JLG 800A Service And Maintenance Manual
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JLG 800A Service And Maintenance Manual

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Service and Maintenance Manual
Model
800A
800AJ
S/N 0300183034 to Present
3121628
February 08, 2019 - Rev F
AS/NZS

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Summary of Contents for JLG 800A

  • Page 1 Service and Maintenance Manual Model 800A 800AJ S/N 0300183034 to Present 3121628 February 08, 2019 - Rev F AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - September 16, 2016 Revised B - October 13, 2016 Revised C - September 05, 2017 Revised D - May 30, 2018 Revised E - June 29, 2018 - Revised Covers Revised F - February 08, 2019 3121628...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment .......
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Inflation.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.15 Generator..................3-78 Maintenance Schedule .
  • Page 8 Capacity Indicator System (800A only) ........
  • Page 9 Dual Capacity Angle Limit Switch (800A only) ........
  • Page 10 Platform Level Cylinder (800A - SN 0300245051 to Present) ....... .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Cylinder Removal And Installation ..............5-129 Main Boom Telescope Cylinder Removal .
  • Page 12 To Connect the JLG Control System Analyzer ........
  • Page 13 Swing Bearing Removal (800A) ........
  • Page 14 Deutz TD2.9L4 Engine Installation (800A) - Sheet 1 of 8 .......
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-105. Filter Lock Assembly ................3-184 3-106.
  • Page 16 Platform Level Cylinder (800A - SN 0300245051 to Present) ....... .
  • Page 17 Master Cylinder (800A) ........
  • Page 18 Main Boom Telescopic Cylinder (800A SN 0300245051 to Present) ....... .
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-188. Pressure Compensation Control Adjustment ............5-139 5-189.
  • Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-8. Phoenix Contact M12................7-6 7-9.
  • Page 21 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Capacities .
  • Page 22 Machine Configuration Programming Information (Software Version P6.22)......6-9 800A Machine Configuration Programming Settings (Software Version P6.22)......6-17 800AJ Machine Configuration Programming Settings (Software Version P6.22).
  • Page 23 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 24: Specifications

    36 ft. 6 in. (11.13 m) RATING RANGE Wheel base 10 ft. (3.06 m) 15-625 pneumatic 95 psi (6.5 bar) Platform Height - 800A 15-625 foam-filled Above Grade +80 ft.(24.38 m) 18-625 foam-filled Below Grade -15 ft. 7 in. (4.75 m) Platform Height - 800AJ 1.4 ENGINE DATA...
  • Page 25 SECTION 1 - SPECIFICATIONS Table 1-8. Ford 2.5L DF, MSG-425 Table 1-5. Deutz TD 2.9 Specifications Fuel Gasoline/LP Gas Fuel Ultra Low Sulfur Diesel (15 ppm) Oil Capacity 7 qt (6.6 L) Output 67 hp (50 kW) Coolant Capacity 0.63 Gallons (2.4 L) Torque 173 ft.lbs.

  • Page 26: Component Data

    SECTION 1 - SPECIFICATIONS 1.5 COMPONENT DATA 1.6 TORQUE REQUIREMENTS Table 1-12. Torque Requirements Drive System DESCRIPTION TORQUE VALUE (DRY) INTERVAL HOURS Table 1-9. Drive System Specifications Drive Motor Displacement Wheel Bolts 300 ft. lbs. 2.439 cu. in. max. 1.347 cu. in. min. (407 Nm) (40 cc max.

  • Page 27: Hydraulic Oil

    Excel 32. ISO Viscosity Grade 32/46 Specific Gravity .922 NOTE: Aside from JLG recommendations, it is not advisable to mix Pour Point, Max -25°F (-32°C) oils of different brands or types, as they may not contain Flash Point, Min. 428°F (220°C) the same required additives or be of comparable viscosi- ties.

  • Page 28: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS Table 1-18. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Table 1-19. Major Component Weights Pour Point -76°F (-60°C) MAJOR COMPONENTS LBS. Flash Point 217°F (103°C) VISCOSITY Platform & Control Console at 40° C 25.8 cSt Main Boom (Inc.

  • Page 29: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS Critical Stability Weights DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUN- TER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY.
  • Page 30 SECTION 1 - SPECIFICATIONS 8,9,10,12 Figure 1-1. Maintenance and Lubrication Diagram 3121628...

