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Oshkosh JLG 1500SJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
1500SJ
PVC 2001
31215064
December 12, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Model 1500SJ PVC 2001 31215064 December 12, 2019 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • 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 mobile elevat- ing work platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION nance personnel pay strict attention to these warnings and COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A precautions to avoid possible injury to themselves or others,...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 5 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires and Wheels ................. . . 3-1 Tire Damage .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.17 Swing Motor ..................3-74 Disassembly and inspection .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Boom Systems ..................4-1 Broken Cable Indicator System.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.17 Wire Rope ..................4-80 Inspection .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Assembly instructions for Adjustable Port End (BSPP) Fittings ........5-42 Assembly Instructions for Flange Connections: (FL61 and FL62) .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Function Pump (Sauer) ................5-174 Disassembly .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 6.15 Calibrating Platform Level ................6-89 Step 1: Setting The Platform Valve Minimums .
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-5 2-1.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-55. Swing Bearing Torque Sequence..............3-115 3-56.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-28. Torque Sequence for Fly Extend Rope ............. . 4-84 4-29.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-44. Wiper Seal Installation ................5-68 5-45.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-101. Cylinder Cap Removal ................5-94 5-102.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-157. Hydraulic Schematic - Sheet 8 of 10 ..............5-203 5-158.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-27. Chassis Electrical Components - Sheet 2 of 2 ............7-21 7-28.
  • Page 19 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-35 Jib Control Valve Specifications ..............5-116 5-36 Fitting Torque .
  • Page 20 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 21: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Machine Specifications Machine Dimensional Data Capacity - ANSI Turning Radius (Axles Retracted) Unrestricted 500 lb (227 kg) Outside 22 ft. 6 in. (6.8 m) Restricted 1000 lb (454 kg) Inside 14 ft.

  • Page 22: Tires

    SECTION 1 - SPECIFICATIONS 1.4 TIRES 1.5 ENGINE DATA Size 445/50D710 Table 1-1. Deutz TD2011L4 Specifications Load Range Type Liquid Cooled Ply Rating Number of Cylinders Foam Fill Polyurethane HD (55 Durometer) Foam Bore 3.7 in. (94 mm) Diameter 46.45 in. (117.9 cm) Stroke 4.4 in.

  • Page 23: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS Table 1-4. Mobilfluid 424 Specs Table 1-3. Deutz TD2.9L4 Specifications SAE Grade 10W30 Type Diesel Gravity, API 29.0 Number of Cylinders Density, Lb/Gal. 60° F 7.35 Bore 3.6 in. (92 mm) Pour Point, Max -46° F (-43° C) Stroke 4.3 in.

  • Page 24: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.7 MAJOR COMPONENT WEIGHTS Table 1-7. Mobil EAL H 46 Specs Type Synthetic Biodegradable DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT ISO Viscosity Grade WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT- Density at 15°...
  • Page 25 SECTION 1 - SPECIFICATIONS 16A,16B 12,14 10A,10B,11 Figure 1-1. Maintenance and Lubrication Diagram 31215064...

  • Page 26: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-11. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 27 SECTION 1 - SPECIFICATIONS Swing Brake B: Wheel Drive Hub - Reggiana Riduttori Lube Point(s) - Level/Fill Plug Capacity - 0.5 quarts (0.5 liters) ± 10% Lube - EPGL Interval - Change after first 150 hours then every 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position.
  • Page 28 SECTION 1 - SPECIFICATIONS Hydraulic Charge Filter Suction Strainers (In Tank) Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator. Hydraulic Oil Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation.
  • Page 29 SECTION 1 - SPECIFICATIONS B. Oil Change w/Filter - Deutz TCD2.9 A. Fuel Filter - Deutz TD2011 Lube Point(s) - Replaceable Element Lube Point(s) - Fill Cap/Spin-on Element Interval - Every year or 600 hours of operation. Capacity - 2.4 Gallon (8.9 L) Lube - EO B.
  • Page 30 SECTION 1 - SPECIFICATIONS Fuel Strainer - Deutz TD2011 Fuel Pre-Filter TCD2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation. Radiator Coolant TCD2.9 Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation. Lube Point(s) - Fill Cap Capacity - 3.2Gallon (12.1 L) Lube - Anti-Freeze...
  • Page 31 SECTION 1 - SPECIFICATIONS A. Air Filter - DEUTZ TD2011 Platform Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as Interval - Change after first 50 hours and then every year indicated by the condition indicator.

