JLG RT2669 Service And Maintenance Manual
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JLG RT2669 Service And Maintenance Manual

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Service and Maintenance Manual
AS/NZS
Models
RT2669
RT3669
ERT2669
ERT3669
PVC 2004
31215923
January 08, 2021 - Rev A

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Summary of Contents for JLG RT2669

  • Page 1 Service and Maintenance Manual Models RT2669 RT3669 ERT2669 ERT3669 PVC 2004 31215923 January 08, 2021 - Rev A AS/NZS...

  • Page 3: Section A. Introduction - Maintenance Safety Precautions

    FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE • Use only replacement parts or components that are MANUFACTURER. approved by JLG. To be considered approved, replace- ment parts or components must be identical or equiv- The specific precautions to be observed during mainte- alent to original parts or components.
  • Page 4 INTRODUCTION REVISON LOG A - January 08, 2021 Original Issue 31215923...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................. . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION 2 - GENERAL Machine Preparation, Inspection, and Maintenance ........2-1 General.
  • Page 7 TABLE OF CONTENTS SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Operating Characteristics ..............3-1 Leveling Jacks (If Equipped) .
  • Page 8 TABLE OF CONTENTS Steer Installation ............... . . 3-57 Steer Cylinder Removal .
  • Page 9 TABLE OF CONTENTS SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Cylinders - Theory of Operation ............4-1 Valves - Theory of Operation .
  • Page 10 Connecting the JLG Control System Analyzer........
  • Page 11 TABLE OF CONTENTS SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS General ................. . 7-1 Multimeter Basics .
  • Page 12 TABLE OF CONTENTS viii 31215923...
  • Page 13 LIST OF FIGURES LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location ..............1-3 1-2.
  • Page 14 Joystick Controller............... . 3-66 3-47. Scissor Arm Component - RT2669, ERT2669 Assembly - Sheet 1 of 2......3-68 3-48.
  • Page 15 LIST OF FIGURES 4-21. Lift Relief Valve ................4-32 4-22.
  • Page 16 LIST OF FIGURES 7-8. Connector Assembly Figure 3............. 7-8 7-9.
  • Page 17 LIST OF TABLES LIST OF TABLES TABLE NO. TITLE PAGE NO. Standard UTTO Hydraulic Fluid Specs ........... . .1-4 Premium Hydraulic Fluid (VG 32) Specs .
  • Page 18 LIST OF TABLES LSS Troubleshooting Chart - Measurement Performance........6-8 LSS Troubleshooting Chart - Host System Functionality.

  • Page 19: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS Specification RT2669 RT3369 Single Oscillating Axle 8090 - 8240 lb 9080 - 9230 lb Machine Specifications - For RT (3670 - 3737 kg) (4118.62 - 4186.65 Specification RT2669 RT3369 Dual Oscillating Axle...

  • Page 20: Generator Specifications (If Equipped)

    Steering Information Machine Height 102.8 in. (261.11 96.6 in. (245.36 cm) (Top of Rails/Platform Stowed) Model RT2669, ERT2669 RT3369, ERT3369 Machine Width 69.25 in. (175.89 69.25 in. (175.89 Toe In / Out, (+/-) Max 0.3 in .(7.62 mm) 0.3 in. (7.62 mm)

  • Page 21: Batteries (For Ert)

    SECTION 1 - SPECIFICATIONS Batteries (For ERT) Critical Stability Weights Specification Lead Acid DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF- Voltage FERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: FILLED TIRES, Total 48 V 48 V ENGINE). DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Per Battery Amp Hour Rating 310 Amp @20 hr...

  • Page 22: 1.3 Lubrication

    Viscosity Index not contain the same required additives or be of comparable viscosities. NOTE: When temperatures remain consistently below 20° F (-7° C), JLG Industries recommends the use of a pre- mium cold weather hydraulic fluid (viscosity grade 32). 31215923...
  • Page 23 SECTION 1 - SPECIFICATIONS Table 1-3. Biodegradable Synthetic Hydraulic Fluid (VG 32) Table 1-5. Gear Fluid (80W-90) Specs Specs Recommended Optional Inspection Data SHELL SPIRAX S4 AX MOBILUBE GX Optional Recommended 80W-90 80W-90 MOBIL EAL Inspection Data SHELL NATURELLE ENVIROSYN SAE Grade 80W-90 80W-90...

  • Page 24: 1.4 Hydraulic Pressure Settings

    SECTION 1 - SPECIFICATIONS 1.4 HYDRAULIC PRESSURE SETTINGS 1.6 ENGINE SPECIFICATIONS Table 1-6. Kubota Diesel (D1305-E4B) - For RT Description Setting- RT Setting- ERT Main Relief Pressure 3800 psi (262 bar) 2750 psi (189.6 bar) Emissions CARB, EPA - Tier 4 Final, China Stage III, and EU Stage V Steer Relief Pressure Right 2750 psi (189.6 bar)

  • Page 25: Battery Charger (Ert Machines)

    SECTION 1 - SPECIFICATIONS Table 1-7. Kubota (WG972-GL-E4 - Dual Fuel) - For RT 1.7 BATTERY CHARGER (ERT MACHINES) Emissions CARB, EPA Phase 3 Description Specification Fuel Type: Gasoline - 87 Octane minium Battery Charger Delta-Q - Ethanol/Gas Mix-10% max. Electrical System Voltage (DC) 48V (960 W) - Methanol/Gas Mix-5% maximum...

  • Page 26: 1.8 Elevation/Tilt Limit Settings

    • Elevation Sensor (Arm Angle Tilt Sensor) - High Speed Drive is Cutout when Transport State = FALSE is 5.8 ft. (1.8 m) for RT2669, ERT2669 and 6.7 ft. (2 m) IF THE TILT INDICATOR WARNING LIGHT/ALARM IS ACTIVATED WHEN...
  • Page 27 1001256522-A MAF42060A Figure 1-2. Hydraulic Oil Operating Temperature Specifications (For RT) NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE “HYDRAULIC FLUID OPERATION CHART”MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.
  • Page 28 SECTION 1 - SPECIFICATIONS ENGINE OIL OPERATION NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.

  • Page 29: 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 30: 1.10 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 31 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 32 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 33 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 34 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 35 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 36: 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 37 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 38 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 39 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 40 SECTION 1 - SPECIFICATIONS 1-22 31215923...

  • Page 41: Section 2 - General

    Technician as a person who has successfully completed It is important to establish and conform to a compre- the JLG Service Training School for the subject JLG prod- hensive inspection and preventive maintenance pro- uct model. Reference the machine Service and Mainte- gram.