  • Page 31: Operator Maintenance

    Synthetic-Based Oil, Non-Flammable. Withstands temperatures within - Interval - Every 2 years or 1200 hours of operation Lube® 45° to 450°F (-43° to 232° C). JLG P/N 3020042. 3. Wheel Drive Hub LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- MAL CONDITIONS.
  • Page 32 SECTION 1 - SPECIFICATIONS 4. Swing Drive Hub 7. Hydraulic Tank Lube Point(s) - Fill Cap Lube Point(s) - Level/Fill Plug Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L) Capacity - 43 oz. (1.3 L) System Lube - 90w80 Gear oil Lube - HO Interval - Check level every 3 months or 150 hours of Interval - Check Level daily;...
  • Page 33 Comments - Check level daily/Change in accordance with engine manual. 9. Oil Change w/Filter - GM Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual.
  • Page 34 SECTION 1 - SPECIFICATIONS 10. A. Fuel Filter - Deutz D2011 D. Fuel Filter - Deutz TD 2.9 L4 China III Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation B. Fuel Filter - Deutz TD2.9 (On Hydraulic Tank) Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual 11.
  • Page 35 SECTION 1 - SPECIFICATIONS 13. Air Filter 14. Fuel Filter (Propane) - GM Engine Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Filter Lube Point(s) - Replaceable Element Replacement. Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator B.
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121628 1-13...
  • Page 37 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5) 1-14 3121628...
  • Page 38 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121628 1-15...
  • Page 39 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 4 of 5) 1-16 3121628...
  • Page 40 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 3121628 1-17...
  • Page 41 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 42: General

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

  • Page 43: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...

  • Page 44: Bearings

    SECTION 2 - GENERAL Bearings 2. Disassemble and reassemble parts on clean work sur- face. Clean all metal parts with non-flammable cleaning 1. When a bearing is removed, cover it to keep out dirt and solvent. Lubricate components, as required, to aid abrasives.

  • Page 45: Hydraulic Oil

    2. JLG recommends Mobilfluid 424 hydraulic oil, which has the service container. Always clean the mesh element of an SAE viscosity of 10W-30 and a viscosity index of 152.

  • Page 46: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST Table 2-2. Cylinder Drift Max. Acceptable Drift Theory Cylinder Bore Diameter in 10 Minutes When a hydraulic cylinder is supporting a load, cylinder drift inches inches may occur as a result of any of the circumstances below: 76.2 0.026 0.66...

  • Page 47: Pins And Composite Bearing Repair Guidelines

    2. 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.
  • Page 48 SECTION 2 - GENERAL 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 1, 2 Pivot Pins and Pin Retainers 1, 2 1, 2 Sheaves, Sheave Pins...
  • Page 49 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 50 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...
  • Page 51 -10°F(-23° C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL -20°F(-29° C) AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30°F(-34° C) GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER).
  • Page 52 -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) .
  • Page 53 SECTION 2 - GENERAL 4150548 E Figure 2-3. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425 2-12 3121628...
  • Page 54 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 55: Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the air load). pressure that is stenciled on the side of the JLG product or rim Unless specifically approved by JLG Industries Inc. do not decal for safe and proper operational characteristics.

  • Page 56: Lockout Cylinder Bleeding

    SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence: 3.2 LOCKOUT CYLINDER BLEEDING 1. Start the engine. 2. Position the turntable to the normal stowed position. 3. Attach clear tubing to bleeder valve nipple. 4. Position a small bucket/bottle in front of the lockout cyl- inder bleeder valve and insert clear tubing.
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 10, A 10, A 10, A 10, A 10, A 10, A A. Apply JLG Threadlocker P/N 0100011 1001151037 C 1001154584 D 1. Oscillating Axle 4. Keeper Pin 7. Stop Plate 10. Bolt 2. Fixed Axle 5.
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 5, A 5, A 5, A 5, A A. Apply JLG Threadlocker P/N 0100011 1001151034 F 1001151035 E 1. Drive Spindle 4. Kingpin 7. Composite Bearing 10. Keeper PIN 2. Steer Cylinder 5. Bolt 8.

  • Page 59: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE 3.3 OSCILLATING AXLE LOCKOUT TEST 9. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel. 10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- is on top of block.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Lockout Cylinder 4. Drive Motor 2. Flow Drive Valve 5. Drive Hub 3. Swivel Figure 3-3. Chassis Component Location 3121628...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1. Ground Control Box 5. Auxiliary Power Pump 9. Generator 13. Fuel Tank 2. Headlight 6. Swivel 10. Deutz Module & Diagnostic Connector 14. Hydraulic Oil Tank 3. Auxiliary Power Relay 7. Drive Pumps 11.