  • Page 32: Threadlocking Compound

    SECTION 1 - SPECIFICATIONS 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 33: 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 34 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 35 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 36 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 37 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 38 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 39: 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 40 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 41 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 42 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 43 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 44: General

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

  • Page 45: 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 Operation and Safety Manual At each Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic...

  • Page 46: Component Disassembly And Reassembly

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

  • Page 47: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION The only exception to the above is to drain and fill the system with Premium Hydraulic Fluid oil or its equiva- lent. This will allow start up at temperatures down to -20 Hydraulic System degrees F (- 29 degrees C).

  • Page 48: Cylinder Drift

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

  • Page 49: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on Filament wound bearings. an external structure, or component, Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment...
  • Page 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields Extend/Retract Chain or Cable Systems...
  • Page 51 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Drive Brakes Swing Brakes Auxiliary Power...
  • Page 52 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications Function Test of All Systems 21, 22...
  • Page 53 SECTION 2 - GENERAL 1001159163-B Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 31215064...
  • Page 54 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERATURE 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 55: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Wheel Installation It is extremely important to apply and maintain proper wheel Tire Damage mounting torque. For polyurethane foam filled tires, JLG Industries, Inc. recom- mends that when any of the following are discovered, mea- sures must be taken to remove the JLG product from service WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE...

  • Page 56: Axle Extension System

    SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Wheel Torque Chart restricted to operation within the transport position. If a signal from any axle extend sensing switch is lost when the boom TORQUE SEQUENCE beyond the transport position, the axle set indicator will flash and drive/steer functions will be disabled until the boom is 1st Stage 2nd Stage...

  • Page 57: Drive System

    SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE SYSTEM The drive system utilizes 2 traction pumps so each side is pow- ered individually. This produces maximum tractive effort to wheels by minimizing flow divider losses. The maximum drive speed is modulated with the steered angle of the wheels to eliminate the whiplash effect of driving at full speed and maxi- mum steering lock.

