Oshkosh Corporation JLG E400Anarrow Service And Maintenance Manual
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Oshkosh Corporation JLG E400Anarrow Service And Maintenance Manual

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Service and Maintenance Manual
Model
E400A/AJP
E400A/AJPnarrow
M400A/AJP
M400A/AJPnarrow
P/N - 3121827
March 20, 2014

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  • Page 1 Service and Maintenance Manual Model E400A/AJP E400A/AJPnarrow M400A/AJP M400A/AJPnarrow P/N - 3121827 March 20, 2014...

  • Page 3: Bhydraulic System Safety

    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 per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON- NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISON LOG Original Issue - August 15, 2000 Revised - October 1, 2001 Revised - December 18, 2001 Revised - April 11, 2002 Revised - May 24, 2004 Revised - September 17, 2007 Revised - January 21, 2008 Revised - January 27, 2009 Revised - January 7, 2013...

  • 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 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Cylinder Drift Test ............. .2-4 Platform Drift .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Swing Bearing ..............3-39 Turntable Bearing Mounting Bolt Condition Check .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Engine Oil Temperature Sensor ..........3-65 Alternator Output Current Sensor .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.12 Helac Rotary actuator ............4-12 Theory Of Operation .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ........6-1 Introduction .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Locations............1-6 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-9. Platform Support Torque Values...........4-10 4-10.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-10. Connector Disassembly ............7-25 7-11.
  • Page 14 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ............1-1 Capacities .

  • Page 15: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS OPERATING SPECIFICATIONS HYDRAULIC PUMP/ELECTRIC MOTOR ASSEMBLY Table 1-1. Operating Specifications Table 1-5. Hydraulic Pump/Electric Motor Assembly Maximum Work Load (Capacity) Motor 48 VDC, 2.14 H.P . @ 2700 rpm. Unrestricted: 500 lb. (230 kg) Pump 0.098 in.[3]/rev.

  • Page 16: Dimensional Data

    SECTION 1 - SPECIFICATIONS DIMENSIONAL DATA FUNCTION SPEEDS Table 1-9. Function Speeds Table 1-8. Dimensional Data Function Seconds Machine Height (stowed) Main Lift Up 30-24 E/M400AJP 6 ft. 7 in. (2.0 m) Main Lift Down 29-23 E/M400AJPnarrow 6 ft. 5.75 in. (1.31m) E/M 400A 6 ft.

  • Page 17: Machine Orientation When Doing Function Tests

    SECTION 1 - SPECIFICATIONS Machine Orientation When Doing Function 8. LOWER LIFT: Upper boom horizontal, telescoped in. Lower lift up, Tests record time. Lower lift down, record time. 1. LIFT: 9. JIB SWING: Boom retracted, telescope retracted. Lift up, record Platform level and centered with the boom.

  • Page 18: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS 1.11 CYLINDER SPECIFICATIONS 1.12 MAJOR COMPONENT WEIGHTS Table 1-12.Major Component Weights NOTE: All dimensions are given in inches (in.), with the met- ric equivalent, millimeters (mm), given in parenthe- Component ses. Platform and Support 97.5 Table 1-11. Cylinder Specifications Upper Boom Complete Mid Boom Complete Cylinder...

  • Page 19: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS 1.13 CRITICAL STABILITY WEIGHTS Table 1-15. Pressure Settings - S/N 0300062642 Present Table 1-13. Critical Stability Weights Circuit Component Main Control Valve 1746 3850 Counterweight Lift Down Relief Tire & Wheel (foam-filled) Tower Lift Down Relief (E/M400A) 1700 Prior to S/N 86022 Platform (4ft [1.2 m])

  • Page 20: Serial Number Locations

    SECTION 1 - SPECIFICATIONS 1.15 SERIAL NUMBER LOCATIONS Lubrication Specifications For machine identification, a serial number plate is affixed NOTE: Refer to Lubrication Chart, Figure1-2, for specific to the left rear of frame, in front of left rear wheel. If the lubrication procedures.
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance & Lubrication Diagram 3121827 – JLG Lift –...

  • Page 22: Operator Maintenance & Lubrication

    SECTION 1 - SPECIFICATIONS 1.17 OPERATOR MAINTENANCE & 2. Swing Bearing/Worm Gear Teeth LUBRICATION NOTE: The following numbers correspond to those in Fig- ure 1-2., Operator Maintenance & Lubrication Dia- gram. Table 1-19. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F.
  • Page 23 SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 6. Wheel Bearings Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 7.
  • Page 24 SECTION 1 - SPECIFICATIONS 9. Engine Lube Point(s) - Fill Cap Capacity - Refer to Engine Manual Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 1-10 –...
  • Page 25 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque Torque (Loctite® 242 or 271 Tensile (Loctite® 262 or Vibra- Size Bolt Dia Clamp Load Stress Area (Dry) Lubricated OR Vibra-TITE...
  • Page 26 SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque Tensile (Loctite® 242 or 271 (Loctite® 262 or Vibra- (Dry or Loctite® 263) Size Bolt Dia Clamp Load Stress Area OR Vibra-TITE 111 or TITE 131) K= 0.20...
  • Page 27 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load Torque Size Bolt Dia OR Vibra-TITE 111 or (Dry) K = .17 or Vibra-TITE 131) Stress Area See Note 4 140 OR Precoat 85®...
  • Page 28 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Torque Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load (Dry) Size Bolt Dia OR Vibra-TITE 111 or or Vibra-TITE 131) Stress Area See Note 4 K = .20 140 OR Precoat 85®...
  • Page 29 SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® Torque Tensile Clamp Torque (Loctite® 262 or 271 (Dry or Loctite® Size PITCH Stress Load (Lub) OR Vibra- OR Vibra- Area TITE 131) TITE 111 or 140) Sq mm [N.m]...
  • Page 30 SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque (Lub OR Loctite® Torque Torque Tensile (Dry or Loctite® Clamp or 271 (Loctite® 262 Size PITCH Stress Load Vibra-TITE 111 or Vibra-TITE...
  • Page 31 SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque (Lub OR Loctite® Torque Tensile (Loctite® 262 (Dry or Loctite® Clamp Load or 271 Size PITCH Stress OR Vibra-TITE See Note 4 OR Vibra-TITE Area 131)
  • Page 32 SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121827...

  • Page 33: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventive Maintenance AND MAINTENANCE Schedule for items requiring inspection during the perfor- mance of these inspections. Reference the appropriate General areas of this manual for servicing and maintenance proce- dures.

  • Page 34: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual At each Operator change. Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance...