  • Page 62: Drive Hub (Torque)

    SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE HUB (TORQUE) 3. Inspect bearing mounting surfaces on spindle, hub, input shaft and carrier. Replace components as neces- sary. Disassembly 4. Inspect all geared components for chipped or broken teeth and for excessive or uneven wear patterns. 1.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE d. Remove needle rollers (15) from cluster gear bore. k. Place second set of needle rollers into cluster gear. e. Remove spacer (16) from cluster gear bore and l. Apply grease or petroleum jelly to tang side of two remove second set of needle rollers (15).

  • Page 64: Assembly

    SECTION 3 - CHASSIS & TURNTABLE o. Drive anti-roll pin flush into carrier hole, locking 2. Place bearing cone (4) into bearing cup (3) in small end planet shaft into place. of hub. p. Repeat steps (h) through (o) for remaining two clus- 3.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 5. Place bearing cone (6) over end of spindle and into 8. The disengage spacer and spring are installed into the bearing cup. counterbore of the spindle. 9. Install retaining ring into input shaft groove to secure 6.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 11. Install thrust washers and thrust bearing (39, 40) on the 14. Place input shaft assembly (35) into spindle bore with portion of the spindle which extends into the internal unsplined end facing out. gear.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 17. Place o-ring (22) into cover assembly counterbore. Use 20. While holding ring gear, and cluster gears in mesh, place petroleum jelly or grease to hold o-ring in place. Slight small side of cluster gears into mesh with internal gear. stretching of o-ring may be necessary to insure proper On ring gear, locate hole marked ‘X’...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 23. Install thrust washers and thrust bearing (39, 40) into 27. Install bolts (41) in remaining holes. Torque bolts to carrier counterbore. 47 ft. lbs. (64 Nm). 24. Place o-ring (22) into cover assembly counterbore. Use 28.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 1. Spindle 2. Seal 2. Seal 3. Bearing Cup 3. Bearing Cup 4. Bearing Cone 4. Bearing Cone 5. Bearing Cup 5. Bearing Cup 6. Bearing Cone 6. Bearing Cone 7. Hub 7.

  • Page 70: Drive Brake

    SECTION 3 - CHASSIS & TURNTABLE DRIVE BRAKE Assembly 1. Lightly lubricate rotary shaft seal (12) and assemble to Disassembly housing (2) taking care not to damage seal lip. 1. Supporting brake:, remove the six socket head cap- 2. Apply ring of Loctite 641 or equivalent adhesive to full screws and washers (13 &...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug 2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural) 3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23.

  • Page 72: Drive Motor

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

  • Page 73: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve 2. Using a 1/4 in hex wrench remove plug (3). 3. Remove O-rings (4, 5, and 6). REMOVAL 4. Using pliers, remove centering springs (7, 8, and 9). 1. Using a 11/16 in internal hex wrench remove plug (1) 5.

  • Page 74: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-2. 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 the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.

  • Page 75: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 23. End Cap 25. Valve Plate 24. O-ring 26. End Cap 27. O-ring Figure 3-12. End Cap 28. O-ring 29. Angle Stop 13. Using an 8 mm internal hex wrench, remove the endcap 30.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring (30) 20. Turn the housing over and remove the snap ring (32) from the housing. retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34).
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-17. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer 23.

  • Page 79: Inspection

    SECTION 3 - CHASSIS & TURNTABLE SLIPPERS Inspect the running surface of the slippers. Replace any piston RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES assemblies with scored or excessively rounded slipper edges. FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO Measure the slipper foot thickness.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. Cylinder Block Measurements Measurement L25 mm (in.) L30 mm (in.) L35 mm (in.) K38 mm (in.) K45 mm (in.) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) Minimum Cylinder Block Height (A) Cylinder Block Surface Flatness 0.002 0.002...