  • Page 42: Preventive Maintenance And Inspection Schedule

    BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION REPORT” FORM. NOTE: This machine requires periodic safety and mainte- nance inspections by a JLG Dealer. A decal located on the frame affords a place to record (stamp) inspection dates. Notify dealer if inspection is over- due.
  • Page 43 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule (For RT) INTERVAL Pre-Delivery Annual AREA ON MACHINE (Yearly) Or Frequent Inspection Inspection FUNCTIONS/CONTROLS Control levers, switches, gauges and instruments Detents properly lock, Control enclosure and protective 1, 3 boots/guards Emergency stop switches at ground and platform Lift, drive and speed cut-outs...
  • Page 44 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule (Continued)(For RT) INTERVAL Pre-Delivery Annual AREA ON MACHINE (Yearly) Or Frequent Inspection Inspection Pot Hole Protection system 1, 2, 3 1, 2, 3 Side-Compartment Door Installation 1, 3, 5 1, 3, 5 Drive Motors 1, 4, 5...

  • Page 45: Footnotes

    Or Frequent Inspection Inspection General Structural Condition and Welds Grease and lubrication specification Function test of all system Notify JLG change in machine ownership ANSI and AEM handbook Capacity Decals All decals/placards Annual machine inspection Safety publication All fasteners, pins, shields and covers...
  • Page 46 SECTION 2 - GENERAL Table 2-3. Preventive Maintenance & Inspection Schedule (For ERT) INTERVAL Pre-Delivery Annual AREA ON MACHINE (Yearly) Or Frequent Inspection Inspection FUNCTIONS/CONTROLS Control levers, switches, gauges and instruments Detents properly lock, Control enclosure and protective 1, 3 boots/guards Emergency stop switches at ground and platform Lift, drive and speed cut-outs...
  • Page 47 Hydraulic Fluid GENERAL No Unauthorized Modifications or Additions Paint and overall appearance. Operation and safety manual General Structural Condition and Welds Grease and lubrication specification Function test of all system Notify JLG change in machine ownership ANSI and AEM handbook 31215923...

  • Page 48: Footnotes

    SECTION 2 - GENERAL Table 2-3. Preventive Maintenance & Inspection Schedule (Continued)(For ERT) INTERVAL Pre-Delivery Annual AREA ON MACHINE (Yearly) Or Frequent Inspection Inspection Capacity Decals All decals/placards Annual machine inspection Safety publication All fasteners, pins, shields and covers 1, 2 1, 2 Refer to Operators Manual for machine specific instructions.

  • Page 49: Service And Guidelines

    SECTION 2 - GENERAL SERVICE AND GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, General complete the procedural steps in sequence. Do not par- tially disassemble or assemble one part, then start on The following information is provided to assist you in another.

  • Page 50: Hydraulic Lines And Electrical Wiring

    Components and assemblies requiring lubrication and servicing are shown in the Section 1.3, Lubrication. 2. JLG recommends Standard UTTO Fluid, which has an SAE viscosity of 10W-30 and a viscosity index of 152. 3. The only exception to the above is to drain and fill the system with Premium Hydraulic Fluid oil or its equivalent.

  • Page 51: Changing Hydraulic Oil

    The red safety prop is located at the rear of the machine proper equivalent. Avoid mixing petroleum and syn- in the armstack. To engage the safety prop follow the thetic base oils. JLG Industries recommends chang- below steps : ing the hydraulic oil annually.

  • Page 52: General Maintenance Tips

    SECTION 2 - GENERAL General Maintenance Tips Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank. Oil should be visible in ADD sight window on hydraulic NOTE: Be sure to lubricate like items on each side of tank.
  • Page 53 SECTION 2 - GENERAL 16 17 MAF42840 7. Safety Prop 14. Main Control Valve 1. Platform Controls 8. Wheels and Tires 15. Hydraulic Tank 2. Front Oscillating Axle 9. Ladder 16. Battery Installation 3. Spindle Assembly 10. Ground Controls 17. Battery Charger 4.

  • Page 54: Fuel Tank

    SECTION 2 - GENERAL Fuel Tank Hydraulic Oil Tank MAF42190 MAF42200 • Lube Point - Fill Cap/Fill Level • Fuel - Diesel or Gasoline (Per Engine Type - Reference Decal on Machine) • Lube - HO - API service classification GL-3 (Refer to Figure 1-2.) •...

  • Page 55: Oil Change With Filter

    SECTION 2 - GENERAL Oil Change with Filter • Lube - EO - Minimum API CF • Interval - Initial oil and filter change at first 50 hours Oil Cap of operation, then every year or 200 hours of opera- tion.

  • Page 56: Air Filter

    SECTION 2 - GENERAL • Interval - Check every 100 hours; change every year • Interval (Filter) - Change every 750 hours. in accordance with engine manual. Quality of fuel may require replacement of filter more often. Air Filter • Interval (Water Bowl) - Empty Daily. Loosen drain cock on underside of fuel filter and allow all water to drain into a container until clear fuel is visible.

  • Page 57: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. Pinned joints should be disassembled and Platform Drift inspected if the following occurs: Measure the drift of the platform to the ground.
  • Page 58 SECTION 2 - GENERAL 2-18 31215923...

  • Page 59: Operating Characteristics

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SECTION 3. CHASSIS, PLATFORM, & SCISSOR ARMS OPERATING CHARACTERISTICS NOTE: There is a limit switch that senses when all four cylin- ders are fully retracted and this will light up the four leveling jack lights in the platform control station.

  • Page 60: Quiklevel Advanced (Dual Oscillating Axles) (If Equipped)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Quiklevel Advanced (Dual Oscillating Axles) (If MANUAL LEVEL ADJUSTMENT (TRIM) Equipped) NOTE: There is an override feature on the QuikLevel Advanced system that allows the operator to adjust Th e m a c h i n e m a y b e q u i p p e d w i t h Q u i k Le ve l (trim) the level of the machine to the left or right Advanced, auto-leveling dual oscillating axles with a when the platform is completely lowered.

  • Page 61: Tires, Wheels & Drive Assembly

    JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recom-...

  • Page 62: Drive Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Drive Assembly NOTE: Front Axle shown MAF41730 1. Tire & Rim 4. Bolt 7. Bolt 2. Lugnut 5. Washer 8. Washer 3. Drive Hub 6. Drive Motor Figure 3-1. Drive Assembly - For RT (4WD) 31215923...
  • Page 63 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF41740 1. Tire & Rim 4. Bolt 7. Gasket 2. Lugnut 5. Washer 8. Washer 3. Drive Hub 6. Drive Motor 9. Nut Figure 3-2. Drive Assembly - For RT (2WD) 31215923...
  • Page 64 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS REMOVAL SHUT MACHINE OFF, BRACE AXLES AND CHOCK WHEELS TO PREVENT MACHINE FROM MOVING DURING REPAIRS. 1. Disconnect, cap, and label all hydraulic lines attached to Drive Motor (6). If required, disconnect all electri- cal wiring.
  • Page 65 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF46270 1. Tire 4. Bolt 7. Spindle 2. Lugnut 5. Washer 3. Spindle Assembly Hub 6. Nut Figure 3-3. Spindle Assembly Hub - For RT (2WD) 31215923...
  • Page 66 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS REMOVAL 1. Disconnect, cap, and label all hydraulic lines attached to Spindle Asembly. If required, disconnect all electri- cal wiring. 2. With axle raised and supported, remove the Tires (1) from the spindle assembly Hub (3) by removing the 9 Lugnuts (2).
  • Page 67 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001247420-F MAF44210F 1. Tire 5. Washer 2. Lugnut 6. Electric Drive Motor 3. Drive Hub 7. Adapter Motor Plate 4. Bolt Figure 3-4. Drive Assembly - For ERT 31215923...
  • Page 68 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS REMOVAL SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO PREVENT MACHINE FROM MOVING DURING REPAIRS. 1. Disconnect, cap, and label all hydraulic lines attached to Electric Drive Motor (6). 2. Disconnect and label all electrical connection to Elec- tric Drive Motor (6).