  • Page 35: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, com- Clearly mark or tag hydraulic lines and electrical wiring, as plete the procedural steps in sequence. Do not partially well as their receptacles, when disconnecting or removing disassemble or assemble one part, then start on another.

  • Page 36: Hydraulic Oil

    SECTION 2 - GENERAL Lubrication Specifications fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of Specified lubricants, as recommended by the component metal particles. manufacturers, are always the best choice, however, 3. Cloudy oils indicate a high moisture content which multi-purpose greases usually have the qualities which permits organic growth, resulting in oxidation or cor- meet a variety of single purpose grease requirements.

  • Page 37: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING WELDING ON JLG EQUIPMENT REPAIR GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the Filament wound bearings. machine on an external structure, or component, 1.
  • Page 38 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Boom Assembly 1,2,4 1,2,4 Boom Weldments 1,2,9,12 1,2,9,12 Hose/Cable Carrier Installations Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings...
  • Page 39 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 40 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions...

  • Page 41: Engine Operating Temperature Specifications - Kubota

    SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE F(43 C) F(38 C) F(32 C) F(27 C) F(21 C) ENGINE F(16 C) SPECIFICATIONS F(10 C) F(4 C) F(-1 C) F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS F(-12 C) TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
  • Page 42 SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121827...

  • Page 43: Section 3 - Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replace- Tire Inflation ment tire, ensure that all tires are inflated to the pressure The air pressure for pneumatic tires must be equal to...

  • Page 44: Spindle

    SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence: 5. Check the unit for end play by moving the hub up & down parallel along the centerline of the spindle. If you can feel excessive end play (over the 0.010" [0.25 mm] specification), recheck the nut to see what is causing the excessive end play.
  • Page 45 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle Figure 3-3. Spindle Assembly 3121827 – JLG Lift –...

  • Page 46: Drive Hub (Part No. 2780236)

    SECTION 3 - CHASSIS & TURNTABLE DRIVE HUB (PART NO. 2780236) 15. Inspect the planetary stage assemblies as complete units. Thoroughly clean and check both the gearing The final drive consists of two planetary stages with an and the bearings for damage and apply new oil. If integrated disconnect mechanism.

  • Page 47: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly Assembly of first stage planetary assembly 1. Loosen and remove hex head bolts (53) to remove cover (51). 1. Pre-freeze planet pins (5) and install into planet car- rier (7). 2. Remove shaft rod (56) and “o” ring (54). 2.

  • Page 48: Final Assembly

    SECTION 3 - CHASSIS & TURNTABLE Final Assembly Maintenance Daily: - Check for oil leakage 1. Install thrust washer (29) in spindle (60). Weekly: - Check oil level 2. Install “o” ring (19) into groove of support ring (6). Monthly: - Check mounting bolt torque 3.
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE 1. Planet Gear 15. Retaining Ring 31. thru 32. (Not Used) 56. Shaft Rod 2. Planet Gear 16. Retaining Ring 33. O Ring 57. thru 58. (Not Used) 3. Sun Gear 17. Support Disc 34.

  • Page 50: Drive Brake - Mico

    SECTION 3 - CHASSIS & TURNTABLE DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover (21). Disassembly NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. This 1.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE NOTE: The speed sensor port in the cover (21) should be 180° from the brake release port in the pressure plate (3). 1. Capscrew 7. Piston 13. Rotor Disc 19. Retaining Ring 2. Washer 8.
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive Brake Diagnosis Corrective Problem Cause Explanation Action Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions system brake, holding torque will be reduced. in other hydraulic components.

  • Page 53: Speed Sensor Adjustment

    SECTION 3 - CHASSIS & TURNTABLE SPEED SENSOR ADJUSTMENT Adjustment Procedure 1. Back off the locking nut and o-ring. 2. Thread the sensor in until it bottoms out (don’t use excessive force). 3. Back-off 1-2 turns and align the notch with the axis of the brake.

  • Page 54: Speed Sensor Orientation

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-3. Speed Sensor Orientation 3-12 – JLG Lift – 3121827...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE 3121827 – JLG Lift – 3-13...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 3-14 – JLG Lift – 3121827...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 3121827 – JLG Lift – 3-15...

  • Page 58: Speed Sensor Installation Verification

    SECTION 3 - CHASSIS & TURNTABLE Speed Sensor Installation Verification 3. Power up the machine in platform mode and plug in the Analyzer in the platform. The motor controller averages the readings from the right 4. Use the right and left cursor keys on the analyzer to and left speed sensors and therefor, it can be difficult to highlight “DIAGNOSTICS”...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 18. While watching the analyzer display, select drive for- 22. After obtaining the display in step 10, operate the ward. Be ready to remove your foot from the foot machine in both the forward and reverse directions. switch if the machine lunges forward.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 3-18 – JLG Lift – 3121827...

  • Page 61: Positrac/Tilt Module

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Drive Components POSITRAC/TILT MODULE 5. Use the right arrow key to curse over to “LEVEL VEHICLE”. Depress Enter. Depress Enter again. When installing a new positrac/tilt module, always ensure 6. Verify that the tilt reading is now “0.0; 0.0". that it is calibrated using the JLG Control System analyzer before operating the machine.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE Figure 3-9. Tilt Sensor Location 3-20 – JLG Lift – 3121827...

  • Page 63: Swing Motor - S/N 0300135649 To Present

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING MOTOR - S/N 0300135649 TO PRESENT Figure 3-10. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

  • Page 65: Swing Motor - Exploded View

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

  • Page 66: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its 1. Place the motor in a soft jawed vice, with coupling components read this entire section. It provides impor- shaft (12) pointed down and the vise jaws clamping tant information on parts and procedures you will need firmly on the sides of the housing (18) mounting...
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove 8. Remove manifold (7) and inspect for cracks surface seal ring from commutator, using an air hose to blow scoring, brinelling or spalling. Replace manifold if air into ring groove until seal ring is lifted out and dis- any of these conditions exist.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 9. Remove rotor set (8) and wearplate (9), together to 10. Place rotor set (8) and wear plate (9) on a flat sur- retain the rotor set in its assembled form, maintain- face and center rotor in stator such that two rotor ing the same rotor vane to stator contact surfaces.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 12. Check exposed portion of coupling shaft (12) to be keyway. Replace coupling shaft if any of these con- sure you have removed all signs of rust and corro- ditions exist. sion which might prevent its withdrawal through the seal and bearing.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 15. Remove thrust bearing (15) and thrust washer (14). 18. Inspect housing (18) assembly for cracks, the Inspect for wear, brinelling, corrosion and a full com- machined surfaces for nicks, burrs, brinelling or cor- plement of retained rollers.