  • Page 81: Assembly

    SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate 1. Install new O-ring (1) and piston seal (2) to the servo pis- the bearings while feeling for uneven movement. Bearings ton (3). Install the piston seal over the O-ring. should spin smoothly and freely.
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE 4. Turn the block over and install the retaining ring (8), hold-down pins (9), and ball guide (10) to the cylinder block. RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO 5.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated. ing onto shaft with lettering facing out. Lubricate bear- Install the cylinder kit (19) onto the shaft. Install with the ing rollers.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the endcap. Install 15. Install the endcap (25) onto the housing with the end- the bearing with letters facing out. Press until bearing cap screws (26). Check to ensure the endcap will prop- surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap sur- erly seat onto the housing without interference.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation Press seal into housing until it bottoms out.

  • Page 86: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). Initial Start-up Procedures Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage incurred dur- ing shipping.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE FRAME REF. 1001156136 A 1. Swing Drive 4. Swing Bearing 7. Grease Line 2. Swing Motor 5. Outer Race Bearing Bolt 8. Bolt 3. Inner Race Bearing Bolt 6. Turntable Lock Pin 9. Jam Nut Figure 3-30.

  • Page 88: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll, Leak And Brake Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 89: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32). NOTE: Refer to Figure 3-31. 5. Remove O-ring Plugs (23) from Motor Control Valve (32). 1.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 1P. O-ring Plug 30. Elbow Fitting 6. Hydraulic Brake 31. Hydraulic Motor 21. Hex Bolt 32. Motor Control Valve 22. Lockwasher 35. Hydraulic Tubing 23. Plug Figure 3-31. Motor Control Valve 3-36 3121628...

  • Page 91: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 4. Remove the Springs (8L) from the piston. 5. Apply less than 50 psi (3.45 bar) air to the “brake port” to NOTE: Refer to Figure 3-32. remove Brake Piston (8A). 1.

  • Page 92: Main Drive Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly 5. Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Subassembly. NOTE: Refer to Figure 3-33. 6. Remove Ring Gear (4) from Housing (1G). 7. Remove O-ring (5) from between Ring Gear (4) and 1.

  • Page 93: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G). NOTE: Refer to Figure 3-34. NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by 1.

  • Page 94: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E). NOTE: Refer to Figure 3-35. 3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).

  • Page 95: Hub-Shaft Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-35. NOTE: Refer to Figure 3-34. 1. Apply a liberal Coat of grease to the bore of Cluster Gear 1. Press Bearing Cup (1C) into Housing (1G) taking care to (3F).

  • Page 96: Main Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing. NOTE: Refer to Figure 3-33. 9.

  • Page 97: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-32. NOTE: Refer to Figure 3-31. 1. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. 1. Lay assembly down with motor ports facing up. Remove splines) into bore of Brake Housing (6).
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 1A. Output Shaft 1G. Housing 2. Internal Gear 5A. O-Ring 12. Bolt 1B. Lip Seal 1H. Thrust Washer 3. Carrier Assembly 6. Brake Housing 13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4. Ring Gear 8.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 6. Brake Housing 8L. Spring 35. Tube 108. Rotor Set 117. Back-up Washer 8A. Piston 21. Thrust Washer 101. Bolt 109. Wear Plate 118. Housing 8D. 0-Ring 22. Lock washer 102. End Cover 110. Drive Link 119.

  • Page 100: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING MOTOR Disassembly and inspection 1. Place the Torqmotor™ 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 101 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8. Rotor Set 12. Coupling Shaft 18A. O-Ring 2. End Cover 8A. Rotor 13. Bearing/Bushing, Inner 19. Bearing/Bushing, Outer 3. Seal Ring-Commutator 8B. Stator or Stator Vane 14. Thrust Washer 20. Dirt & Water Seal 4.
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve com- inspection of end cover, commutator, manifold, and rotor ponents, remove the two previously loosened plugs set. (21). 7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 9. Remove manifold (7) and inspect for cracks surface scor- NOTE: The rotor set (8) components may become disassembled ing, brinelling or spalling. Replace manifold if any of during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pen- these conditions exist.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets 14. Check exposed portion of coupling shaft (12) to be sure of seven vanes (8C & 8E) as shown in the alternate con- you have removed all signs of rust and corrosion which struction TG rotor set assembly view, check the rotor lobe might prevent its withdrawal through the seal and bear-...
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and 0.020 inches (0.51 mm) diametrically, replace coupling discard seal shaft. 20. A blind hole bearing or seal puller is required. NOTE: A slight “polish”...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 22. 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 107: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ 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 108 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqmotor™ 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 109 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the ORIGINAL DESIGN LARGE FRAME, TF & TG TORQMOTORS™ THAT DO NOT HAVE mounting flange. BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- tant grease has been applied to the lower (outer) hous- ing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 10. Install drive link (10) the long splined end down into the 12. Apply a small amount of clean grease to a new seal ring coupling shaft (12) and engage the drive link splines (4) and assemble it into the seal ring groove on the wear into mesh with the coupling shaft splines.
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 14. Apply clean grease to a new seal ring (4) and assemble it 16. Apply grease to a new seal ring (4) and insert it in the in the seal ring groove in the rotor set contact side of seal ring groove exposed on the manifold.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 bolt end cover bolt hole relationship to housing port bosses.
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts bolts after the other bolts are in place.