  • Page 69: Drive Hub - 2Wd (For Rt)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS DRIVE HUB - 2WD (FOR RT) 1. Tighten (but do not torque) bolt ”A” until snug. 2. Go to the opposite side of the bolt circle and tighten bolt ”B” until equally snug. Roll and Leak Testing 3.
  • Page 70 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1. Hub-Spindle Sub-Assembly 2. Internal Gear 6. Cover Sub-Assembly 7. Input Shaft Sub Assembly A. Spindle 3. Carrier Sub-Assembly A. Cover A. Input Shaft A. Carrier Housing B. Seal B. Cover Cap B.
  • Page 71 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 6H 6G Figure 3-6. Drive Hub 31215923 3-13...
  • Page 72 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS NOTE: Refer to Figure 3-6., Drive Hub. Table 3-2. Drive Hub Part Description Item # Description Table 3-2. Drive Hub Part Description Sun Gear Item # Description Thrust Washer Spindle/Housing Assembly Bolt Spindle Dowell Pin Seal...

  • Page 73: Main Disassembly For Drive Hub

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Main Disassembly for Drive Hub 17. At this point the main disassembly for drive hub is complete. NOTE: Refer to Figure 3-5. for part location and listing. Hub-Spindle Disassembly 1. Turn hub (1G) over onto its side. Remove coupling NOTE: Start with large end of hub facing up, large end of (14) from the wide end of spindle (1A).

  • Page 74: Cover Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Cover Disassembly Carrier Assembly 1. Remove the two bolts (6C) holding disconnect cap 1. Apply grease to the inside of one cluster gear (3F) (6D) to cover (6A). and line one half of cluster gear with 16 needle roll- ers (3C).
  • Page 75 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 4. Set carrier housing (3A) sideways on a table. Insert a 7. Following the cluster gear, place one more thrust planet shaft (3E), roll pin hole last, into one of the washer (3B) onto planet shaft (3E) through the oppo- planet shaft holes from roll-pin-holed side of carrier site planet shaft hole in carrier housing (3A).

  • Page 76: Cover Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover cap (6B) onto cover (6A), aligning the pipe plug hole in the cover cap over the pipe plug hole in the cover. 1.

  • Page 77: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 7. With the large end down, place the disconnect cap 10. Apply a light coat of "Never-Seize" to pipe plug (6H) (6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover hole in the disconnect cap over the pipe plug hole in (6A).
  • Page 78 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3. Apply a light coat of "Never-Seize" to two pipe plugs 6. Press seal (1B) into the small end of hub (1G). (1J) and tighten them into the two pipe plug holes in the side of the hub (1G).

  • Page 79: Main Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS NOTE: Make sure the retaining ring is securely seated in the Main Assembly groove. 10. Place retaining ring (1I) over the spacer onto spindle (1A) in hub (1G). BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING.
  • Page 80 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 4. Place thrust washer (11) around spindle (1A) so it 7. Place other spacer (7D) onto the smooth end of input rests on the bottom of the internal gear (2). shaft (7A). 5.
  • Page 81 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 10. Place thrust spacer (9) onto input shaft (7). NOTE: You may lift the ring gear off the hub to align the shoulder bolt holes. The ring gear and carrier are installed together only to keep the punch marks on the carrier in place.
  • Page 82 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS NOTE: The O-ring may be stretched or pinched together to 19. Place shoulder bolts (13) into the four shoulder bolt holes in cover (6) and tighten by hand. make it fit the counterbore exactly. 20.
  • Page 83 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 22. Torque the shoulder bolts (13) 18 to 25 ft. lbs. (25 to 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for 2 34 Nm). Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 to 3 minutes.

  • Page 84: Tool List

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E). 6.625" (168.3 mm) The following specialized tools are used to assemble this unit. The tool diagrams included in this manual are 0.125" (3.1 mm) 6"...

  • Page 85: Drive Hub - 4Wd (For Rt)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS DRIVE HUB - 4WD (FOR RT) NOTE: Service information not available at the time of publishing. 31215923 3-27...

  • Page 86: Drive Hub (For Ert)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS DRIVE HUB (FOR ERT) 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 beyond their specified torque. The following steps describe how to tighten and torque bolts or socket head capscrews in a bolt circle.

  • Page 87: Main Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Main Disassembly 1F. Ring Gear 6. Cover Sub-Assembly 11. Second Stage Sun Gear 1G. Housing 18. O-Ring 6G. Retaining Ring 2. Washer 19. Flat Head Bolts 7. Coupling 3. Carrier Sub-Assembly 9. Input Shaft 4.
  • Page 88 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 8. Remove the second stage sun gear (11). 9. Remove the input shaft (9). NOTE: Sun gear and input shaft need to be removed together on units with a ration 48:1. 10. Remove the output stage carrier sub-assembly (4). 11.

  • Page 89: Output Carrier Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Output Carrier Disassembly 3A. Carrier 4C. Needle Rollers 4G. Roll Pin 4. Planet Gear Sub-Assembly 4D. Thrust Spacer 4H. Thrust Washer 4A. Output Carrier 4E. Planet Shaft 4B. Thrust Washers 4F. Planet Gears Figure 3-9.
  • Page 90 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 5. Remove 4 Thrust Washers (4B), 28 Needle Rollers (4C) and the Thrust Spacer (4D) from the Second Stage Planet Gear (4F). 6. Repeat steps 1 to 5 for the remaining two Planet Gears (4F).

  • Page 91: Input Carrier Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Input Carrier Disassembly 3A. Carrier 3E. Planet Shaft 3B. Thrust Washers 3F. Planet Gear 3C. Needle Bearings 4G. Roll Pins Figure 3-10. Input Carrier Disassembly 1. Drive the roll pin (4G) into the planet shaft (3E) until it bottoms against the carrier (3A) using a 1/8"...

  • Page 92: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Hub-Spindle Disassembly 1A. Spindle 1E. Bearing Cone 1B. Seal 1G. Hub 1C. Bearing Cone 1H. Stud 1D. Bearing Cup Figure 3-11. Hub-Spindle Disassembly 1. 1.Place the hub-spindle assembly on the bench with 8.

  • Page 93: Cover Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Cover Disassembly 2. Thrust Washer 6E. O-ring 6A. Cover 6F. O-Ring Pipe Plugs 6B. Disengage Cap 17. O-Ring 6C. Hex Head Bolts 6D. Disengage Rod Figure 3-12. Cover Disassembly 1. Remove O-Ring (17) from groove in Cover (6A). 2.