  • Page 72: Assembly

    SECTION 3 - CHASSIS & TURNTABLE replaced. If the housing has passed this inspection 20. If the bearings, bushing or thrust washers must be the disassembly of the motor is completed. replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from hous- ing (18) without damaging the housing.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE (19) THE BEARING/BUSHING DEPTHS SPECIFIED MUST BE COULD CAUSE INJURY OR DEATH.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing 6. Assemble thrust washer (14) then thrust bearing (15) (18) outer bearing counterbore. The dirt and water that was removed from the motor. seal (20) must be pressed in until its’...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion 9. Apply a small amount of clean grease to a new seal resistant grease has been applied to the lower ring (4) and insert it into the housing (18) seal ring (outer) housing bearing/bushing (19).
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: It may be necessary to turn one alignment stud out alignment studs onto the housing (18). of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs 18. Assemble a new seal ring (3) flat side up, into com- and drive link (10) and onto the rotor set. Be sure the mutator (5) and assemble commutator over the end correct manifold surface is against the rotor set.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 25-30 ft.

  • Page 79: One Piece Stator Construction

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

  • Page 80: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction 8. Assemble six vanes, or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor set (8) that cannot be readily assem- 9. Grasp the output end of coupling shaft (12) bled by hand and has a two piece stator can be assem- with locking pliers or other appropriate turning bled by the following procedures.

  • Page 81: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE SWING BEARING 2. Check the turntable to bearing attach bolts as fol- lows: Turntable Bearing Mounting Bolt Condition a. Elevate the fully retracted boom to 70 degrees Check (full elevation). b. At the positions indicated on Figure 3-13. try and NOTE: This check is designed to replace the existing bear- insert the 0.0015"...

  • Page 82: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance fully extended and Mid/Lower Boom stowed, (See Figure 3-13.), using a magnetic base dial indicator, 1. With the boom positioned over the side of the measure and record the distance between the swing machine, the Upper Boom horizontal with telescope bearing and turntable.

  • Page 83: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE f. Carefully place the turntable on a suitably sup- ported trestle. g. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installa- tion.

  • Page 84: Swing Bearing Torquing Sequence

    SECTION 3 - CHASSIS & TURNTABLE g. Following the torque sequence diagram shown in Figure 3-15., tighten the bolts to an initial IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT torque of 130 ft. lbs. (175 Nm). Then following WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT the same sequence, tighten to a final torque of BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD 190 ft.

  • Page 85: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Adjusting End Play Install bolts with Loctite - 190 ft. lbs. (260 Nm). 1. Remove end plate. Checking Worm Gear End Play 2. Measure and record total thickness of existing shim pack.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Figure 3-16. Swing Components 3-44 – JLG Lift – 3121827...

  • Page 87: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE BATTERY MAINTENANCE AND Charging Sequence of Remote LED Card CHARGING 1. Plug in charger. Battery Maintenance, Quarterly 2. All three LED’s (light emitting diode) flash three times. 1. Open battery compartment cover to allow access to 3.

  • Page 88: Battery Cable Connections

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Battery Cable Connections 3-46 – JLG Lift – 3121827...

  • Page 89: Battery Charging (On Board Charger)

    SECTION 3 - CHASSIS & TURNTABLE Battery Charging (On Board Charger) WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE 1. For maximum battery life: PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE a. Avoid completely discharging the batteries. GROUND EMERGENCY STOP SWITCH IS ON (PULLED OUT), THE b.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 3-48 – JLG Lift – 3121827...

  • Page 91: Battery Charger (S/N 0300059350 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY CHARGER (S/N 0300059350 4. If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. TO PRESENT) Maintenance Instructions 1. For flooded lead-acid batteries, regularly check LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN water levels of each battery cell after charging and GAS DURING NORMAL OPERATION.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 3. DC Power Cable to Batteries 2. Charger Interlock Cable 4. LED Indicator Cable Figure 3-21. Battery Charger ((S/N 0300059350 to Present) 3-50 – JLG Lift – 3121827...
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is Indicates the battery failed to charge within the allowed not connected or that the AC voltage is too low. It could time.

  • Page 94: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    SECTION 3 - CHASSIS & TURNTABLE Excessive Battery Watering Requirements or [5 Flashes] - Over Temperature Strong Sulphur (Rotten Egg) Smell This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge These symptoms indicate over-charging or high battery time will be extended significantly.

  • Page 95: Checking/Changing The Battery Charger Algorithm

    SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger 3. Remove the AC power from the charger and recon- nect the charger’s positive connector to the battery. Algorithm It is recommended to check a newly changed algo- rithm by repeating the above steps 1 and 3. The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Table 3-4.

  • Page 96: Generator (Prior To S/N 88539)

    SECTION 3 - CHASSIS & TURNTABLE 3.12 GENERATOR (PRIOR TO S/N 88539) The start control relay is located on the fuel solenoid bracket on the right side of the engine. The start control relay is energized by the engine/generator controller. NOTE: Throughout the Generator section, the abbreviations RBS and CTS are used.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Generator Components 3121827 – JLG Lift – 3-55...
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 2. Time Delay Pre-Heat (TDPH) 6. Time Delay Bypass (TDBP) TDPH, if enabled, occurs after TDES has elapsed Once the engine starts, TDBP must elapse before and the engine temperature is below the factory set low oil pressure and underspeed shutdowns are engine preheat temperature setting.

  • Page 99: To Connect The Jlg Control System Analyzer To The Generator

    SECTION 3 - CHASSIS & TURNTABLE To Connect the JLG Control System Analyzer Alarms and Fault Flash Codes to the Generator In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. The JLG Control System Analyzer can be used to monitor generator settings and conditions.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 3-58 – JLG Lift – 3121827...

  • Page 101: Output Current And Voltage Settings

    SECTION 3 - CHASSIS & TURNTABLE • Over Speed • Loss Of Voltage Sense If the engine speed exceeds the overspeed limit, the If the voltage measured at the alternator output is less engine will stop immediately and an overspeed alarm will than half of the system nominal voltage, the RBS will stop be indicated.

  • Page 102: Priming The Fuel Line

    SECTION 3 - CHASSIS & TURNTABLE Priming the Fuel Line 5. Clean up any spilled fuel and try to start the genera- tor engine. The following procedure is for re-priming the fuel line on 6. If the engine still doesn’t start, remove the steel line the generator engine in the event fuel system components from the fuel injector pump.

