JLG 450A Service And Maintenance Manual
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JLG 450A Service And Maintenance Manual

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Service and Maintenance Manual
Models
450A
450AJ
PVC 2001
31215022
December 19, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Models 450A 450AJ PVC 2001 31215022 December 19, 2019 - Rev A 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: Bhydraulic System Safety

    • USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, R EP L AC E M E N T PA R T S O R CO M P O N E N TS M US T BE...
  • Page 4 INTRODUCTION REVISON LOG Original Issue December 19, 2019 - Rev A 31215022...

  • 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 3.14 Swing Motor ..................3-50 Removal .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Platform Level Cylinder ................4-9 Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Lubricating O-rings In The Hydraulic System ............5-1 Cup and Brush .
  • Page 10 To Connect the JLG Control System Analyzer ........
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram - Deutz 2.3L Engine ......... . 1-4 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-51. Power Board PC1 Electrical Circuit Diagram ............3-77 3-52.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-5. ORFS Thread ..................5-3 5-6.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-62. Wiper Seal Installation ................5-82 5-63.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-1. Hand Held Analyzer ................6-1 6-2.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-37. Platform Console Harness (Without SkyGuard) - Sheet 3 of 12 ........7-33 7-38.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-94. Deutz 2.9 Harness - Sheet 2 of 12 ..............7-96 7-95.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Deutz D2011L03 ................. . . 1-2 Deutz D2.9L4 .
  • Page 19 Machine Configuration Programming Information (Software Version P2.7) ......6-19 Machine Configuration Programming Settings - 450A (Software Version P2.7) ......6-25 Machine Configuration Programming Settings - 450AJ (Software Version P2.7) .
  • Page 20 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 21: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.3 CAPACITIES Capacity Hydraulic System 38 gal. (143.8 L) Unrestricted 550 lb (249.5 kg) Hydraulic Oil Tank (to Full Level) 31.7 gal. (119.9 L) Maximum Operating Slope 5° Drive Hub 24 oz.

  • Page 22: Engine Data

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

  • Page 23: Major Component Weight

    SECTION 1 - SPECIFICATIONS Table 1-4. Mobilfluid 424 Specs Table 1-7. Mobil EAL 224H Specs SAE Grade 10W-30 Type Synthetic Biodegradable Gravity, API 29.0 ISO Viscosity Grade 32/46 Density, Lb/Gal. 60°F 7.35 Specific Gravity 0.922 Pour Point, Max -46°F (-43°C) Pour Point, Max -25°F (-32°C) Flash Point, Min.
  • Page 24 SECTION 1 - SPECIFICATIONS 2WD ONL Y Figure 1-1. Maintenance and Lubrication Diagram - Deutz 2.3L Engine 31215022...
  • Page 25 SECTION 1 - SPECIFICATIONS 2WD ONL Y Figure 1-2. Maintenance and Lubrication Diagram - Deutz 2.9L Engine 31215022...
  • Page 26 SECTION 1 - SPECIFICATIONS 2WD ONL Y Figure 1-3. Maintenance and Lubrication Diagram - Kubotas Engine 31215022...