  • Page 58: Drive/Steering Speed Control

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE/STEERING SPEED CONTROL for 3 seconds after the end the last drive/steer command. If the timer expires, the DOS override switch must be re-engaged to The Drive/Steering Speed Control system uses the steering enable drive/steer.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE Press ENTER , the screen should read: Use the Left or Right arrow key until you see: To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press ENTER , the screen should read: Swing and drive functions can now be used to swing the turn-...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1001119385-D Figure 3-5. Chassis Component Location - Sheet 1 of 2 31215064...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Limit Switch (Right Front) 10. Steer Angle Sensor (Left Rear) 2. Steer Angle Sensor (Right Front) 11. Chassis Module 3. Steer Valve (Front) 12. Swivel/Collector Ring 4. Axle Lockout Valve 13. Axle Lockout Pressure Switch 5.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 26 25 23 22 1001119385-C Figure 3-7. Turntable Component Location - Sheet 1 of 2 31215064...
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 1. Ground Control Box 15. Starter Relay 2. Headlight 16. Glow Plug Relay 3. Deutz EMR2 Module & Diagnostic Connector 17. Swivel 4. 110V / 220V Generator 18. Alarm 5. 110V / 220V Generator Control Box 19.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE DETAIL A * AXLE STOP SHIMMING PROCEDURE: ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 11,12,B,G 11,12,A,G 11,12,C,G DETAIL A 11,12,D,G 11,12,E,G 11,12,F,G A - Assemble to Axle Box Mid Plate; Typical 8 Places DETAIL B B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 inches (12.7 ±...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL A AXLE STOP SHIMMING PROCEDURE: 1) ALL 4 WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2) SHIM AXLE STOPS TO WITHIN THE THICK NESS OF THE THINNEST SHIM.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE -ASSEMBLE TO TOP PLATE OF AXLE BOXES -TYP 4 PLACES, 2 AXLE BOXES -TORQUE GRADE 8 PER JLG SPEC 5000059 -SELECT APPROPRIATE BOLT (ITEM #16, #17, OR #18) TO ENSURE 1/2" 1/16" THREAD ENGAGEMENT ASSEMBLE TO SIDE PLATES OF AXLE WELDMENTS TYP 16 PLACES, 4 AXLES...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE * Apply Medium Strength Threadlocking Compound * * Apply High Strength Threadlocking Compound *** Apply High Strength Threadlocking Compound Figure 3-13. Axle Threadlocking Compound Application 3-14 31215064...
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes Apply Medium Strength Threadlocking Com- pound Apply High Strength Threadlocking Com- pound Apply Low Strength Threadlocking Com- pound Preload Torque 100-300 ft. lb. (136-407 Nm) on Slot Nut Spindle Steer Cylinder Pivot Pin Angle Sensor Assembly King Pin...

  • Page 70: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground Lockout Cylinder Bleeding when traveling on rough terrain.

  • Page 71: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test Telescope the boom out of the transport position. The front axles will oscillate when the boom is in the transport Drive machine off of block and ramp back onto the level position (i.e.

  • Page 72: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.11 WHEEL DRIVE ASSEMBLY Remove hardware securing wheel and remove wheel assembly. Removal Place a wheel assembly on Clean area. Installation NOTE: The drive motor can be removed through the axle flange as part of the wheel drive assembly or they can be removed Place blocking strong enough to support the weight of separately through the bottom of the frame while leaving the machine under the frame and remove the jack.

  • Page 73: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE MOTOR Installation Make sure that the pump shaft is properly aligned. Removal NOTE: The drive motor weighs approximately 34 lb (15.4 kg). Place machine on the firm level surface. Install the drive motor to the drive hub and secure using Disconnect the battery power and all electrical connec- bolts and washers.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE MAE37590B 1. Bolt 9. Snap ring 17. Cylinder Piston 25. Gasket 33. Snap ring 2. End cap motor 10. Spring Retainer 18. Piston Ring 26. Plug 34. Snap ring 3. Locating pin 11. Spring 19.

  • Page 75: Drive Hub - If Equipped With Bonfiglioli

    SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE HUB - IF EQUIPPED WITH BONFIGLIOLI Installation of the Wheel Drive on the Machine Clean the mating surfaces from oils or paint and fit the NOTE: After SN 0300134389 Machines may be built with either wheel drive on the machine frame.

  • Page 76: General Information

    SECTION 3 - CHASSIS & TURNTABLE Connecting the Brake After having finished running-in the gearbox, follow the steps given below. The gearbox is fitted with a negative multi disk safety brake with hydraulic control release (parking brake). For information Check that there are no oil leaks. If leaks are present, regarding the characteristics of the brake refer to the installa- fix them before proceeding.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5......Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..Brake port Figure 3-19. Hub Assembly 31215064 3-23...

  • Page 78: Gearbox Disengagement

    SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade Ambient temperature -20°C / +30°C +10°C / +45°C Oil viscosity SAE 80W/90 SAE 85W/140 Manufacturer Oil Brand SHELL SPIRAX HD SPIRAX HD AGIP ROTRA MP ROTRA MP...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE Take out the cap nut (5). THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. Turn the cap nut (5) upside down. As result the pin (3) will be pushed inside in order to permit disengagement of the gearbox.