  • Page 103: Generator (S/N 88539 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.13 GENERATOR (S/N 88539 TO PRESENT) Dynamo and Dynamo Voltage Regulator NOTE: Throughout the Generator section, the abbreviation RBS is used. RBS stands for Rotary Battery System, which is the generator system. The engine-driven generator is designed to produce a DC output directly without the need of a separate rectifier.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 1. Glow Plug Relay 8. Temperature Sensor 2. Fuel Control Relay 9. Voltage Regulator 3. Start Control Relay 10. Alternator 4. Fuel Solenoid 11. Starter 5. Fuel Pump 12. Starter Solenoid 6. Low Oil Pressure Switch 13.

  • Page 105: Start Battery

    SECTION 3 - CHASSIS & TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead-acid start battery (not sup- plied with the system), which provides starting power and power for the RBS controls. This battery is charged by the engine dynamo and dynamo regulator when the engine is running.

  • Page 106: Fuel Control Relay

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

  • Page 107: Fuel Pump

    SECTION 3 - CHASSIS & TURNTABLE Fuel Pump Engine Low Oil Pressure Switch The fuel pump runs in parallel with the fuel solenoid hold coil which is run by the fuel control relay. The pump runs whenever the engine runs, and keeps the fuel filter filled.

  • Page 108: Alternator Output Current Sensor

    SECTION 3 - CHASSIS & TURNTABLE RBS Engine/Generator Controller engine. The signal is also used in determining if the air glow plug should be energized. The control system enclosure houses the RBS engine/ The engine oil temperature sensor is connected to the generator controller, which performs all control tasks engine/generator controller at pins J2-8 and J2-19.

  • Page 109: Warnings And Safety Precautions

    SECTION 3 - CHASSIS & TURNTABLE Warnings and Safety Precautions System Settings CALL TO START SETTINGS Low battery voltage call to start level 48.0 VDC THE RBS MAY START WITHOUT WARNING. Low battery voltage remove call to start level 54.0 VDC Low temperature call to start level 5°C Low temperature remove call to start level...

  • Page 110: Rbs Start

    SECTION 3 - CHASSIS & TURNTABLE RBS Start RBS shutdown Call to start Manual 48V DC applied to the input Call to start removed Manually Inhibit run input applied Automatic 1 Low battery voltage (below Automati- 1 Battery voltage above 48VDC) cally: 54VDC and finish charging cur-...

  • Page 111: Rbs Alarms And Flash Codes

    SECTION 3 - CHASSIS & TURNTABLE RBS Alarms and Flash Codes In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. Table 3-10. RBS Alarms and Flash Codes Flash Code Problem RBS Condition Below 7psi...

  • Page 112: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-11. Troubleshooting Flash Code Problem Solution Unit Off / Disabled (engine will not Check position of selector switch. crank) Verify that the inhibit run is released. Check the warning LED. Remedy fault if present and restart the RBS. Check the start battery voltage.

  • Page 113: Apu Engine Start Battery Boosting

    SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Troubleshooting Flash Code Problem Solution Engine Starting System fault Check engine start battery charging system for current output. Check for failed engine start battery. Loss Of Voltage Sense APU Engine Start Battery Boosting Always connect the POSITIVE (+) of the booster battery DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID to the POSITIVE (+) of the APU start battery, and the...

  • Page 114: Supplementary Fuse For Apu

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SUPPLEMENTARY FUSE FOR APU 2. Find where the harness attaches to the rear cover of the generator and the connection point for the new The purpose of this section is to describe the procedure to inline fuse.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE conductors of the harness. 6. Re-install the harness with the new fuse in place. 7. Reconnect the lift and APU start battery. The APU is now ready for use. 5. Cut wire 106 going to the Engine/Generator Control- ler after the existing connection point and install the conductors that lead to the new inline fuse holder.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-74 – JLG Lift – 3121827...

  • Page 117: Section 4 - Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE e. Remove hardware securing the master cylinder pin #2. Using a suitable brass drift and hammer, remove pin #2 from the base boom. Removal f. Remove hardware securing the base boom pin #3.

  • Page 118: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 4. Remove hardware securing telescope cylinder #1 to the fly boom section, then remove pin from fly. 1. Inspect boom pivot pin for wear, scoring or other 5. Remove hardware securing telescope cylinder to damage, and for tapering or ovality.

  • Page 119: Installation

    SECTION 4 - BOOM & PLATFORM Installation 6. Using suitable lifting equipment, slide fly boom sec- tion out to gain access to telescope cylinder attach pin hole. 1. Using suitable lifting equipment, position boom assembly on upright so that boom pivot holes in 7.

  • Page 120: Upper (Main) Boom Lift Cylinder

    SECTION 4 - BOOM & PLATFORM 4.2 UPPER (MAIN) BOOM LIFT CYLINDER 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. Removal 4. With function speed switch at its slowest setting, extend the cylinder rod until attach pin hole aligns 1.

  • Page 121: Installation

    SECTION 4 - BOOM & PLATFORM Installation 3. Remove the hardware securing the cylinder rod attach pin #5 to the boom. Using an appropriate brass drift, drive out the cylinder rod attach pin #5. NOTE: Coat I.D. of bushings with specified lubricant prior to installing pins.

  • Page 122: Upper Boom Telescope Cylinder

    SECTION 4 - BOOM & PLATFORM 4.5 UPPER BOOM TELESCOPE CYLINDER 6. Remove the four (4) bolts securing the telescope cylinder barrel end to the base boom. Removal NOTE: Care should be taken when removing the telescope cylinder, do not leave cylinder rest on power track 1.

  • Page 123: Mid And Lower Lift Cylinder Bleeding Procedure

    SECTION 4 - BOOM & PLATFORM 4.7 WEAR PADS 6. Carefully install the telescope cylinder barrel end to base, securing cylinder to the base boom with four (4) bolts and hardware. 1. Shim up wear pads until snug to adjacent surface. 7.

  • Page 124: Boom Synchronizing Procedure

    SECTION 4 - BOOM & PLATFORM 4.8 BOOM SYNCHRONIZING PROCEDURE Disassembly 1. Remove mounting hardware from articulating jib NOTE: If the Lower Boom assembly does not fully lower: boom pivot pins #3 and #4. Using a suitable brass drift and hammer, remove the pins from articulating 1.
  • Page 125 SECTION 4 - BOOM & PLATFORM Figure 4-8. Jib/Platform Components and Attaching Hardware 3121827 – JLG Lift –...

  • Page 126: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 5. Align articulating jib boom pivot weldment with attach holes in fly boom assembly. Using a soft head mallet, install pivot pin #2 into fly boom assembly NOTE: For location of components See Section 4-7., Loca- and secure with mounting hardware.
  • Page 127 SECTION 4 - BOOM & PLATFORM Figure 4-10. Boom Limit Switches 3121827 – JLG Lift – 4-11...