  • Page 27: Maintenance And Lubrication

    Lubrication Diagram - Kubotas Engine. Table 1-9. Lubrication Specifications. SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424 EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or...
  • Page 28 SECTION 1 - SPECIFICATIONS Hydraulic Tank Hydraulic Tank Breather Lube Point(s) - Fill Cap Total Capacity - 24.8 Gal. (93.9 L) to Full Level Interval - Change after first 50 hrs. and every 6 months Lube - HO or 300 hrs. thereafter. Interval - Check Level daily;...
  • Page 29 SECTION 1 - SPECIFICATIONS Drive Brake Oil Change w/Filter - Deutz 2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 gal (8.9 L) Lube Point(s) - Fill Plug Lube - EO Capacity - 2.7 oz. (89 mL) Interval - Every Year or 600 hours of operation Lube - Premium Hydraulic Fluid Comments - Check level daily/Change in accordance Interval - Change as necessary...
  • Page 30 SECTION 1 - SPECIFICATIONS Fuel Pre-Filter - Deutz D2.9L Fuel Filter (Gasoline) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Drain water daily; Every year or 600 hours of Interval - Every 6 months or 300 hours of operation operation Fuel Filter (Propane) Fuel Filter - Deutz D2.9...
  • Page 31 SECTION 1 - SPECIFICATIONS Charge Filter Engine Coolant Lube Point(s) - Fill Cap Interval - Change after first 50 hrs. and every 6 months Capacity (Deutz 2.9L)- 2.9 gal. (11.3L) or 300 hrs. thereafter. Capacity (Kubota)- 2.25 gal. (8.5L) Comments - Remove the engine tray retaining bolt and Lube - Anti-Freeze pull out engine tray to gain access.
  • Page 32 SECTION 1 - SPECIFICATIONS Oil Change w/Filter - Kubota Fuel Filter - Kubota Lube Point(s) - Replaceable Component Interval - Every year or 600 hours of operation Fuel Filter (Propane) - Kubota Interval - Every year or 1000 hours of operation Comments - Replace filter.

  • Page 33: Threadlocking Compound

    SECTION 1 - SPECIFICATIONS 1.9 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 34: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.10 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...

  • Page 35: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 36 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...

  • Page 37: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...

  • Page 38: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 39: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 40: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...

  • Page 41: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 42 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...

  • Page 43: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
  • Page 44 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 45: 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 Preparation, Inspection, and Maintenance product model. Reference the machine Service and Mainte- nance Manual and appropriate JLG inspection form for perfor- mance of this inspection.

  • Page 46: Service And Guidelines

    Maintenance nance Manual. NOTE: Inspections forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. SERVICE AND GUIDELINES At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves.

  • Page 47: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Unless specific torque requirements are given within the text, standard torque values should be used on heat- When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with the procedural steps in sequence.

  • Page 48: Lubrication And Information

    Hydraulic Oil Refer to Section 1 for recommendations for viscosity ranges. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below - 15°F (-26°C) is not recommended.

  • Page 49: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST 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 applied and appropriately positioned to detect drift.

  • Page 50: Pins And Composite Bearing Repair Guidelines

    Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. Equipment b. Cracked or damaged liner backing.
  • Page 51 SECTION 2 - GENERAL NOTE: Refer the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1, 2 1, 2 Hose/Cable Carrier Installations 1, 2...
  • Page 52 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Functions/Controls Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Ground Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Function Control Locks, Guards, or Detents...
  • Page 53 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months; Out of service for 3 months or more; Purchased used Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body Indicates a 50 hour interval required to perform task after initial use of machine.
  • Page 54 SECTION 2 - GENERAL 1001159163 B Figure 2-1. Engine Operating Temperature Specifications - Deutz 2.9 2-10 31215022...
  • Page 55 CO2 Conversion > 60% per EPA 560/6-82-003 NOTICE: CO2 Conversion > 80% per CEC-L-33-A-93 MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF ** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203 THE TEMPERATURE BOUNDARIES OUTLINED IN *** Fire Resistant classification indicates Factory Mutual Research Corp.
  • Page 56 SECTION 2 - GENERAL 1001151190 B Figure 2-3. Engine Oil Operating Temperature Specifications - Deutz 2011 2-12 31215022...
  • Page 57 SECTION 2 - GENERAL 1. MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERAT URE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
  • Page 58 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 59: Chassis & Turntable

    Please refer to the ers. If you do not have a torque wrench, tighten the fasteners JLG Parts Manual for the part number of the approved tires for with a lug wrench, then immediately have a service garage or a particular machine model.