  • Page 115: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. 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 116: Swing Hub Installation

    Jam Nut Jack Bolt 3. Apply JLG Threadlocker P/N 0100019 and torque pivot bolt to 205 ft. lbs. (280 Nm) (shown below). 7. Apply JLG Threadlocker P/N 0100019 and torque jack bolt 50 ft. lbs. (68 Nm).

  • Page 117: Swing Drive Lubrication

    SECTION 3 - CHASSIS & TURNTABLE 9. Torque mounting bolts to 340 ft. lbs. (Nm). 3.10 SWING HUB REMOVAL 1. Disconnect all wiring harness terminals connected to the swing motor. 2. Gently loosen the set screw. Do not remove. 3. Remove the pivot bolt using Allen Wrench. Jam Nut Jack Bolt 10.

  • Page 118: Swing Bearing

    NOTE: This check is designed to replace the existing bearing bolt head and hardened washer at the arrow indicated torque checks on JLG Lifts in service. This check must be position. performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Swing Bearing Tolerance Boom Placement (Sheet 1 of 2) 3121628 3-65...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE 3-66 3121628...

  • Page 121: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-42. Swing Bearing Tolerance Measuring Point Figure 3-41. Swing Bolt Feeler Gauge Check Swing Bearing Replacement Wear Tolerance REMOVAL 1. From the underside of the machine, at rear center, with the main boom fully elevated and fully retracted, and 1.

  • Page 122: Swing Bearing Torque Values

    P/N 0100019. ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED. 2. Inner Race - 190 ft. lbs. (260 Nm) w/JLG Threadlocker P/N 0100019. 2. Apply a light coating of JLG Threadlocker P/N 0100019 3.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 3121628 3-69...
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE 3-70 3121628...

  • Page 125: Tilt Indicator System

    SECTION 3 - CHASSIS & TURNTABLE FRONT NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-45. Swing Bearing Torque Sequence 3.12 TILT INDICATOR SYSTEM 3.13 SPARK ARRESTER CLEANING INSTRUCTIONS 1. Remove the cleanout plug in the bottom of spark 1.

  • Page 126: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.14 ROTARY COUPLING 7. Assemble lip seals (2) in direction shown in Figure 3-46., Rotary Coupling Seal Installation. Use the following procedure to install the seal kit. 8. Reassemble O-ring (4). 1. If not already removed, remove the axle oscillation valve 9.
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 6. Thrust Ring 2. Seal 7. Snap Ring 3. Housing 8. Valve Block (Axle Oscillation) 4. O-ring 9. O-ring 5. Seal 10. Proximity Switch Figure 3-47. Rotary Coupling Cutaway 3121628 3-73...
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE Figure 3-48. Rotary Coupling Port Location (7 Port) 3-74 3121628...
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Figure 3-49. Rotary Coupling Port Location (9 Port) 3121628 3-75...
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE 1. JLG Threadlocker 6. Rotary Coupling 11. Ring 16. O-ring 21. Bolt 2. Bolt 7. Spool 12. Seal 17. Valve 22. Nut 3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 23. Washer 4.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Coupling Port Information Table (9 port) Table 3-8. Coupling Port Information Table (7 port) Operating Proof Operating Proof Port Port Port Size Description Pressure Pressure Outlets Port Size Description Pressure Pressure Outlets PSI (Bar) PSI (Bar) PSI (Bar)

  • Page 132: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.15 GENERATOR Overload Protection Maintenance Schedule STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT EVERY 250 HOURS BREAKER. Every 250 hours of operation, check the drive belt for proper tension. The circuit breaker protects the generator windings from over- load.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2.