  • Page 80: Maintenance Information

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

  • Page 81: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting The following table is provided to help locate problems in the gearbox. Table 3-6. Troubleshooting Symptom Causes Remedies External oil leakage: From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal From the end cover a) O-ring seal damaged a) Replace O-ring seals...
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Install the special tool (6689960310) on the flanged hub Mark the position of the springs (45) as a reference for (31) and turn the screw until it compresses the springs the reassembly. (45). Remove the springs (45) from their seats in the brake piston (44).
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring 2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring 3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE By using a puller remove, at the same time, the brake Remove the external O-Ring seal (38) and the backup piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39). Remove the O-ring seal (42) and the backup ring (43) from their seats in the flanged hub (31).
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Remove the disengagement shaft kit (15). By using pliers remove the elastic ring (11) from the splined shaft (14). Place the disengagement shaft kit (15) inside the special tool (6689960240). Remove the special tool and remove the spring (13) and the washers (12).
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Remove the cap nut (5). Unscrew the draining-filling-level oil plugs (6) by a male hex head wrench. Remove the pin (3). Unscrew the 10 screws M10X25 (1), grade 12,9, from the end cover (7). Remove the O-ring seal (2) from its seat in the end cover (7).
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE Remove the O-ring seal (9) from its seat in the end cover Remove the 2nd stage sun gear (17). (7). Remove the 2nd reduction assembly (18). Remove the 1st stage sun gear (10). By using pliers remove the circlips (19) from their seats in the flanged hub's pins (31).
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE By using a puller remove the planet assemblies of the By using a tackle place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 3rd reduction (20). By using the torque multiplier (ATZ.09.016.0) loosen the Remove the spacer (21) from their seats in the pins of ring nut (22).

  • Page 89: Inspection Of Parts

    SECTION 3 - CHASSIS & TURNTABLE By using a puller and a metal stopper, remove the By using a screwdriver, remove the 1st half-seal (29) flanged hub (31) from the gearbox housing (23). from the flanged hub (31). By using a tackle remove the gearbox housing (23) from By using a screwdriver, remove the 2nd half-seal (29) the flanged hub (31).

  • Page 90: Assembly

    SECTION 3 - CHASSIS & TURNTABLE When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate seals to make reassembly easier.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Carefully clean the metallic faces of the lifetime seal (29) By using a hoist, place the gearbox housing (23) on the and lube the surfaces with oil. flanged hub (31). By using a press and a metallic stopper, push the gear- Insert the seal ring (30) in its seat in the flanged hub (31).
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE By using a hoist place the torque multiplier NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm). (ATZ.09.016.0) on the ring nut (22). Assemble correctly the spacers (21) on the pins of the By using the multiplier (ATZ.09.016.0), tighten the ring flanged hub (31).
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE By using a rubber hammer and a metal stopper push the Insert the 2nd stage sun gear (17). planet assemblies of the 3rd reduction (20) against the shoulder until assembly is complete. Assemble the 1st reduction assembly (16). By using pliers, assemble the circlips (19) in the flanged hub pin seats (31).
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE Assemble the O-ring seal (9) into its seat in the end Insert the plugs (6) into the oil draining-filling holes of cover (7). the end cover (7). Torque the plugs to 52 ± 7 ft.lbs. (70±10 Nm).
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Assemble the cap nut (5). Insert the spring (13) in the splined shaft (14). Insert the splined shaft (14) in the equipment Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. (6689960240). (25 Nm).
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Torque the 2 screws M5x16, grade 8.8, of the cover to Insert the disengagement shaft kit (15) in the flanged 18.4 ft.lbs. (25 Nm). hub (31). By using pliers assemble the circlip (36) into its seat in By using pliers, assemble the elastic ring (11) into its seat the brake shaft (35).
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Assemble the brake discs package according to the fol- Fit the external O-ring seal (38) and the backup ring (37) lowing order: first, insert one sintered bronze disc with into their seats in the spacer (39). external teeth (33).
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE Lube the seal seats into the flanged hub (31) and assem- Insert the brake piston (44) inside the flanged hub (31), ble the O-ring seal (42) and the backup ring (43). paying attention not to damage the seals already fitted. By using a rubber hammer and a metal stopper push the NOTE: The O-ring seals (A) and backup rings (B) must be fitted in brake piston (44) against the flanged hub (31), paying...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE Insert the springs (45) into the holes in the brake piston Install the special tool (6689960310) on the flanged hub (44) marked previously. (31) and turn the screw until it compresses the springs (45). Insert the spring retainer disc (46).