  • Page 60: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.3 LOCKOUT CYLINDER BLEEDING The tightening of the nuts should be done in stages. Fol- lowing the recommended sequence, tighten nuts per wheel torque chart. Start the engine. Table 3-1. Wheel Torque Chart Position the turntable to the normal stowed position. TORQUE SEQUENCE Attach clear tubing to bleeder valve nipple.
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1001164093 C 1. Bolt 4. Keeper Pin 7. Bolt 10. Shim 13. Pin 2. Bolt 5. Washer 8. Wear Pad 11. Axle 14. Shim 3. Bearing 6. Washer 9. Shim 12. Axle Lockout Cylinder 15.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 1001164092 F 1. Thrust Bearing 5. Keeper Pin 8. Steer Cylinder 11. Kingpin 6. Washer 9. Link 12. Spindle 2. Bolt 3. Bolt 7. Washer 10. Nut 13. Pin 4. Bolt Figure 3-2. Steer Installation (Without Tow Package) 31215022...
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 1001164095 D 1. Thrust Bearing 6. Bearing 11. Washer 15. Steer Cylinder 19. Spindle 23. Link 2. Bolt 7. Pin 12. Washer 16. Link 20. Bracket 24. Pin 3. Bolt 8. Keeper Pin 13. Washer 17.

  • Page 64: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE 3.5 OSCILLATING AXLE LOCKOUT TEST 3.6 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) is intended to indicate to the operator conditions that could make the direction of movement of the chassis different than the direction of move- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- ment of the drive/steer control handle.

  • Page 65: Drive System

    SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE SYSTEM Drive speed is varied by a combination of drive pump dis- placement, engine speed, and motor displacement. Traction The four wheel drive system consists of one variable displace- control is full-time and is present in all drive modes. There are ment closed loop pump, four variable displacement piston three drive modes that can be selected at the platform con- motors, gear reduction hubs, and a traction control manifold...

  • Page 66: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.8 WHEEL DRIVE ASSEMBLY NOTE: The drive hub and drive motor assembly weighs approxi- mately 149 lb (68 kg). Removal Use a supporting device capable of handling the weight of the drive hub and drive motor, and unbolt the drive NOTE: The drive motors can be removed through the axle flange hub from the frame.

  • Page 67: Torque Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.9 TORQUE HUB Tightening and Torquing Bolts Roll and Leak Testing USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN Always roll and leak test Torque-Hubs after assembly to make sure that the unit’s gears and sealants are working properly. BOLTS BEYOND THEIR TORQUE SPECIFICATION.

  • Page 68: Main Disassembly For "B" Drives

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly for “B” Drives Hub-Spindle Disassembly Turn hub (1G) on side, Remove coupling (14) from wide NOTE: Start with large end of hub facing up and large end of spin- end of spindle (1A). dle facing down.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 2780267 H Figure 3-6. Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 1 of 2 3-11 31215022...
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Roll Pin Thrust Spacer Gasket 1A Spindle Ring Gear Sun Gear Cylinder 1B Seal O-Ring Thrust Washer Piston Bearing Cone O-Ring Bolt Ball Bearing 1D Bearing Cup Cover Assembly Dowel Pin Retaining Ring Bearing Cup Thrust Spacer Coupling...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 2780268 E Figure 3-8. Drive Hub (4WD Front Only) -Sheet 1 of 2 3-13 31215022...
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Carrier Assembly Cover Assembly Shaft Spindle 3A Carrier Thrust Spacer Retaining Ring Seal 3B Retaining Ring Cover Plate Spring Bearing Cone 3C Needle Bearing O-Ring Thrust Spacer Bearing Cup 3D Thrust Washer Disconnect Rod Gear, Sun Bearing Cup...
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 1. Hub-Spindle Sub-Assembly 2. Internal Gear A. Cover C. Spring A. Spindle 3. Carier Sub-Assembly B. Cover Cap D. Spacer A. Carrier Housing B. Seal C. Bolt 8. Input Gear B. Thrust Washer C. Bearing Cup 9.