  • Page 128: Helac Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.12 HELAC ROTARY ACTUATOR Theory Of Operation The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is com- posed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular...
  • Page 129 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.
  • Page 130 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.

  • Page 131: Tools Required For Assembly/Disassembly

    SECTION 4 - BOOM & PLATFORM Tools Required for Assembly/Disassembly Disassembly Upon assembly and disassembly of the actuator there are 1. Remove the cap screws (113) over end cap lock basic tools required. The tools and their intended func- pins (109). tions are as follows: 1.
  • Page 132 SECTION 4 - BOOM & PLATFORM 4. Install the end cap (4) removal tools provided with 7. Remove the stop tube if included. The stop tube is the Helac seal kit. an available option to limit the rotation of the actua- tor.
  • Page 133 SECTION 4 - BOOM & PLATFORM 9. Prior to removing the shaft, (2), use a felt marker to 12. To remove the piston (3) use a rubber mallet and a clearly indicate the timing marks between shaft and plastic mandrel so the piston is no damaged. piston.
  • Page 134 SECTION 4 - BOOM & PLATFORM 15. Remove the wear guides (302) from the end cap (4) 18. Remove the wiper seal (304.1) from its groove in the and shaft (2). end cap (4) and shaft (2). 16. To remove the main pressure seals (205), it is easi- 19.

  • Page 135: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection Assembly 1. Clean all parts in a solvent tank and dry with com- 1. Gather all the components and tools into one loca- pressed air prior to inspecting. Carefully inspect all tion prior to re-assembly. Use the cut away drawing critical areas for any surface finish abnormalities: to reference the seal orientations.
  • Page 136 SECTION 4 - BOOM & PLATFORM 4. Using a seal tool install the main pressure seal (205) 7. Beginning with the inner seal (200) insert one end of onto shaft (2) and end cap (4). Use the seal tool in a b/u ring in the lower groove and feed the rest in circular motion.
  • Page 137 SECTION 4 - BOOM & PLATFORM 10. Looking from the opposite end of the housing (1) 13. Install 2 bolts in the threaded holes in the flange. you can see if your timing marks are lining up. When Using a bar, rotate the shaft in a clockwise direction they do, tap the piston (3) in until the gear teeth until the wear guides are seated inside the housing mesh together.
  • Page 138 SECTION 4 - BOOM & PLATFORM 16. Install the O-ring (204) and back-up ring (207) into 19. Place the lock pins (109) provided in the Helac seal the inner seal groove on the end cap (4). kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.

  • Page 139: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Testing the Actuator Refer to Figure 4-13., Rotator Counterbalance Valve. If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the 1. Make sure the surface of the actuator is clean, free pressure at which the shaft begins to rotate —...
  • Page 140 SECTION 4 - BOOM & PLATFORM Figure 4-13. Rotator Counterbalance Valve 4-24 – JLG Lift – 3121827...

  • Page 141: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the After installation of the actuator on the equipment, it is two bleed nipples.

  • Page 142: Troubleshooting

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

  • Page 143: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.13 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the powertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be differ- ent.
  • Page 144 SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together 4. insert the tool into the rolled over end of the rivet as must be removed. Use a right-angle pneumatic die shown. Grind out the middle of the rivet until the grinder with a ¼”...
  • Page 145 SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet 6. Using a flat head screwdriver between the links, out by using a center punch with a hammer. twist the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.

  • Page 146: Installing A New Link

    SECTION 4 - BOOM & PLATFORM Installing a New Link 7. Remove the link from the other section of the pow- ertrack using a screwdriver. 1. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section. 4-30 –...
  • Page 147 SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new 3. After the new link is installed in the powertrack the link and slide the peanut end of the track section round half-shears will not fit properly in the peanut into it.
  • Page 148 SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the 6. Push pin thru center hole then slide washer on pin. new connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs.
  • Page 149 SECTION 4 - BOOM & PLATFORM 7. Install the snap ring in the groove on the pin. Repeat NOTE: When installing snap rings make sure they are the pin installation steps for all center holes that seated in pin groove and closed properly. have the rivets removed.
  • Page 150 SECTION 4 - BOOM & PLATFORM 9. Pull up on the other end of the round bar and slide NOTE: Maximum tightening torque is 18-20 in-lbs. the new poly roller onto the bar. 4-34 – JLG Lift – 3121827...

  • Page 151: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Fixed End Brackets 10. Install a new 8-32 x 0.500 self threading screw on the other side. 1. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
  • Page 152 SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap NOTE: When installing snap rings make sure they are Ring. seated in pin groove and closed properly. CLOSED SNAP RING 3. Take the new bracket and install bracket center pin and snap ring.

  • Page 153: Replacing Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. 1. Remove existing pins and center rivet. Remove the 2. Take new bracket and install center pin with snap rivet the same way as shown in the link removal ring.
  • Page 154 SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and NOTE: When installing snap rings make sure they are install snap rings. Repeat with other moving end if seated in pin groove and closed properly. replacing as well.

  • Page 155: Section 5 - Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com- pletely saturated.

