package

    140° F (60° C). This determination will occur one second after the Power/Emergency Stop switch has been pulled on. The lamp and glow plugs will remain ener- gized for the period of time specified by the setting in the JLG MINIMUM LEVEL, OIL HOT Control System.

  • Page 176: Changing The Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE 5. Open the oil drain valve. Changing the Oil Filter WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING. 1. Wipe the area around the filter to clean any dirt from the area.

  • Page 177: Replacing The Fuel Filter

    SECTION 3 - CHASSIS & TURNTABLE 6. Manually screw in the new filter until the gasket is flush. 8. Open the fuel shut-off valve. 9. Check for leaks. Cleaning the Fuel Strainer 7. Tighten the filter another half-turn. 8. Check the oil level. 9.
  • Page 178 The lamp and glow plugs will remain ene- COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING. gized for the period of time specified by the setting in the JLG DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU- Control System.
  • Page 179 SECTION 3 - CHASSIS & TURNTABLE Replacing the Oil Filter Replacing the Primary Fuel Filters Figure 3-80. Location of the Primary Fuel Filter Figure 3-79. Location of the oil filter 1. Wipe area around filter to clean any dirt from area. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY.
  • Page 180 SECTION 3 - CHASSIS & TURNTABLE 8. Check for leaks. Replacing the Fuel Pre-Filter 1. Fuel Supply Flow to the Pump 4. Drain Plug 2. Venting Screw 5. Filter Element 3. Electrical Connection for Water 6. Fuel Inlet from the Fuel Tank Level Sensor Figure 3-82.
  • Page 181 When Water in Fuel condition occurs, the machine will respond in the following way: • The engine will shut down automatically. • The JLG Control System will set DTC 4375 - Water in Fuel. • An alarm will sound from the active control station (ground or platform).
  • Page 182 SECTION 3 - CHASSIS & TURNTABLE ELEMENT REPLACEMENT DRAINING WATER Frequency of element replacement is determined by the con- Frequency of water draining is determined by the contamina- tamination level of the fuel. Replace the elements every 500 tion level of the fuel. Inspect or drain the collection bowl of hours, if power loss is noticed or annually, which ever comes water daily or as necessary.
  • Page 183 SECTION 3 - CHASSIS & TURNTABLE 3.31 DEUTZ TD2011 ENGINE 1001116015-D MAE35960D 1. Fan 6. Oil Cooler 11. Oil Drain 16. Muffler Bracket 2. Rod 7. Muffler 12. Lanyard 17. Motor Mount 3. Exhaust 8. Air Cleaner Assembly 13. Front Engine Mounting Plate 18.
  • Page 184 SECTION 3 - CHASSIS & TURNTABLE 3.32 DEUTZ 2.9 L4 (GUO III) ENGINE 1001221259-C MAE35970C 1. Surge Tank 5. Muffler 2. Radiator 6. Exhaust Tail Pipe 3. Fan 7. Engine Mount 4. Alternator 8. Fuel Filter Figure 3-85. Detuz 2.9 L4 (GUO III) Engine Installation - Sheet 1 of 2 3-136 3121142...

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