  • Page 134: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-10. Troubleshooting Trouble Remedy No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform. Check and secure electrical connections at platform, generator, and control box. Be sure all equipment is turned off when starting unit.

  • Page 135: Generator Disassembly And Assembly

    SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly 2. Remove brush holder assembly. 3. Disassemble generator parts shown in Figure 3-52. Refer to Figure 3-53. and Figure 3-54. to determine if trouble is in stator, rotor, control box, or combination of these compo- 4.
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Figure 3-53. Generator Troubleshooting Circuit Diagram (Sheet 1 of 2) 3-82 3121628...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Figure 3-54. Generator Troubleshooting Circuit Diagram (Sheet 2 of 2) 3121628 3-83...
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE 3-84 3121628...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 3121628 3-85...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Figure 3-57. Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2) 3-86 3121628...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE Figure 3-58. Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2) 3121628 3-87...

  • Page 142: 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 3-11.

  • Page 143: Auxiliary Power System

    SECTION 3 - CHASSIS & TURNTABLE 3.16 AUXILIARY POWER SYSTEM The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or The auxiliary power system is intended as a secondary means engine fail.

  • Page 144: Deutz Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.17 DEUTZ ENGINE 1. Fan 9. Turbocharger 17. Rear Engine Mount 25. Flywheel 33. Oil Filter 2. Adapter 10. Exhaust Pipe 18. Coupling 26. Fuel Filter 34. Belt Tensioner 3. Drive Belt 11. Spark Arrester 19.
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE NOTE: HOITCH PIN SHOWN HERE FOR CLARITY 1. Radiator Assembly 5. Coolant Level Sensor 9. Battery Relay 13. Hitch Pin 2. Coolant Recovery Tank 6. Fuel Pump 10. Power Module Relay 14. Engine Tray 3.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 1001185670-E MAF07860E Figure 3-62. Deutz TD2.9L4 Engine Installation (800A) - Sheet 1 of 8 3-92 3121628...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL A 1/2" FUEL LINE FROM TANK TO PRE-FILTER ROUTE FUEL LINE FROM TANK AND PUMP THRU SIDE SHEET HANGER 3/8" FUEL LINE FROM PUMP TO FINE FILTER ON ENGINE DETAIL A 1001185672-E MAF07440E Figure 3-63.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL B ROUTE SUPPLY FUEL LINE AS SHOWN ROUTE RETURN FUEL LINE AS SHOWN DETAIL B 1001185670-D 1001185672-E MAF07450 Figure 3-64. Deutz TD2.9L4 Engine Installation - Sheet 3 of 8 3-94 3121628...
  • Page 149 SIDE SHEET OPENING AND AROUND PIVOT PIN, UP OVER THE ENGINE TRAY AND UNDER HYD PUMPS TO THE FINE FUEL FILTER INLET DETAIL C 1001185670-D MAF07950D Figure 3-65. Deutz TD2.9L4 Engine Installation (800A) - Sheet 4 of 8 3121628 3-95...
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL C ROUTE RETURN FUEL LINE THRU SIDE SHEET OPENING AND AROUND PIVOT PIN THRU SIDE SHEET HANGER AND THEN RUN THRU P-CLAMP AT ENGINE MOUNT TO ENGINE ROUTE SUPPLY FUEL LINE THRU SIDE SHEET OPENING AND AROUND PIVOT PIN, UP OVER THE ENGINE TRAY AND UNDER HYD PUMPS TO...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE PLUG THE BATTERY HEATER CORD, THE TANK IMMERSION HEATER CORD AND THE CABLE EXTENSION CORD INTO THIS END OF 3-WAY EXTENSION CORD. ENSURE PLUG STAYS UNDER HOOD. 1001185672-E MAF07230E Figure 3-67. Deutz TD2.9L4 Engine Installation (800AJ) - Sheet 6 of 8 3121628 3-97...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE SUPPLY LINE TO FUEL LINE FILTER (3350mm) SUPPLY LINE FROM TANK 1001185670-D 1001185672-E MAF07460 Figure 3-68. Deutz TD2.9L4 Engine Installation- Sheet 7 of 8 3-98 3121628...
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE 3121628 3-99...
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE PLUG INTO FUEL PUMP AND FILTER ASSEMBLY MOUNTED ON SIDE SHEET VENT LINE SUPPLY LINE FUEL RETURN LINE VIEW A MAE19170B Figure 3-70. Deutz TD2.9L4 China III Engine Installation - Sheet 1 of 7 3-100 3121628...
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE SHIPPED WITH BASE ENGINE INSTALL ON TURNTABLE SIDE SHEET SEE DETAIL B DETAIL B MAE19180B Figure 3-71. Deutz TD2.9L4 China III Engine Installation - Sheet 2 of 7 3121628 3-101...
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE RETURN FUEL LINE FUEL FILTER SHOWN TRANPARENT FOR CLARITY SUPPLY FUEL LINE TO FINE FUEL FILTER REFERENCE FOR HOSE ROUTING MAE19190B Figure 3-72. Deutz TD2.9L4 China III Engine Installation - Sheet 3 of 7 3-102 3121628...
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE SUPPLY LINE TO FINE FUEL FILTER SUPPLY LINE FROM TANK MAE19200B Figure 3-73. Deutz TD2.9L4 China III Engine Installation - Sheet 4 of 7 3121628 3-103...
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL E 1/2" FUEL LINE FROM TANK TO PRE-FILTER ROUTE FUEL LINE FROM TANK AND PUMP THRU SIDE SHEET HANGER 3/8" FUEL LINE FROM PUMP TO FINE FILTER ON ENGINE DETAIL E MAE19210B Figure 3-74.
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL F ROUTE SUPPLY FUEL LINE AS SHOWN ROUTE RETURN FUEL LINE AS SHOWN DETAIL F MAE19220B Figure 3-75. Deutz TD2.9L4 China III Engine Installation - Sheet 6 of 7 3121628 3-105...
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL G SEE DETAIL D ROUTE RETURN FUEL LINE THRU SIDE OPENING AND AROUND PIVOT PIN THRU SIDE SHEET HANGER AND THEN RUN THRU P-CLAMP AT ENGINE MOUNT TO ENGINE DETAIL D ROUTE SUPPLY FUEL LINE THRU SIDE SHEET OPENING AND AROUND PIVOT PIN, UP OVER THE ENGINE TRAY AND UNDER HYD PUMPS TO...
  • Page 161 SECTION 3 - CHASSIS & TURNTABLE 1001154238-E MAF07210E 1. Fan 6. Deutz D2011L04 Engine 10. Engine Support 14. Exhaust Pipe 2. Air Intake Gasket 7. Engine Support 11. Pump Assembly 15. Exhaust Tube 3. Air Intake Adapter 8. Engine Support 12.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE 1001154238-E MAF07220E 18. Radiator Mounting 23. Relay 27. Tray 19. Radiator 24. Raley 28. Air Cleaner assembly 20. Air Intake Indicator 25. Lanyard Cable 29. Control Module 21. Battery 26. Hitch Pin 30. Fuel Tank 22.