  • Page 74: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Assemble Carrier Apply grease to inside of one cluster gear (3F) and line one Remove two bolts (6C) holding disconnect cap (6D) to half of cluster gear with 16 needle rollers (3C). cover (6A).
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE Set carrier housing (3A) on table, sideways. Insert a Following cluster gear, place one more thrust washer planet shaft (3E), roll pin hole last, into one of the planet (3B) onto planet shaft (3E) through opposite planet shaft shaft holes from roll-pin-holed side of carrier housing hole in carrier housing (3A).

  • Page 76: Cover Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Sub-Assembly Set cover (6A) on table, exterior side up. Place cover cap (6B) on cover (6A). Align pipe plug hole in cover cap over Using disconnect rod, push O-ring (6F) into groove pipe plug hole in cover. inside cover cap (6B).

  • Page 77: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE With large end down, place disconnect cap (6D) on Apply a light coat of “Never-Seize” to pipe plug (6H) and cover cap (6B), aligning pipe plug hole in disconnect cap tighten it in pipe plug hole in cover (6A). over pipe plug hole in cover cap.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE Apply a light coat of “Never-Seize” to two pipe plugs (1J) Press seal (1B) in small end of hub (1G). and tighten them in two pipe plug holes in side of hub (1G). Oil spindle, then lower hub (1G) small end down, onto spindle (1A).

  • Page 79: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly Place spacer (1H) on spindle (1A) in hub (1G). SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING. Grease O-ring (5) and place it into counterbore in hub (1G).
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Place thrust washer (11) around spindle (1A) so it rests Place other spacer (7D) on smooth end of input shaft on bottom of internal gear (2). (7A). Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A).
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE Place thrust spacer (9) onto input shaft (7). Place carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning “X” marked shoulder bolt hole in ring gear (4) over one of the shoul- der bolt holes in hub.
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten. SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALL- ING O-RING. Set cover (6A) on table, interior side up. Grease O-ring (5) and place in counterbore around edge of cover (6A).
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Torque shoulder bolts (13) 18 to 25 ft. lbs. (25 to 34 Nm). Roll test unit in clockwise and counterclockwise direc- Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 Nm). tions. Perform same number of turns in each direction as the ratio of the unit.

  • Page 84: Tool List

    SECTION 3 - CHASSIS & TURNTABLE Tool List T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E). The following specialized tools are used to assemble this unit. Tool diagrams in this manual are intended for the customer who may wish to have a tool made. All tools are one piece and must be made from mild steel.

  • Page 85: Re-Align Torque Hub Input Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.10 RE-ALIGN TORQUE HUB INPUT COUPLING 3.11 DRIVE MOTOR This procedure applies to torque hubs with integral brakes: Description Equipment Required Drive motors are low to medium power, two-position axial pis- ton motors incorporating an integral servo piston. They are designed for operation in open and closed circuit applications.

  • Page 86: Shaft Seal Replacement

    SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement Loop Flushing Valve REMOVAL REMOVAL Remove snap ring (1) and support washer (2). Remove plug (1) and (2) with 11/16 in. internal hex wrench. 1. Snap Ring 2. Support Washer 3. Shaft Seal Figure 3-13.

  • Page 87: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level and ensure oil supply to motor is adequate and supply to motor.

  • Page 88: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts are lubricated during start-up. Replace all O-Rings and gaskets. Lightly lubricate O-rings with clean petroleum jelly prior to assembly.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 27. O-ring 29. Angle Stop 23. End Cap 26. End Cap 28. O-ring 30. Servo Spring 24. O-ring Figure 3-17. End Cap Figure 3-18. Valve Plate & Rear Shaft Bearing Using an 8 mm internal hex wrench, remove endcap screws (22).
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 31. Cylinder Kit Assembly Figure 3-19. Cylinder Kit Turn housing on its side and remove cylinder kit assem- bly (31). Set assembly aside. Do not to scratch running 32. Snap Ring surface. 33. Support Washer NOTE: Grooves on surface of cylinder kit identify its displacement: 34.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-22. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer Turn housing over and remove swashplate (39) by lifting 46.