  • Page 94: Input Carrier Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Input Carrier Sub-Assembly Output Planet Gear Sub-Assembly 1. Apply a liberal coat of grease to the bore of one Input 1. Apply a liberal coat of grease to the bore of one Out- Planet Gear (3F).

  • Page 95: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Hub-Spindle Sub-Assembly Main Assembly NOTE: Spray a light film of oil on all component parts NOTE: All components should receive a generous amount during assembly. of lubricant oil as they are being assembled. 1.

  • Page 96: Tool List

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Tool List 3. Smaller Bearing Cone. 1. Bearing Cup Pressing Tool. 2. Seal Pressing Tool. 3-38 31215923...
  • Page 97 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1. Hub-Spindle Sub-Assembly F. Planet Gear 10. Input Sun Gear 2. Thrust Spacer A. Spindle 11. Output Sun Gear G. Roll Pin 3. Input Carrier Sub-Assembly 15. ID Plate B. Seal H. Thrust Washer A.

  • Page 98: Drive Motor (Sauer)

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

  • Page 99: Loop Flushing Valve

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS INSPECT THE COMPONENTS 2. Using a 1/4 in. hex wrench, remove plug (3). Inspect the new seal, the motor housing seal bore, and 3. Remove O-rings (4, 5, and 6). the sealing area on the shaft for rust, wear, and contami- 4.

  • Page 100: Troubleshooting

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply to oil supply to the motor.

  • Page 101: Disassembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 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 102 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring 28. Rear Shaft Bearing Figure 3-19. End Cap 29. Minimum Angle Stop 30. Servo Spring 13. Using an 8 mm internal hex wrench, remove the end- cap screws (22).
  • Page 103 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS To avoid damaging the shaft during seal removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal. 31.

  • Page 104: Inspection

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever. 24. Remove the servo piston (40). Remove the piston RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING seal (41) and O-ring (42) from the servo piston.
  • Page 105 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Table 3-7. Slipper Foot Thickness & End Play to the specifications shown in the drawing, provided resurfacing will not reduce the block height below the Measurement L Frame K Frame minimum specification. Table 3-8, Cylinder Block Mea- surements.
  • Page 106 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS BALL GUIDE AND SLIPPER RETAINER SWASHPLATE AND JOURNAL BEARINGS Inspect the ball guide and slipper retainer for damage, Inspect the running face, servo ball-joint, and swash- discoloration, or excessive wear. A discolored ball guide plate journal surfaces for damage or excessive wear.

  • Page 107: Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SERVO PISTON AND MINIMUM ANGLE STOP Assembly Inspect the minimum angle stop, servo piston head, and 1. Install new O-ring (1) and piston seal (2) to the servo servo piston ball-socket for damage or excessive wear. piston (3).
  • Page 108 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS retaining ring (7) into the groove in the cylinder the bearings, install them in the original location and block. orientation. Lubricate the journal bearings. 13. Journal Bearings 14. Swash Plate Figure 3-28. Swash Plate and Journal Bearing 7.
  • Page 109 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 8. Press front shaft bearing (15) onto shaft (16). Press journal bearings, and servo piston are all secure and bearing onto shaft with lettering facing out. Lubri- properly installed. cate bearing rollers. Install snap-ring (17) onto shaft. 19.
  • Page 110 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above prevent the endcap from seating properly. Ensure endcap surface. the O-rings seat properly when installing the endcap. 3 mm [0.12 in] 2 mm 8 mm [0.08 in] 35-45 ft.lbs.
  • Page 111 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Press evenly to avoid binding and damaging the seal. 19. Install remaining plugs and fittings to the housing. Install seal support washer (28) and snap ring (29). Refer to the drawing below for wrench sizes and installation torques.

  • Page 112: Initial Start-Up Procedures

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 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 11/16 in incurred during shipping.

  • Page 113: Axle Installation

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS AXLE INSTALLATION MAF42430A 1. Axle 3. Pivot Pin Bushing 5. Pin Keeper and Bolt 7. Wear Pad Shims 2. Pivot Pin 4. Thrust Washer 6. Wear Pad 8. Hex Head Screws Figure 3-37. Axle Installation (Front Axle) 31215923 3-55...

  • Page 114: Removal

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF42460A 1. Axle 3. Pivot Pin Bushing 5. Pin Keeper and Bolt 7. Wear Pad 2. Pivot Pin 4. Thrust Washer 6. Wear Pad Shim 8. Hex Head Screws Figure 3-38. Axle Installation (Rear Axle)- For Dual Oscillating Removal Assembly 1.

  • Page 115: Steer Installation

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS STEER INSTALLATION 1001244392-B MAF42080B 1. Bolt 5. Cotter Pin 9. Spindle 13. Washer 2. Thrust Bearing 6. Washer 10. Tie Rod 14. Thrust Bearing 3. Bushing 7. King Pin 11. Clevis Pin 4.
  • Page 116 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Steer Cylinder Removal 1. Disable machine operation and block all wheels. Dis- connect, cap and label all hydraulic lines on steer cyl- inder (8). 2. Remove the cotter pin (5), clevis pin (11) and bushing (3) connecting cylinder rod to tie rod (10).
  • Page 117 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001250520-B MAF44220B 1. Bolt 6. Washer 11. Clevis Pin 16. Bolt 2. Thrust Bearing 7. King Pin 12. Washer 17. Locknut 3. Bushing 8. Steer Cylinder 13. Steering Sensor Cover 18. Washer 4.

  • Page 118: Steer Cylinder Removal

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS STEER CYLINDER REMOVAL 1. Disable machine operation and block all wheels. Dis- connect, cap and label all hydraulic lines on steer cyl- inder (8). 2. Disconnect all electrical connections to the steering &...

  • Page 119: Oscillating Axle Cylinder

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Oscillating Axle Cylinder MAF42090 1. Oscillating Axle Cylinder 2. Bolt 3. Washer Figure 3-41. Oscillating Axle Cylinder REMOVAL NOTE: Make sure the shoulder on the cylinder is firmly against the bottom of the mounting plates on the 1.

  • Page 120: Leveling Jacks (If Equipped)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS LEVELING JACKS (IF EQUIPPED) Cylinder Removal NOTE: Applies to both front and rear of machine. 1. Leveling Jack Cylinder 2. Leveling Jack Weldment 3. Leveling Jack Cover 4. Pad Angle Plate MAF42100 Figure 3-42.

  • Page 121: Assembly Removal

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Assembly Removal NOTE: Applies to both front and rear of machine. MAF42110C 1. Leveling Jacks Assembly 2. Bolt 3. Washer Figure 3-43. Leveling Jacks Assembly REMOVAL 5. Carefully lower assembly from the frame. INSTALLATION 1.

  • Page 122: 3.10 Platform

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.10 PLATFORM 1. Platform 2. Scissor Arms 3. Slide Block 4. Bolt 5. Locknut 6. Pin 7. Spacer Tube 8. Bolt 9. Locknut 10. Pin Keeper 11. Pin MAF42120 Figure 3-44. Platform Removal 5.

  • Page 123: Platform Control Station

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Platform Control Station MAF42140 1. Upper Extrusion Housing 3. Lower Extrusion Housing 5. Control Box Latch Pin 7. Control Box Side Panel 2. Stud 4. Joystick Controller 6. Display Shield 8. Display Panel Figure 3-45.