  • Page 100: Final Test And Reinstallation

    SECTION 3 - CHASSIS & TURNTABLE Final Test and Reinstallation Open the flow valve and release the brake with the pilot pressure of 50 bar. Check the product by remounting it to the machine. Close the flow valve and keep the brake released 3 min- utes or longer.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Figure 3-23. Drive Hub Special Tools - Sheet 1 of 4 31215064 3-47...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE Figure 3-24. Drive Hub Special Tools - Sheet 2 of 4 3-48 31215064...
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE Figure 3-25. Drive Hub Special Tools - Sheet 3 of 4 31215064 3-49...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE Figure 3-26. Drive Hub Special Tools - Sheet 4 of 4 3-50 31215064...

  • Page 105: Drive Hub - If Equipped With Reggiana Riduttori

    SECTION 3 - CHASSIS & TURNTABLE 3.14 DRIVE HUB - IF EQUIPPED WITH REGGIANA Wrench for M6, M8, M10 socket head screws and 1/4" G plug. RIDUTTORI Socket wrench for M6 hexagonal screw. NOTE: After SN 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Ø210 Ø130 Ø30 M-1321 High Strength High Strength Threadlocking compound Threadlocking compound N° 4 Hole to 90° Ø40 M-1320 Ø197.5 Ø210 Figure 3-29. Bearing Spacer Mounting CO16117 Figure 3-30. Assembly Diagram 1 3-52 31215064...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE M- 1316 M- 1020 M- 1317 M- 1317 N° 4 M- 1317 216.5 Ø11 Ø230 10x45° M- 1316 Ø17 M- 1317 M- 1317 Figure 3-33. Anti-rotation Block M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-31.
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-35. Assembly Diagram 2 3-54 31215064...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE M- 1546 M- 1548 Ø105 Ø93.5 Ø48 +0.1 Ø20 Ø46 +0.2 Ø8.5 Ø13.5 Ø40.5 Ø46 M- 1547 Ø39.5 Ø20 -0.1 VTCEI M8X16 n°1 Figure 3-36. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 31215064 3-55...

  • Page 110: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly Release the screws from the release cover and pull the pin out. Remove the plugs and pour the lubricant in a container. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring. Release the screws to disassemble the motor flange tak- ing care not to damage the O-Ring.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 3-58 31215064...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 31215064 3-59...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE Loosen the M10x25 flathead socket screws and remove Loosen the M6x6 socket headless screws and also the planetary ring without damaging the O-Ring. remove the 3/16" balls. Remove the release joint together with the spring. Loosen the ring nut using the special wrench.