  • Page 92: Inspection

    SECTION 3 - CHASSIS & TURNTABLE Inspection Table 3-7. Slipper Foot Thickness & End Play Wash all parts after disassembly (including end-cap and hous- Measurement L Frame K Frame ing) thoroughly with clean solvent and allow to air dry. Blow Slipper Foot Thickness 2.71 4.07...
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE VALVE PLATE Inspect journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively Valve plate condition is critical to motor efficiency. Inspect worn. Polymer wear layer must be smooth and intact. valve plate surfaces for excessive wear, grooves, or scratches.

  • Page 94: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Install new O-ring (1) and piston seal (2) to servo piston COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY. COMPRESS- (3). Install piston seal over O-ring. ING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE NOTE: Installing piston seal stretches it, making it difficult to EFFORT.
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Press front shaft bearing (15) onto shaft (16). Press bear- ing onto shaft with lettering facing out. Lubricate bear- IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. ing rollers. Install snap-ring (17) on shaft. Install pistons (11) to slipper retainer (12).
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Verify swashplate and bearings are properly seated. Press rear shaft bearing (22) into endcap. Install bearing Install cylinder kit (19) onto shaft. Install with slippers with letters facing out. Press until bearing surface is facing swashplate.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Install endcap (25) on housing with endcap screws (26). Cover shaft splines with an installation sleeve. Install a Check endcap properly seats on housing without interfer- new shaft seal (27) with cup side facing motor. Press seal ence.

  • Page 98: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE Initial Start-Up Procedures Install orifice poppet (30). Follow this procedure when starting up a new motor or after Install shift spool (31). reinstalling a motor. Install spring retaining washers on springs (32 and 33). Prior to installing motor, inspect for damage incurred during Carefully install centering springs (34, 35, and 36).

  • Page 99: Drive Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE BRAKE Assembly Lightly lubricate the rotary shaft seal (12) and assemble Refer to Figure 3-35., Drive Brake. it to the housing (2) taking care not to damage the seal Disassembly lip. Apply a ring of Medium Strength Threadlocking Com- Supporting the brake on Face A, remove the socket pound or equivalent adhesive to the outside diameter head capscrews and washers (13 &...
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 2. Housing 3. Inner Friction Plate 4. Pressure Plate 5. Gasket (Not Shown) 6. Outer Plate 7. Gasket 8. Cylinder 9. Piston 10. Ball Bearing 11. Retaining Ring 12. Rotary Shaft Seal 13.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 1001165946 B 1. Bolt 4. Washer 7. Swing Motor 2. Bolt 5. Washer 8. Turntable Bearing 3. Grease Fitting 6. Capscrew Figure 3-36. Swing System 3-43 31215022...

  • Page 102: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING BEARING Installation Using an adequate lifting device, place the bearing Removal assembly onto the frame. Align the 1/8 NPT holes in the bearing with the notches in the frame and install the Attach an adequate support sling to the boom and draw grease fittings as shown in Figure 3-36., Swing System.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE Figure 3-37. Swing Bearing Torque Sequence 3-45 31215022...

  • Page 104: Turntable Bearing Mounting Bolt Condition Check

    SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation Figure 3-38.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE MAIN BOOM UPPER TOWER LINK LOWER TOWER LINK MEASURING POINT Figure 3-40. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 3-47 31215022...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 3-48 31215022...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE 3-49 31215022...

  • Page 108: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING MOTOR 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. Figure 3-43. Swing Motor - Cutaway 3-50 31215022...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or “O” Rings. Torque to manufac- turers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

  • Page 110: Removal

    SECTION 3 - CHASSIS & TURNTABLE SWING BEARING WASHER ASSEMBLY BOLT SWING MOTOR Figure 3-44. Swing Motor Removal and Installation Removal Refer to Figure 3-44., Swing Motor Removal and Installation Thoroughly clean the area around the swing motor to prevent any dirt from entering the system. Tag and disconnect the hydraulic lines running to the swing motor.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 1001104850 A 1. Bolt 6. Ring 10. Drive Link 14. Thrust Washer 18. Housing 2. End Cover 7. Manifold 11. Coupling Shaft 15. Thrust Bearing 19. Bearing 3. Commutator Seal 8. Rotor Set 12. Woodruff Key 16.