  • Page 124: Joystick Controller

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Joystick Controller MAF42130 Figure 3-46. Joystick Controller Table 3-9. Joystick Specifications Table 3-10. Joystick Plug Loading Chart Type Single Axis (Y Axis Only) Terminal Color Function Input Voltage 4.9-5.1 VDC Handle COM Current Consumption 10 mA @ 12 VDC VIOLET...

  • Page 125: 3.11 Scissor Arms

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.11 SCISSOR ARMS INSTALLATION 1. Follow Removal Steps in reverse. Lift Cylinder Removal Scissor Arm Assembly Removal REMOVAL NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEMBLY.
  • Page 126 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001248820-C MAF42040C Figure 3-47. Scissor Arm Component - RT2669, ERT2669 Assembly - Sheet 1 of 2 3-68 31215923...
  • Page 127 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001248820-C MAF42050C Figure 3-48. Scissor Arm Component - RT2669, ERT2669 Assembly - Sheet 2 of 2 31215923 3-69...
  • Page 128 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001248821-C MAF42020C Figure 3-49. Scissor Arm Component - RT3369, ERT3369 Assembly - Sheet 1 of 2 3-70 31215923...
  • Page 129 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 1001248821-C MAF42030C Figure 3-50. Scissor Arm Component - RT3369, ERT3369 Assembly - Sheet 2 of 2 31215923 3-71...

  • Page 130: 3.12 Side Compartment Covers

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.12 SIDE COMPARTMENT COVERS MAF42150 1. Engine Cover Shield 4. Hinge 7. Coolant and Oil Fill Access Plate 2. Door Compartment 5. Latch Striker Bracket 3. Locking Latch 6. Hood Bumper Figure 3-51. Left Side - Engine Compartment Covers - RT 3-72 31215923...
  • Page 131 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF43870E 1. Engine Cover Shield 3. Locking Latch 5. Latch Striker Bracket 2. Door Compartment 4. Hinge 6. Hood Bumper Figure 3-52. Left Side - Battery Compartment Covers - ERT 31215923 3-73...
  • Page 132 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF42160 1. Hydraulic Cover Shield 4. Hinge 7. Hood Cover 2. Door Compartment 5. Latch Striker Bracket 3. Locking Latch 6. Hood Bumper Figure 3-53. Right Side - Hydraulic/Fuel Compartment Covers 3-74 31215923...

  • Page 133: Cover Removal

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Cover Removal 3.13 GROUND CONTROL STATION Control Station Removal NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING, OR OVERHEAD SLING. NOTE: Procedures apply to both left and right side compart- ment hoods.
  • Page 134 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS REMOVAL 1. Disable machine operation. 2. Open tank side hood door to get access to ground control panel assembly. 3. Disconnect and label all electrical harnesses from the ground control panel assembly (1). 4.

  • Page 135: Ground Control Station Components

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Ground Control Station Components 1001251231-C MAF42180C 1. Ground Control Panel Bracket 5. E-stop Switch 2. Switch Guard 6. Lift Up/Down Switch 3. Engine Start Push Button Switch 7. Ground Display 4. Key Switch 8.
  • Page 136 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF43890B 1. Ground Control Panel Bracket 5. E-stop Switch 2. Switch Guard 6. Lift Up/Down Switch 3. E-Brake Release Button 7. Ground Display 4. Key Switch 8. LSS Overload Indicator LED Figure 3-57. Ground Control Station Components - ERT 3-78 31215923...

  • Page 137: 3.14 Battery

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.14 BATTERY 1001255875-B MAF41900B 1. Battery 4. Battery Positive Terminal 2. J - Bolt 5. Battery Negative Terminal 3. Battery Holder Bracket 6. Auxiliary block Figure 3-58. Battery Removal - RT REMOVAL Remove the bolts, washers and nuts securing the block to the machine compartment cover.
  • Page 138 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF43900B 1. Battery Positive Terminal 4. Battery 2. Battery Negative Terminal 5. J-bolt 3. Battery Secure Top Plate Figure 3-59. Battery Removal - ERT REMOVAL 4. Remove the J-bolt (5) by removing hardware secur- ing battery secure top plate (3) to battery tray.

  • Page 139: 3.15 Tank

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.15 TANK 1001248349-D MAF42260D 6. Fuel Tank 9. Hydraulic Tray 7. Hydraulic Tank 10. Drain Plug 8. Bolt and Washer Figure 3-60. Tank Installation - RT Removal Installation 1. Disable machine operation. 1.
  • Page 140 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS MAF43910C 1. Hydraulic Tank 3. Hydraulic Tray 2. Bolt and Washer 4. Drain Plug Figure 3-61. Tank Installation - ERT REMOVAL 1. Disable machine operation. 2. Drain fuel from hydraulic tank (1). Store fuel in appro- priate receptacle.

  • Page 141: Battery Charger

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS 3.16 BATTERY CHARGER Delta-Q - Battery Charger Battery Charging MAF43920C MAF44300 • AC Power On: BLUE LED ON 1. Connect the charger AC input plug to a grounded • Low State of Charge: Bottom Panel - GREEN LED outlet using a 3 wire heavy duty extension cord.

  • Page 142: Battery Charger Maintenance

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Battery Charger Maintenance If the output voltage of the charger seems exces- sive, return the charger for service. Contact JLG to get the expected battery voltage settings for the charger in question. Be sure to have the char- USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM ger’s serial number and charge algorithm setting...

  • Page 143: Ic Series Setup And Troubleshooting Guide

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS IC Series Setup and Troubleshooting Guide IC650 – DC OUTPUT Table 3-12. IC900/IC1200 – DC Output Recommended BE CAREFUL TO NOT ALLOW BATTERY VOLTAGE TO BE APPLIED TO THE Wire Size (AWG/ Description Notes BLADE TERMINALS (C1, C2, C3) AS IT WILL RESULT IN PERMANENT...
  • Page 144 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS IC650 DC WIRING INSTRUCTIONS 3. Lift the cover and remove the bag of parts. To attach DC cabling to the IC650 Charger, you will need the following items: • 1 - Torx T30 screwdriver •...
  • Page 145 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS IC900 & IC1200 DC WIRING INSTRUCTIONS To attach DC cabling to the IC900 and IC1200 chargers, you need the following items: • 1 Torx T30 screwdriver • 1 Torx T10 screwdriver • 2 Torx T30/M6 screws (provided) •...
  • Page 146 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SIGNALS AND CONTROL CONNECTOR Figure 3-62. Sample AMP Seal Connector and Pinout NOTE: Pin numbers 1, 5, 6, 9, 10, and 14 are labeled on the Table 3-13. IC650 – DC Output connector’s inside face, next to the pins.
  • Page 147 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS IC-SERIES CHARGER INTERFACE • The Charging Output Indicator is solid yellow when the charger output is active. Take appropriate actions while handling the charger as there is a risk of elec- tric shock. •...
  • Page 148 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS STATE-OF-CHARGE INDICATORS Fault / Error / USB Indicator will flash green during reading and writing. Bulk charging, <80% complete 3. If the drive contains compatible configuration files, the charger will load them. 4.
  • Page 149 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Table 3-15. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution Battery Voltage is too high to start charge. Check the battery voltage and cable connections. E-0-0-1 High Battery Voltage Error Check battery size and condition. This error will automatically clear once the condition has been corrected.
  • Page 150 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Table 3-15. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution E-0-1-7 USB operation failed This could be caused by a faulty USB drive or connections. If it persists, try a different USB drive. Retry by removing and re-inserting the USB drive.
  • Page 151 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Table 3-15. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution Inspect for objects on or near the button or damage to the button. If alarm persists, replace E-0-3-9 Button Stuck Down charger.
  • Page 152 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Table 3-15. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution The charger compares the Battery written voltage with its output voltage. Check that the cor- CAN Battery Voltage Report Mis- E-0-6-2 rect voltage is being sent to the charger.