  • Page 163: Deutz Engine - Td2.9L4

    SECTION 3 - CHASSIS & TURNTABLE 3.18 DEUTZ ENGINE - TD2.9L4 Change Engine Oil 1. Allow engine to warm up. Engine oil should reach NOTE: Refer to engine manufacturer’s manual for detailed oper- approximately 176° F (80° C). ating and maintenance instructions. 2.

  • Page 164: Change Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Change Oil Filter Change Fuel Filters 1. Wipe area around filter to clean any dirt from area. 2. Using a suitable oil filter removal tool, loosen lube oil fil- FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE ter cartridge and spin off.

  • Page 165: Deutz Engine - D2011Lo4

    Power/Emergency Stop switch has been pulled on. The lamp and glow plugs will remain ener- gized for the period of time specified by the setting in the JLG Control System. Engine start shall be disabled during this period.

  • Page 166: Replacing Engine Oil

    SECTION 3 - CHASSIS & TURNTABLE Replacing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-82., Engine Oil Viscosity for the 1. Allow the engine to warm up. The engine oil should proper grade.

  • Page 167: Replacing The Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Replacing the Oil Filter 6. Manually screw in the new filter until the gasket is flush. 7. Hand-tighten filter another half-turn. 8. Check oil level. 9. Check oil pressure. 10. Check the oil filter cartridge and make sure there are no leaks.

  • Page 168: Dual Fuel System

    3.21 DEUTZ EMR 2 The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control Sys- IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT tem are connected by means of separate cable harnesses to the EMR control unit.
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE Figure 3-83. EMR 2 Engine Side Equipment 3121628 3-115...
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE 3-116 3121628...
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE 3121628 3-117...
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE 3-118 3121628...

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