  • Page 156: Dip Method

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

  • Page 157: Cylinders - Theory Of Operation

    SECTION 5 - HYDRAULICS 5.2 CYLINDERS - THEORY OF OPERATION check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made. Double Acting Cylinder (Upper Boom Lift, Mid Boom Lift, Lower Boom Lift, Tele- Cylinders With Single Counterbalance scope, Slave, Master, Rotator, and Steer) Valve...
  • Page 158 SECTION 5 - HYDRAULICS 3*,4*,24 Prior to S/N 0300106518 1683779-E 1. Loctite #242 7. Bearing 13. O-ring Plug 19. Wear Ring 25. Seal 2. Loctite #222 8. Bushing 14. Piston 20. Wear Ring 26. Bolt 3. Primer #7471 9. Cylinder Head 15.
  • Page 159 SECTION 5 - HYDRAULICS 1. Barrel 7. Tube Spacer 13. O-ring 19. Loctite #242 2. Cylinder Rod 8. Holding Valve 14. O-ring 20. Loctite #222 3. Retainer 9. Setscrew 15. Wear Ring 21. Pipe Sealant 4. Piston 10. Pipe Plug 16.
  • Page 160 SECTION 5 - HYDRAULICS 1. Loctite #242 7. Cylinder Rod 13. Wear Ring 19. Backup Ring 2. Primer #7471 8. Barrel 14. Backup Ring 20. Seal 3. Socket Head Bolt 9. Washer Ring 15. O-ring 21. Valve Cartridge 4. Tapered Bushing 10.
  • Page 161 SECTION 5 - HYDRAULICS 1. Barrel 7. Tube Spacer 13. Wear Ring 19. Not Used 2. Cylinder Rod 8. Holding Valve 14. O-ring 20. Loctite #242 3. Retainer 9. Holding Valve 15. Wear Ring 21. Loctite #222 4. Piston 10. Pipe Plug 16.
  • Page 162 SECTION 5 - HYDRAULICS 1. Barrel 6. Hex Nut 11. Plug 16. Not Used 21. Loctite #242 2. Cylinder Rod 7. Washer 12. Setscrew 17. O-ring 22. Loctite #222 3. Retainer 8. Spacer 13. Lock Ring 18. Backup Ring 23. Locking Primer 4.
  • Page 163 SECTION 5 - HYDRAULICS 1. Barrel 6. Hex Nut 11. Setscrew 16. Wear Ring 21. Locking Primer 2. Cylinder Rod 7. Tube Spacer 12. Setscrew 17. O-ring 22. Loctite #222 3. End Cap 8. Not Used 13. Wear Ring 18. Seal 23.
  • Page 164 SECTION 5 - HYDRAULICS 1. Barrel 6. Hex Nut 11. O-ring 16. Locking Primer 2. Cylinder Rod 7. Tube Spacer 12. O-ring 17. Loctite #242 3. Retainer 8. Setscrew 13. Wear Ring 18. Loctite #222 4. Piston 9. T-Seal 14. Rod Seal 5.
  • Page 165 SECTION 5 - HYDRAULICS 1. Loctite #242 6. Piston 11. Not Used 16. O-ring 21. Bolt 2. Locking Primer 7. Washer 12. Lock Ring 17. Wiper 3. Bolt 8. Head 13. Wear Ring 18. Seal 4. Tapered Bushing 9. Barrel 14.
  • Page 166 SECTION 5 - HYDRAULICS 1. Wiper 6. Backup Ring 11. Piston 16. Rod 2. Spanner Nut 7. O-ring 12. Wear Ring 17. Rod 3. Retaining Ring 8. Guide 13. Seal 4. Lip Seal 9. Barrel 14. O-ring 5. Wear Ring 10.
  • Page 167 SECTION 5 - HYDRAULICS 7. Bolt 13. Cap Seal 19. Loctite #242 25. Fitting 1. Barrel 2. Rod 8. Plug 14. O-Ring 20. Not Used 26. Cap 3. Piston 9. Setscrew 15. Wear Ring 21. Fitting 27. Lockwasher 4. Head 10.

  • Page 168: Cylinders With Dual Counterbalance Valve

    SECTION 5 - HYDRAULICS Cylinders With Dual Counterbalance Valve 5.4 CYLINDER REPAIR (Lower Lift, Mid Lift, Telescope, and Slave Cylinders) NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION Disassembly ONLY.

  • Page 169: Cleaning And Inspection

    SECTION 5 - HYDRAULICS 5. Mark cylinder head and barrel with a center punch 9. Using suitable protection, clamp the cylinder rod in for easy realignment. Using an allen wrench, loosen a vise or similar holding fixture as close to the piston the cylinder head retainer cap screws, and remove as possible.

  • Page 170: Assembly

    SECTION 5 - HYDRAULICS 6. Inspect piston surface for damage and scoring and 16. Inspect the oil ports for blockage or the presence of for distortion. Dress piston surface or replace piston dirt or other foreign material. Repair as necessary. as necessary.
  • Page 171 SECTION 5 - HYDRAULICS 2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove. Figure 5-17. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the applica- ble outside diameter groove of the cylinder head.
  • Page 172 SECTION 5 - HYDRAULICS NOTE: When installing the tapered bushing, piston and mat- ing end of rod must be free of oil. WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER, OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY. 11.
  • Page 173 SECTION 5 - HYDRAULICS 19. Continue pushing the rod into the barrel until the cyl- Table 5-2. Cylinder Piston Nut Torque Specifications) inder head gland can be inserted into the barrel cyl- inder. Nut Torque Setscrew Valve (Wet) Description Torque Value 20.

  • Page 174: Pressure Setting Procedures

    SECTION 5 - HYDRAULICS 5.5 PRESSURE SETTING PROCEDURES Platform Level Up Relief Cold temperatures have a significant impact on pressure 1. On machines prior to S/N 0300062642, install the readings.JLG Industries Inc. recommends operating the pressure gauge at the “G” port on Main Control machine until hydraulic system has warmed to normal valve, activate and bottom out Platform Level Up.

  • Page 175: Platform Level Down Relief

    SECTION 5 - HYDRAULICS Platform Level Down Relief Steer Relief 1. On machines prior to S/N 0300062642, install the 1. With pressure gauge at “G” port on steer/brake pressure gauge at the “G” port on Main Control valve, activate and bottom out Steer Left or Right. valve, activate and bottom out Platform Level Down.
  • Page 176 SECTION 5 - HYDRAULICS Table 5-4. Pressure Settings - Prior to S/N 0300062642 Table 5-5. Pressure Settings - S/N 0300062642 Present Circuit Circuit Main Control Valve Main Control Valve Lift Down Relief Lift Down Relief Tower Lift Down Relief 1700 Tower Lift Down Relief (E/M400A) 1700 Prior to S/N 86022...
  • Page 177 SECTION 5 - HYDRAULICS MAIN RELIEF STEER RELIEF CHECK PRESSURE CARTRIDGE SWITCH GAUGE PORT BRAKE RELEASE CARTRIDGE STEER CARTRIDGE SHUTTLE CARTRIDGE PROPORTIONAL HYDRAULIC (FLOW CONTROL) FILTER CARTRIDGE Figure 5-25. Brake/Steer Valve Components 3121827 – JLG Lift – 5-23...
  • Page 178 SECTION 5 - HYDRAULICS Figure 5-26. HydraForce Cartridge Torque Value Chart 5-24 – JLG Lift – 3121827...
  • Page 179 SECTION 5 - HYDRAULICS Figure 5-27. Main Valve Components Prior to S/N 62642 3121827 – JLG Lift – 5-25...
  • Page 180 SECTION 5 - HYDRAULICS EMERGENCY DESCENT EMERGENCY DESCENT VALVE HAND PUMP UPPER LIFT DOWN RELIEF LOWER LIFT DOWN RELIEF GAUGE PORT TELESCOPE RELIEF RELEVELING VALVE PLATFORM LEVEL RELIEF (BACKWARD) RELEVELING RELIEF PLATFORM LEVEL RELIEF (FORWARD) Figure 5-28. Main Valve Components S/N 62642 to Present 5-26 –...