  • Page 153: Engine Removal

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Engine Removal 1001256031-C 1001255872-C MAF42310C MAF42300C Diesel Dual Fuel - Gas/LPG 1. Kubota Engine (Shown) 4. Engine Isolator Mount 1. Kubota Engine (Shown) 4. Engine Isolator Mount 2. Engine Lifting Lugs 5. Engine Tray 2.

  • Page 154: Dual Fuel/Lpg System

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Dual Fuel/LPG System 5. During transfer of LPG, metal components can become very cold. Always wear gloves when refilling or changing tanks to prevent “freeze burns” to skin. 6. Do not store LPG tanks near heat or open flame. For complete instructions on the storage of LPG fuels, IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER refer to ANSI/NFPA 58 &...

  • Page 155: Generator (If Equipped)

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Generator (If Equipped) MAF42480B 1. Generator 4. Eyebolt Rod 2. Belt 5. Generator Mount 3. Generator Adjust Bracket Figure 3-64. AC Generator Installation 31215923 3-97...
  • Page 156 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS INSTALLATION 1. Follow Removal Steps in reverse. Ensure belt is tight ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- before securing generator with the bolts. ING. NOTE: Apply Medium Strength Threadlocking Compound REMOVAL to the threads of the generator mounting bolts.

  • Page 157: Belt Routing

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Belt Routing NOTE: Refer Figure 3-64., AC Generator Installation and fol- low the procedure below. NOTE: Allow Engine And Components To Cool Down Before Servicing. REMOVAL 1. Disable machine operation. Open engine cabinet doors to get access to generator.

  • Page 158: Exhaust System

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Exhaust System 1001256035-B MAF42350B 1001255876-B MAF42340B Dual Fuel - Gas/LPG Diesel 1. Engine 5. Gasket 1. Muffler 3. Mounting Bracket 2. O2 Sensor 6. O2 Sensor Pipe (Downstream) 2. Gasket 3. Catalytic Coverter/Muffler 7.

  • Page 159: Dual Fuel - Gas/Lpg

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Dual Fuel - Gas/LPG Diesel ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ING. ING. REMOVAL REMOVAL 1. Disable machine operation. Remove engine door & 1.

  • Page 160: Air Cleaner System

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Air Cleaner System 1001256030-A 1001255877-B MAF42330A MAF42320B Dual Fuel - Gas/LPG Diesel 1. Air Cleaner Assembly 4. Clamp 1. Air Cleaner Assembly 4. Clamp 2. Intake Pipe 5. Clamp 2. Intake Pipe 5.
  • Page 161 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Dual Fuel - Gas/LPG Diesel ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- ING. ING. REMOVAL REMOVAL 1. Disable machine operation. Remove engine door & 1.

  • Page 162: Radiator

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Radiator MAF42270C 1. Radiator Mounting Plate 4. Radiator Lower Support Bracket 2. Radiator Assembly 5. Engine Tray 3. Fan Shroud Assembly 6. Drain Plug Figure 3-67. Radiator Installation (All Engines) 5. Re-check that all connections, hoses, etc. are discon- nected and remove complete radiator mounting plate assembly (1) from the engine tray (5).

  • Page 163: Engine Electrical Component Locations

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Engine Electrical Component Locations X88B TO CHASSIS HARNESS SEE DETAIL A MS329-3 MS329-2 DIODE DETAIL A 1001255875-B MAF41910B Figure 3-68. Diesel Engine Compartment- Electrical Component Locations (For RT) 31215923 3-105...
  • Page 164 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL D ECU SHIPPED LOOSE LB327 WITH ENGINE BEACON LIGHT AUX BLOCK POWER AUX BLOCK GROUND EC10 DIESEL ECU BATTERY NEGATIVE SEE DETAIL C X18A BATTERY POSITIVE GEN CONTROL SEE DETAIL B HV604 THROTTLE ACTUATOR SPD SENSOR...
  • Page 165 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS GLOW PLUG RLY START RELAY IGN RELAY FC261 MAIN MDL FUSE FC260 ALT EXCITE FUSE DETAIL C FC258 START FUSE GLOW PLUG DETAIL D 1001255875-B MAF41930B Figure 3-70. Diesel Engine Compartment- Electrical Component Locations (For RT) 31215923 3-107...
  • Page 166 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL E R O U T E B AT T E R Y C A B L E THROUGH CUTOUT ON ENGINE TRAY AS SHOWN COOLANT SNSR TO ALT STUD MS150 ALT CONN OIL PRESSURE START ENG...
  • Page 167 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS ENG DF CONN SEE DETAIL A EC10 ECM CONN POST 02 SNSR 1001256034-C MAF41970C DETAIL A Figure 3-72. Duel Fuel Engine Compartment - Electrical Component Locations (For RT) 31215923 3-109...
  • Page 168 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS LB328 BEACON LIGHT T12+ AUX BLOCK + AUX BLOCK POWER AUX BLOCK GROUND SEE DETAIL C T12- AUX BLOCK - BATTERY NEGATIVE X18A BATTERY CONTROL POSITIVE D5 DIODE SEE DETAIL B ENGINE GROUND DETAIL B 1001256034-A MAF41980A...
  • Page 169 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS RL13 ETV RL RL12 PWR RL RL11 LP SELECT RL RL10 STRT RL IGN RELAY FC273 FC261 ALT FUSE MAIN MDL FUSE FC271 FC274 STRT FUSE PWR RL FUSE DETAIL C 1001256034-A MAF41990A Figure 3-74.
  • Page 170 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL D GD02 ENG GND MS156 PRE O2 SNSR FUEL SEL VALVE TIE DUAL FUEL ENGINE HARNESS ALONG WITH ENGINE HARNESS USING TIE STRAP TO ALT STUD MS153 CONN DETAIL D 1001256034-A MAF42000A Figure 3-75.
  • Page 171 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL E ROUTE BATTERY CABLE THROUGH CUTOUT ON ENGINE TRAY AS SHOWN SECURE THE CONNEC TORS BY STRT SIG REUSING THE EXISTING NUT AND LOCK WASHER WITH STARTER TO ENG B+ STRT POS ENGINE STARTER 1001256034-A...
  • Page 172 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL A EC363B+ GEN POSITIVE EC363B- GENERATOR NEG 1001259034-A MAF46990A Figure 3-77. Genset Engine Compartment - Electrical Component Locations (For ERT) 3-114 31215923...
  • Page 173 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL B INSERT MS191-(3) INTO CAVITY 3 OF MS191 ON THE CHASSIS HARNESS CONNECT X224 TO X225 ON THE CHASSIS HARNESS MS191-(3) GND BUS X460A GENSET ECU CONTROL MODULE LB512 GNST DISTRESS SW472-1 GNST START SW472-2...
  • Page 174 SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS SEE DETAIL C SEE DETAIL D MS351-2D BATT DISCONN BATT NEG X637 BATT DISCONN BATT POS BATTERY X638 NEG STUD RL462 GENST START RELAY RL463 GENST ENBL RELAY 1001259034-A MAF47010A Figure 3-79. Genset Engine Compartment - Electrical Component Locations (For ERT) 3-116 31215923...