  • Page 112: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- Place the motor in a soft jawed vice, with coupling shaft nents read this entire section. It provides important infor- (12) pointed down and the vise jaws clamping firmly on mation on parts and procedures you will need to know to the sides of the housing (18) mounting flange or port...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE Remove commutator (5) and seal ring (3) Remove seal Remove manifold (7) and inspect for cracks surface scor- ring from commutator, using an air hose to blow air into ing, brinelling or spalling. Replace manifold if any of ring groove until seal ring is lifted out and discard seal these conditions exist.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Remove rotor set (8) and wearplate (9), together to Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 retain the rotor set in its assembled form, maintaining degrees apart) and a roller vane centerline are on the the same rotor vane to stator contact surfaces.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Remove thrust bearing (11) from top of coupling shaft Remove coupling shaft (12), by pushing on the output (12). Inspect for wear, brinelling, corrosion and a full end of shaft. Inspect coupling shaft bearing and seal sur- complement of retained rollers.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE Remove and discard seal ring (4) from housing (18). Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is Remove thrust bearing (15) and thrust washer (14). required.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE NOTE: The depth or location of bearing/bushing (13) in relation to If the housing (18) assembly has passed inspection 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 119: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) with- Replace all seals and seal rings with new ones each time you out damaging the housing.
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE NOTE: Bearing mandrel must be pressed against the lettered end Press a new dirt and water seal (20) into the housing (18) of bearing shell. Take care that the housing bore is square outer bearing counterbore. The dirt and water seal (20) with the press base and the bearing/ bushing is not cocked must be pressed in until its’...
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Assemble thrust washer (14) then thrust bearing (15) Be sure that a generous amount of clean corrosion resis- that was removed from the motor. tant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15).
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Apply a small amount of clean grease to a new seal ring Assemble wear plate (9) over the drive link (10) and (4) and insert it into the housing (18) seal ring groove. alignment studs onto the housing (18). Apply a small amount of clean grease to a new seal ring NOTE: One or two alignment studs screwed finger tight into (4) and assemble it into the seal ring groove on the wear...
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE NOTE: It may be necessary to turn one alignment stud out of the Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE Assemble a new seal ring (3) flat side up, into commuta- tor (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set.

  • Page 125: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the A disassembled rotor stator and vanes that cannot be readily other bolts are in place.

  • Page 126: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures.

  • Page 127: Final Checks

    SECTION 3 - CHASSIS & TURNTABLE 3.15 GENERATOR Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device STOP ENGINE BEFORE CARRY OUT SCHEDULE MAINTENANCE.

  • Page 128: Overload Protection

    SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings Refer to Figure 3-46., Inspecting Generator Brushes, Replacing STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes and Cleaning Slip Rings. BREAKER. INSPECTING BRUSH POSITION Inspect brush alignment with slip rings.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 m m) Or Less - Replace 7/16 in - 1/2 in (1 1 - 12 m m) New Figure 3-46.

  • Page 130: Generator Disassembly And Assembly

    SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly Remove brush holder assembly. Disassemble generator parts shown in Figure 3-47. Refer to Figure 3-48. and Figure 3-49. to determine if trouble is in stator, rotor, control box, or combination of these compo- Clean all parts with approved solvent and dry with com- nents.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Figure 3-48. Generator Troubleshooting Circuit Diagram - Sheet 1 of 2 3-74 31215022...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Figure 3-49. Generator Troubleshooting Circuit Diagram - Sheet 2 of 2 3-75 31215022...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE 3-76 31215022...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE 3-77 31215022...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Figure 3-52. Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2 3-78 31215022...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Figure 3-53. Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2 3-79 31215022...