  • Page 181: Section 6 - Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM JLG CONTROL SYSTEM ANALYZER KIT The JLG designed Control System is a 48 volt based motor control unit installed on the boom lift. INSTRUCTIONS The JLG Control System has reduced the need for Introduction exposed terminal strips, diodes and trimpots and provides simplicity in viewing and adjusting the various personality...

  • Page 182: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The JLG Control System controller has a built in LED to The following instructions are for using the hand held ana- indicate any faults. The system stores recent faults which lyzer. may be accessed for troubleshooting. Optional equip- To Connect the JLG Control System Analyzer ment includes an hour meter, beacon light, function cut- out, and ground alarm.

  • Page 183: Using The Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Using the Analyzer If ENTER is pressed again, the display moves to the fol- lowing display: With the machine power on and the analyzer connected properly, the analyzer will display the following: LO G G ED HELP 1: STARTUP ( 2/ 1) HELP: PRESS ENTER...

  • Page 184: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- Analyzer word was entered correctly: When the analyzer is first connected, you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level.

  • Page 185: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - 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 personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: G RO UND ALARM :...

  • Page 186: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM The effect of the machine digit value is displayed along There is a setting that JLG strongly recommends that you with its value. The above display would be selected if the do not change. This setting is so noted below: machine was equipped with a ground alarm and you ELEVATION CUTBACK wanted it to sound when driving.
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5s to 5.0s DECELeration 0.1s to 2.0s MINimum speed 0 to 25% MAXimum speed 0 to 100% ELEVATED MAXimum speed 0 to 25% CREEP MAXimum speed 0 to 45% POSITRAC time 0 to 60s...
  • Page 188 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS TELEscope ACCELeration 0.5 to 5.0 DECELeration 0.1 to 3.0 MINimum IN speed 0 to 20 MAXimum IN speed 0 to 100 MINimum OUT speed 0 to 20 MAXimum OUT speed 0 to 100 BASKET LEVEL...
  • Page 189 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS GROUND MODE Lower LIFT UP speed 0 to 100 Lower LIFT DOWN speed 0 to 100 UPPER LIFT speed 0 to 100 SWING speed 0 to 100 TELEscope speed 0 to 100 BASKET ROTATE speed...

  • Page 190: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM 1. TILT SWITCH Table 6-2. Machine Setup Descriptions When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting MODEL NUMBER... Displays/adjusts machine model NOTE: all personalities reset to default 1=5 degree - reduces the maximum speed of all when model number is altered platform functions to creep when tilted and...

  • Page 191: Level Vehicle Description

    SECTION 6 - JLG CONTROL SYSTEM 3= Motion Alarm - Sounds when any function is Not available at password level 2 ENTER confirms that active (Option) vehicle is currently level, and zeroes the tilt sensor mea- surements 6. PLATFORM ALARM Help Descriptions and Fault Flash Codes 0= Sounds continuously when above elevation and tilted only.
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected. EVERYTHING OK The “normal”...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/2 indicates problems with drive & steer selection. DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range, or the wiper is wire-off. DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FWS Drive was selected before and during footswitch closure.
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/5 indicates that a function is prevented due to a cutout. BOOM PREVENTED - DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive &...
  • Page 195 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 3/3 indicates that a contactor coil is short-circuited. OVERLOADED VALVE SUPPLY-CHECK WIRING. There is a high current draw from the valve supply when no valve is energized; this is probably due to a wir- ing error at the ground module.
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 6/6 indicates problems with the CANbus. 48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data, and the protection circuit which supplies the platform and ground modules has tripped.
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 9/9 indicates problems with the controller. POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off. POWER MODULE FAILURE: HWFS CODE 2 The hardware fail-safe tests did not complete because traction point A is not safe, or the hardware fail-safe is permanently tripped.
  • Page 198 SECTION 6 - JLG CONTROL SYSTEM 6-18 – JLG Lift – 3121827...
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM 3121827 – JLG Lift – 6-19...
  • Page 200 SECTION 6 - JLG CONTROL SYSTEM 6-20 – JLG Lift – 3121827...

  • Page 201: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow In the following structure descriptions, an intended item is keys alter a value if allowed selected by pressing ENTER;...

  • Page 202: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. DIAGNOSTICS - Menu Descriptions TILT... Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direction (pitch) The second value indicates tilt in the left/ right direction (roll) DATALOG MAX.TEMP ...
  • Page 203 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Descriptions ACTIVATE TESTS Not available once tests are activated YES:ENTER, NO:ESC ENTER activates system tests NOTE: cannot be done while controller is in use (footswitch closed) and for a short time afterwards RUN SYSTEM TEST ENTER starts system test Not available until tests are activated Displays messages...
  • Page 204 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages RUNNING Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BAD POWER WIRING The capacitor bank is not charged or pump point A is low or traction point A is high or low.
  • Page 205 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open-and short- circuit valve coils. The valves are tested in the order: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L, SWING R, SWING REST, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, TELE I, TELE O, BYPASS, STEER L, STEER R, STEER PROP, BRAKE NOTE: in platform mode, the foot switch must be closed.
  • Page 206 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral. In platform mode, inputs are tested in the order: UL U, UL D, UL JOY., SWING L, SWING R, SWING JOY., LEVEL U, LEVEL D, PUMP POT., ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY., STEER L, STEER R,...
  • Page 207 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends. If ENTER is pressed, each operator input is prompted for in turn. In platform mode, operator inputs are tested in the order: UL U, UL D, SWING L, SWING R, LEVEL U, LEVEL D, PUMP POT, CREEP, ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV, STEER L, STEER R, POSITRAC...
  • Page 208 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code EVERYTHING OK The "normal" help message in platform mode GROUND MODE OK The "normal" help message in ground mode 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX"...
  • Page 209 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 2252 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY Input was CLOSED during startup SELECTED 2253 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED Input was CLOSED during startup 2254 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY Input was CLOSED during startup...
  • Page 210 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 2514 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configured to not allow simultaneous drive & boom opera- tion.
  • Page 211 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 33364 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized. This maybe due to an open circuit traction motor or power wiring error 33369 REVERSE CONTACTOR COIL - OPEN CIRCUIT...
  • Page 212 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code STALLED PUMP MOTOR OR POWER WIRING ERROR The power module pump MOSFET protection circuit is active, This is due to a massive current drain and could be a stalled pump motor or a power wiring error OPEN CIRCUIT PUMP MOTOR WIRING Pump point A is collapsing when the pump MOSFETs are pulsed,...
  • Page 213 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 99133 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardware failsafe the contactor drive failsafe did not trip within the allowed test time 99134 POWER MODULE FAILURE - HWFS CODE 16 Hardware failsafe tests failed because the hardware failsafe the...
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-34 – JLG Lift – 3121827...