  • Page 175: Hydraulic Pump Installation

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Hydraulic Pump Installation 1001256031-B 1001255872-C MAF42420B MAF42410C Diesel Dual Fuel - Gas/LPG 1. Gear Pump 2. Coupling Assembly 3. Bolt and Washer Figure 3-80. Hydraulic Pump Assemblies INSTALLATION 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC- NOTE: Apply Medium Strength Threadlocking Compound ING.

  • Page 176: Pump Coupling Assembly

    SECTION 3 - CHASSIS, PLATFORM, & SCISSOR ARMS Pump Coupling Assembly MAF42560 MAF42360 Diesel Dual Fuel - Gas/LPG 1. Coupler Housing 3. Engine Pulley 5. Adapter Plate 2. Disc Coupling 4. Engine Flywheel/Coupler Mounting Plate Figure 3-81. Pump Coupling Assembly INSTALLATION 1.

  • Page 177: Section 4 - Basic Hydraulic Information & Schematics

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 4. BASIC HYDRAULIC INFORMATION & SCHEMATICS CYLINDERS - THEORY OF OPERATION Relief Valves Main relief valves are installed at various points within Cylinders are of the double acting type. The steer sys- the hydraulic system to protect associated systems and tem incorporates a double acting cylinder.

  • Page 178: Cylinders With Single Counterbalance Valve

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5. With cylinder fully retracted, shut down engine and OSCILLATING AXLE - LOCKOUT CYLINDER TEST carefully disconnect hydraulic hose from cylinder extend port. 6. Activate engine and retract cylinder. Check extend LOCKOUT CYLINDER SYSTEM TEST MUST BE PERFORMED QUARTERLY, port for leakage.

  • Page 179: Right Side Wheel Test (Ce Market Only)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Right Side Wheel Test (CE MARKET ONLY) Front Oscillating Axle Test (Non-CE Market Only) 1. Place a 4 in. (10.16 cm) high block with ascension NOTE: Begin the test with no load in the platform, in the ramp in front of right wheel of the oscillating axle.

  • Page 180: Gear Pump Priming

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS GEAR PUMP PRIMING HYDRAULIC COMPONENT START-UP PROCEDURES & RECOMMENDATIONS The gear pump is mounted with the suction hose up. Air trapped in this area can cause an air lock on start up. From a hydrostatic component standpoint, the goal at during this period, the pump is running dry, which can system start up is to put into functional operation, the...
  • Page 181 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS that the pump is not being asked to draw an inlet vacuum higher than it is capable of. INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABIL- Be certain to fill the pump and/or motor housing with ITY TO CONTROL THE MACHINE.

  • Page 182: Hydraulic Valves

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC VALVES MAF42490 1. Junction Manifold Valve 2. Main Control Valve Figure 4-1. Hydraulic Compartment Control Valves (For RT) REMOVAL INSTALLATION 1. Disconnect, cap and label all hydraulic hoses and any 1. Reattach valve blocks to tray with bolts. electrical harness connected to valves.

  • Page 183: Electric Option Valve

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF43700 1. Electric Option Valve Figure 4-2. Hydraulic Compartment Control Valves (For ERT) 31215923...
  • Page 184 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Hydraulic Valve MAIN VALVE TOP VIEW RIGHT SIDE LEFT SIDE FRONT VIEW BACK VIEW 1001270103-A MAF42550A Figure 4-3. Main Valve Port Identification (For RT) 31215923...
  • Page 185 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-1. Main Valve Port Identification (For RT) Port VALVE DESCRIPTION FUNCTION Pressure Relief (Valvole Italia) MAIN RELIEF Pressure Relief (VIS Hydraulics) STEER RELIEF Load Holding Valve DRIVE Pressure Reducing Valve BRAKE Pressure Relief Valve LIFT RELIEF Pressure Reducing/Relieving...
  • Page 186 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Junction Manifold Valve MAF42880 Figure 4-4. Junction Manifold Vavle (For RT) Table 4-4. Junction Manifold Valve Porting Specs (For RT) Port Size SAE 6 SAE 10 SAE 12 4-10 31215923...
  • Page 187 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215923 4-11...
  • Page 188 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Electric Option Valve BOTTOM VIEW TOP VIEW LEFT SIDE RIGHT SIDE FRONT VIEW BACK VIEW 1001247381-C MAF43690C Figure 4-5. Electric Option Valve (For ERT) 4-12 31215923...
  • Page 189 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-5. Electric Option Valve Port Identification (For ERT) Port VALVE DESCRIPTION FUNCTION Pressure Relief (Valvole Italia) MAIN RELIEF Pressure Reducing/Relieving AXLE CHARGE Proportional Flow Control W/ Bypass FLOW CONTROL Pressure Relief (VIS Hydraulics) STEER RELIEF 4-3 Directional Valve STEER...

  • Page 190: Leveling Jack Valves (If Equipped)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Leveling Jack Valves (If Equipped) 180 BAR 8:1 PILOT 150 BAR 180 BAR 8:1 PILOT HYD SCHEMATICS NOTE: Applies to all Leveling Jacks. MAF42510 Figure 4-6. Leveling Jack Valves Table 4-7. Leveling Jack Valves Torque Specs Item Torque 3 to 4.5 ft.

  • Page 191: Traction Valve (2Wd)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Traction Valve (2WD) TOP VIEW BOTTOM VIEW LEFT SIDE RIGHT SIDE 11, 10 BACK VIEW FRONT VIEW 1001246959-D MAF43280D Figure 4-7. Traction Valve (2WD) 31215923 4-15...
  • Page 192 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-8. Traction Valve (2WD) Port Identification Port VALVE DESCRIPTION Body Shuttle Valve Check Valve Solenoid Operated Directional Valve Solenoid Operated Directional Valve Flow Divider-combiner Valve Pressure Reducing/ Relieving Valve Boss Plug Boss Plug Boss Plug Orifice Plug...