  • Page 137: Lead Connection List For Generator

    SECTION 3 - CHASSIS & TURNTABLE Lead Connection List for Generator NOTE: Apply small amount of dielectric grade, nonconductive electric grease to connectors where factory-applied grease NOTE: Table shows physical lead connections and should be used had been present. with circuit diagram (table replaces wiring diagram). Table 3-10.

  • Page 138: Deutz Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.16 DEUTZ ENGINE 1001166304 1. Engine 6. Surge Tank 11. Fuel Pre-Filter 2. Gear Pump 7. Radiator 12. Hydraulic Filter 3. Piston Pump 8. Alternator 13. Exhaust System 4. Pump Coupling 9. Oil Filter 14.
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 1001166305 1. Gear Pump 5. Engine Tray 9. Forward Solenoid 2. Piston Pump 6. Muffler 10. Reverse Solenoid 3. Pump Coupling Kit 7. Oil Cooler 11. Hydraulic Filter 4. Engine 8. Radiator Figure 3-55. Deutz D2011Engine Components - Sheet 1 of 3 3-82 31215022...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 1001166305 F 12. Fan 14. Glow Plug Relay 13. Starter Relay 15. Auxiliary Pump Relay Figure 3-56. Deutz D2011Engine Components - Sheet 2 of 3 3-83 31215022...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE 1001166305 F 16. Air Cleaner 19. ECM 17. Muffler 20. Alternator 18. Exhaust Pipe 21. Air Intake Restriction Indicator Figure 3-57. Deutz D2011Engine Components - Sheet 3 of 3 3-84 31215022...

  • Page 142: Kubota Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.17 KUBOTA ENGINE 1001210764 1. Engine 5. Engine Tray 9. Alternator 2. Gear Pump 6. Air Cleaner 10. Regulator assembly 3. Piston Pump 7. Radiator 11. Forward Solenoid 4. Pump Coupling 8. Coolant Overflow Container 12.
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE 1001210764-H 13. Muffler 16. Air Cleaner 19. Fuel Filter 14. Exhaust Pipe 17. Fuel System Mount 20. Fuel Manifold 15. Fan 18. Fuel Pump 21. Oil Filter Figure 3-59. Kubota Engine Components - Sheet 2 of 2 3-86 31215022...

  • Page 144: Deutz Engine - D2.9L4

    SECTION 3 - CHASSIS & TURNTABLE 3.18 DEUTZ ENGINE - D2.9L4 Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-60., Engine Oil Viscosity. NOTE: Refer to engine manufacturer's manual for detailed oper- ating and maintenance instructions. Limited engine main- tenance items are presented here for convenience but detailed engine maintenance items and schedule are included in the engine manufacturer's manual.

  • Page 145: Replacing The Fuel Filters

    SECTION 3 - CHASSIS & TURNTABLE Catch any escaping oil. Clean any dirt from filter carrier sealing surface. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL Lightly coat new oil filter rubber gasket with clean oil.

  • Page 146: Deutz Engine - D2011

    SECTION 3 - CHASSIS & TURNTABLE 3.19 DEUTZ ENGINE - D2011 NOTE: Refer to engine manufacturer's manual for detailed oper- 0,1,080 2,/ ating and maintenance instructions. Limited engine main- /(9(/ tenance items are presented here for convenience but detailed engine maintenance items and schedule are included in the engine manufacturer's manual.

  • Page 147: Replacing Engine Oil

    SECTION 3 - CHASSIS & TURNTABLE Replacing Engine Oil Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-65., Engine Oil Viscosity for the Allow the engine to warm up. The engine oil should proper grade.

  • Page 148: Replacing The Fuel Filter

    SECTION 3 - CHASSIS & TURNTABLE Using a suitable oil filter removal tool, loosen lube oil fil- Hand-tighten filter another half-turn. ter element and spin off. Check oil level. Check oil pressure. Check the oil filter cartridge and make sure there are no leaks.

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