  • Page 114: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Disassemble the Ø160 inner snap ring and pull the Assembly spring holder spacer out. Remove the springs and using a compressed air jet in the brake control hole pull the Make sure all the component parts of the wheel gear are piston out of the spindle.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Fit the brake sealing rings O-Ring and PARBAK (lubri- Prepare the hub support, mounting on it the two roller cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner the brake discs making sure to centre them on the spin- track.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Now check the unit roll torque and proceed in the fol- Using the special tool and hammer make four dents on lowing order: the spindle thread by the M6 holes of the ring nut. By keeping the spindle locked, apply a setting preload by tightening the ring nut at 40daNm, turn completely the hub support twice using the special wrench to...
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE Fit the bearings onto the 3rd stage planetary gears and Place the hub onto the support making the two holes using a spacer mounting mount everything on the spin- coincide for tightening the M10x25 flathead socket dle pins.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE Prepare the closing cover fitting the O-ring 5-582 suit- Fit the O-Ring 2-163 suitably greased, onto the motor coupling flange S-D LC/KC. Mount the flange on the ably greased and lock it with the shimming ring. Lubri- spindle with 6 M8x25 socket capscrews at the torque of cate the bearings.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE MAE36280 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-39. Swing System 3-66 31215064...

  • Page 120: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened Roll and Leak Testing beyond their specified torque.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE 1001228488-B MAE37600B Figure 3-40. Swing Drive - Sheet 1 of 2 3-68 31215064...
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 11. Spacer 21. Pinion 31. Seal 41. O-ring 2. Ring 12. O-Ring 22. Ring 32. O-Ring 42. Cover 3. Oil Seal 13. Planetory Gear 23. Spacer 33. Steel Disc 43. Screw 4. Bearing 14.

  • Page 123: Swing Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING BRAKE HYDRAULIC/MECHANICAL To check brake release, connect an appropriate hydraulic pres- Pre-Installation Checks sure supply set to the required level up to a maximum of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. MECHANICAL Checks prior to assembly, the mounting features and other Remove hydraulic supply from brake, checking to ensure that...

  • Page 124: Installation

    SECTION 3 - CHASSIS & TURNTABLE Installation Remove springs (8). Take note of quantity and orienta- tion of springs. Position 1-off gasket (5) over male pilot on brake housing (4). Should it be necessary to replace ball bearing (10) or Locate brake shaft (1) and secure brake in position using 2-off shaft seal (12), reverse remainder of brake sub-assembly, 1/2”...