  • Page 215: Section 7 - Basic Troubleshooting, Electrical Information, & Schematics

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS SECTION 7. BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.1 GENERAL It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has This section contains basic troubleshooting information been made to ensure that all likely problems in these and basic electrical information to be used for locating...
  • Page 216 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Automatic leveling inoperative. Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on Clean, repair, or replace line or fitting.
  • Page 217 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered. Check wiring/Run System Test. Personalities not set correctly Check settings. 3121827 – JLG Lift –...
  • Page 218 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature build- Flush system and change oil using recom- mended viscosity Moisture in oil.
  • Page 219 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Restricted or broken supply line on valve bank or Clean or replace line. hydraulic pump. Directional valve not functioning properly. Repair or replace valve. Lift cylinder not functioning properly.
  • Page 220 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function Speed and Drive Speed does not operate below horizontal. Damaged wiring on level limit switch. Repair or replace wiring/Run System Test Creep Switch Open.
  • Page 221 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom extends and retracts erratically. Hydraulic system oil low. Replenish oil as necessary. Wear pads worn. Replace pads as required. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
  • Page 222 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction. Hydraulic system oil low. Replenish oil as necessary. Lack of lubricant on swing gear or speed reducer Lubricate as required.
  • Page 223 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-3. Turntable Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVE. Valve Spool Sticking. Dirt in oil causing excessive temperature built- Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the Loosen valve and check mounting.Repair as unit.
  • Page 224 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY GENERATOR. Engine will not start. Enable switch is open. Actuate switch. Fuses open. Determine and correct cause; replace fuse. Ground EMS is open. Pull out EMS to activate.
  • Page 225 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY FRONT FRAME AXLE AREA. One or both wheels will not steer. Steering link or tie rod broken or attaching hard- Replace steering link, tie rod or hardware as nec- ware missing.
  • Page 226 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Joystick not functioning properly. Replace joystick/Run System Test. Charger plugged in. Check help message. Drive prevented. Check help message. Brake(s) not releasing. Determine cause and repair or replace.
  • Page 227 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Valve not functioning properly. Repair or replace valve. Hydraulic pump not functioning properly. Repair or replace pump. Personality Settings Incorrect. Adjust settings.
  • Page 228 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Brake Drags or runs hot. Low actuation pressure. Place pressure gauge in bleed port & check pres- sure with system on. Bearing failure.
  • Page 229 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEMS - GENERAL. Hydraulic pump noisy. Air entering system through broken line or fitting. Repair or replace line or fitting. (Suction Side.) Air bubbles in oil.
  • Page 230 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function sluggish during operation. (System pressure too low.) Main relief valve set too low. Reset valve as required. Pump section not delivering sufficient oil. Repair or replace pump section or pump.
  • Page 231 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS. No power to platform controls. 15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary.
  • Page 232 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hourmeter inoperative. Damaged wiring in hourmeter circuit. Repair or replace wiring. Inoperative hourmeter. Replace hourmeter. Platform alarm circuit. Platform alarm inoperative. Check platform alarm/Run System Test.

  • Page 233: Multimeter Basics

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.3 MULTIMETER BASICS nal and the lead on the other port goes to the positive side of the signal. A wide variety of multimeters or Volt Ohm Meters (VOM) Scale can be used for troubleshooting your equipment. This section shows diagrams of a common, digital VOM con- M = Mega = 1,000,000 * (Displayed Number) figured for several different circuit measurements.

  • Page 234: Resistance Measurement

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Resistance Measurement • Use firm contact with meter leads Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to Figure 7-2. Resistance Measurement enable audible continuity testing •...

  • Page 235: Current Measurement

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Current Measurement b. Change the switch position. c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short.

  • Page 236: Automatic Switches

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Automatic Switches • LSS Modules connections, • Deutz EMR 2 ECM connection. If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the Silicone Dielectric Compound must be used on all electri- switch to test it.

  • Page 237: Amp Connector

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as- Applying Silicone Dielectric Compound to shipped, position (See Figure 7-5.). Proceed as follows: AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: •...
  • Page 238 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).

  • Page 239: Disassembly

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ- INGS.
  • Page 240 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-11. Connector Installation 7-26 – JLG Lift – 3121827...

  • Page 241: Deutsch Connectors

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.7 DEUTSCH CONNECTORS NOTE: The receptacle is shown - use the same procedure for plug. DT/DTP Series Assembly DT/DTP Series Disassembly Figure 7-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the con- Figure 7-13.

  • Page 242: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact 1. With rear insert toward you, snap appropriate size crimp barrel.
  • Page 243 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS This page left blank intentionally. 3121827 – JLG Lift – 7-29...
  • Page 244 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-18. Electrical Components Installation - Sheet 1 7-30 – JLG Lift – 3121827...
  • Page 245 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-19. Electrical Components Installation - Sheet 2 3121827 – JLG Lift – 7-31...
  • Page 246 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-20. Electrical Schematic - Sheet 1 of 4 7-32 – JLG Lift – 3121827...
  • Page 247 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-21. Electrical Schematic - Sheet 2 of 4 3121827 – JLG Lift – 7-33...
  • Page 248 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-22. Electrical Schematic - Sheet 3 of 4 7-34 – JLG Lift – 3121827...
  • Page 249 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-23. Electrical Schematic - Sheet 4 of 4 3121827 – JLG Lift – 7-35...
  • Page 250 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-24. Hydraulic Schematic - M400A/E400A - Sheet 1 of 2 7-36 – JLG Lift – 3121827...
  • Page 251 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-25. Hydraulic Schematic - M400A/E400A - Sheet 2 of 2 3121827 – JLG Lift – 7-37...
  • Page 252 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-26. Hydraulic Schematic - M400AJ/E400AJ - Sheet 1 of 2 7-38 – JLG Lift – 3121827...
  • Page 253 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-27. Hydraulic Schematic - M400AJ/E400AJ - Sheet 2 of 2 3121827 – JLG Lift – 7-39...
  • Page 254 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-28. Hydraulic Schematic - M400AJ/E400AJ - Sheet 1 of 2 7-40 – JLG Lift – 3121827...
  • Page 255 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-29. Hydraulic Schematic - M400AJP/E400AJP - Sheet 2 of 2 3121827 – JLG Lift – 7-41...
  • Page 256 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-30. Hydraulic Schematic Component List 7-42 – JLG Lift – 3121827...
  • Page 258 3121827 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I.

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