  • Page 125: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Clean all parts thoroughly. Reverse procedure previously outlined in Dismantling instruc- tions taking particular care with. a. Assembly of shaft seal (12). b. Assembly of bearing (10). c. Quantity and orientation of springs (8). d.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 8. Cylinder 15. O-Ring 2. Housing 9. Piston 16. Backing Ring 3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring 4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring 5.
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING MOTOR Disassembly and inspection Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing 2. End Cover 8C. Vane 16. Seal 3. Seal Ring-Commutator 8D. Stator Half 17. Backup Washer 4. Seal Ring 9. Wear Plate 18. Housing 5.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Thoroughly wash end cover (2) in proper solvent and Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into blow dry. Be sure the end cover valve apertures, includ- ring groove until seal ring is lifted out and discard seal ing the internal orifice plug, are free of contamination.
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disas- sembly for service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Remove drive link (10) from coupling shaft (12) if it was Remove coupling shaft (12), by pushing on the output not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur- link for cracks and worn or damaged splines.
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Remove thrust bearing (15) and thrust washer (14) Remove housing (18) from vise, invert it and remove and Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is ment of retained rollers.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of the two thrust washers (14) and thrust bearing (15).
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Place housing (18) assembly into a soft jawed vise with Assemble thrust washer (14) then thrust bearing (15) the coupling shaft bore down, clamping against the that was removed from the Torqlink™. mounting flange. NOTE: Torqlinks™...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID.
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the original rotor-drive link spline contact.
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. If shuttle valve components items #21, were removed Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one onto the manifold.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. Assemble the 5 or 7 special bolts (1) and screw in finger tight.
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 3.18 PROCEDURE FOR SETTING GEAR BACKLASH Pre-torque capscrews (shown below) to 90 ft-lb (122 Nm) with High Strength Threadlocking Compound. Set backlash to 0.010 to 0.015" using the following pro- cedure. Place shim (JLG PN 4071041) between pinion and bear- ing on bearing high spot.
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Tighten jam nut (shown below) wit High Strength 3.19 SWING DRIVE LUBRICATION Threadlocking Compound. MAE37630 MAF24760 Swing Gearbox/Brake Fill Port Torque capscrews shown in step 5 to 660 ft-lb (896 Nm). Swing Gearbox/Brake Drain Port Remove shim and discard.
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE 3.20 SWING BEARING Check the turntable to bearing attach bolts as follows: Turntable Bearing Mounting Bolt Condition Check a. Elevate the fully retracted main boom to full eleva- tion. b. At the position indicated on Figure 3-50. try to insert the 0.0015”...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE Figure 3-48. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 3-92 31215064...
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 31215064 3-93...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE If the measurement is greater than 0.094 in. (2.387 mm), the swing bearing should be replaced. If the measurement is less than 0.094 in. (2.387 mm), and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the fol- lowing: a.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE Turntable/Swing Bearing Removal It may be necessary to disconnect additional lines to gain access to certain fittings. Cap or plug all openings. The following procedure was accomplished using two over- head cranes with the jib assembly and the boom removed prior to un-decking the turntable.
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE 3-96 31215064...
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE 31215064 3-97...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE 3-98 31215064...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE 31215064 3-99...
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE Lay the jib control valve aside on the jib. Secure it in Remove the bolt and keeper pin securing the jib level cylinder pivot pin and remove the pin. Place blocking or place so it does not fall. a soft material under the cylinder rod to protect the rod surface from being scratched.
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Attach an adequate supporting device to the jib to sup- At the rear of the turntable, tag and disconnect all wir- ing harnesses that run from the powertrack to the port its weight. Remove the bolt and keeper pin secur- ground control station.
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE Have a container or absorption material ready to catch Remove the cover from the rear of the boom and dis- residual hydraulic fluid. Disconnect the telescope hoses connect the wiring harnesses and hoses running from from the bottom of the hydraulic control valve.
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE Using the Main Lift Crackpoint option under the Calibra- NOTE: To assist in determining when the lift cylinder is properly tions menu on the JLG Analyzer, lift the boom enough to supported, use the JLG Analyzer and select Diagnostics > access the boom lift cylinder rod pivot pin.
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE Disconnect the negative battery terminal from the bat- Remove the attaching hardware securing the side of the tery. hood. Place a container under the machine to catch escaping Remove the attaching hardware securing the top of the hydraulic fluid.
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE Tag and disconnect the hoses from the top of the swivel. NOTE: The complete swing drive assembly weighs approximately 290 lb (132 kg). Cap or plug all openings. Use a tie strap to secure the hoses together.
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE NOTE: The turntable assembly weighs approximately 20,650 lb Lift the turntable assembly off of the swing bearing and (9370 kg). place it on adequate supports. Using the lifting lugs and the center support, attach a lifting device to the front and rear of the turntable to support its weight.
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE Install lifting eyes into the swing bearing for removal. Turntable/Swing Bearing Installation Remove the attaching hardware securing the swivel and lay it off to the side. NOTE: The swing bearing weighs approximately 300 lb (136 kg). Attach an adequate lifting device to the swing bearing and remove it from the frame.
  • Page 161 SECTION 3 - CHASSIS & TURNTABLE Locate the high spot on the swing bearing. This will be Install grease fittings into the bearing and also install marked by blue paint and two X’s on the bearing teeth. two pins to facilitate turning the bearing by hand and for alignment of the turntable.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE Lift the turntable into place on the bearing using the Connect the hoses to the top of the swivel as tagged previously installed guide pins for alignment. during removal. Secure the hoses together with a tie strap as shown.
  • Page 163 SECTION 3 - CHASSIS & TURNTABLE Position the swing drive mounting bolts and backlash Lift the boom from its supports. adjusting shim, JLG PN 4071041. Set backlash following the procedures in this section. Attach the swing bearing remote lubrication lines to the turntable.

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