  • Page 193: Traction Valve (4Wd)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Traction Valve (4WD) TRACTION VALVE (4WD) BOTTOM VIEW TOP VIEW RIGHT SIDE LEFT SIDE BACK VIEW FRONT VIEW 1001244177-C MAF43290C Figure 4-8. Traction Valve (4WD) 31215923 4-17...
  • Page 194 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 4-11. Traction Valve (4WD) Port Identification Port VALVE DESCRIPTION CWCK-LIN CXAA-XBN CXAD-XAN DMBD-XAN912L LODD-XDN Boss Plug Boss Plug Boss Plug Boss Plug Block Table 4-12. Traction Valve (4WD) Torque Specs Component Functionality Resistance Torque...

  • Page 195: Ground Control Panel Installation

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Ground Control Panel Installation SEE DETAIL C SEE DETAIL D SEE DETAIL A SEE DETAIL B HYDRAULIC COMPARTMENT GROUND CONTROL PANEL ASSY X124A TO ARMSTACK CABLE OPERATOR ACCESS KEYPAD DETAIL B MS151 CAN BUSBAR CHASSIS CHASSIS HARNESS...
  • Page 196 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL E HYDRAULIC COMPARTMENT SEE DETAIL F SEE DETAIL G HV49 ST LT HV50 ST RT HV53 LIFT ENABLE RL192 HV48 IGN RELAY P BRK EC378 FUEL PUMP KUBOTA (FOR DUAL FUEL ENGINE ONLY) HV55 JACKS RET CHASSIS HARNESS...
  • Page 197 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL H CO46-J3 CO46-J2 CO46-J1 BLACK GRAY AH95 NATURAL CO46-J14 GROUND ALARM HORN GRAY CHASSIS HARNESS LB143 BEACON ANALYZER X412A HOC IGN X441A TO AUX DESCENT CO46-J8 BLACK AH94 CO46-J4 WIN ALARM CO46-J12 BLUE BLACK...
  • Page 198 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL J SEE DETAIL U HV55 AXLE ENABLE CHASSIS HARNESS DUAL AXLE OPTION VALVE SHOWN MS181 DIODE PACK CHASSIS HARNESS MS153 CAN BUS BAR X491 CAN 3 TERM HV197 RR OA EXT HV198 DETAIL U LR OA EXT...
  • Page 199 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HV71 LEFT FRONT CHASSIS HARNESS SN162 CHASSIS HARNESS PLT STOW SWITCH DETAIL L X158 MOUNTING BLOCK FUSE IP159 FUSE 15A IP190 ROUTE CHASSIS HARNESS THROUGH FRAME CUTOUT FUSE 15A DETAIL K CHASSIS HARNESS HV52 DRV REV...
  • Page 200 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CHASSIS HARNESS SW117-1 SW116-1 KEY SWITCH SN81 ANGLE FRONT SW117-2 AXLE SW116-B SN82 KEY SWITCH ANGLE CHASSIS LB115 SW116-3 OVERLOAD KEY SWITCH SW118-2 ENGINE START X534 DIAGNOSTICS SW118-1 ENGINE START SW119 LIFT SWITCH DETAIL R GD87 DUAL AXIS TILT SENSOR...
  • Page 201 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL C SEE DETAIL D SEE DETAIL A SEE DETAIL B MS151 CAN BUSBAR X124A TO ARMSTACK GROUND CONTROL CABLE PANEL CHASSIS HARNESS X83A TO BLUE- TOOTH HARN X200A TO LIFT DN X150A LEVEL JACKS OPT HARNESS...
  • Page 202 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CHASSIS HARNESS SN81 ANGLE FRONT AXLE SN82 ANGLE CHASSIS SEE DETAIL E GASKET HV70 RIGHT FRONT CHASSIS HARNESS DETAIL F DUAL AXIS TILT SENSOR SEE DETAIL F DETAIL E 1001254548-C MAF46740C Figure 4-15. Ground Control Panel Installation (For ERT) - Sheet 2 of 5 4-26 31215923...
  • Page 203 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL H CO46-J2 MS191 GRAY GROUND BUS BAR CO46-J1 CO46-J3 NATURAL BLACK X499 CAN RESISTOR CO46-J14 GRAY LB143 BEACON ANALYZER CO46-J8 BLACK X578A TO LIFT DN AH94 X225 GROUND ALARM HORN TO GENSET HARNESS CO46-J7 AH95...
  • Page 204 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SEE DETAIL G SEE DETAIL J HV50 ST RT MS181 DIODE PACK MS153 CAN BUS BAR UNIVERSAL TELEMATICS CHASSIS HARNESS DETAIL J RL192 IGN RELAY MS474 12V PWR BUSS DETAIL G 1001254548-C MAF46760C Figure 4-17.
  • Page 205 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CHASSIS HARNESS SW116-1 FORK TERMINAL KEY SWITCH FORK TERMINAL SW116-B KEY SWITCH SW485-2 BRAKE RELEASE SW116-3 KEY SWITCH SW485-1 BRAKE RELEASE LB501 OVERLOAD X534 DIAGNOSTICS SW119 CHASSIS LIFT SWITCH HARNESS GD87 SN162 KONGSBERG DISPLAY PLT STOW SWITCH DETAIL K...
  • Page 206 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4-30 31215923...

  • Page 207: Pressure Relief Valve - Setting Procedures (For Rt)

    (see Figure 4-19.). b. Pressure Setting Check: 1. Turn machine on and start the engine. 2. Enter "Level 1 Access" mode on JLG analyzer. 3. Navigate to the “SERVICE” menu and then "SER VICE: SET MAIN RELIEF?" 4. Enter the access code 51788 and press enter to activate main relief pressure setting mode.
  • Page 208 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Pressure Setting Adjustment 2. Lift Relief Valve; 1. If you are not already in Main Relief Pressure a. Instrumentation/Setup: calibration mode ("SERVICE” Menu, “SET MAIN 1. Install a pressure gauge, 3000 PSI or higher, at the RELIEF?"...
  • Page 209 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 3. Steer Relief Valve Figure 4-22. Location Of Port “M1” (Main Valve) a. Instrumentation/Setup: 1. Install a pressure gauge, 3000 PSI or higher, at the B. Steer Left Relief M1 port on the main control valve located in the 1.
  • Page 210 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 4-23. Jam Nut Location (Steer Right Relief Valve) 3. Once the gauge reads a pressure of 2494 PSI 2. Loosen the jam nut on the steer left relief valve (172Bar) tighten down the jam nut (making sure (highlighted green in Figure 4-24.) and turn the the adjustment screw does not rotate) adjustment screw (highlighted red in Figure 6)

  • Page 211: Pressure Relief Valve - Setting Procedures (For Ert)

    (see Figure 4-25.). b. Pressure Setting Check: 1. Turn machine on and start the engine. 2. Enter "Level 1 Access" mode on JLG analyzer. 3. Navigate to the “SERVICE” menu and then "SERVICE: SET MAIN RELIEF?" once in Access 1 4.
  • Page 212 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Pressure Setting Adjustment 1. If you are not already in Main Relief Pressure calibration mode "SERVICE MODE” Menu, “SET MAIN RELIEF?" in analyzer access level 1, then follow steps of Section b., Pressure Setting Check: 2.
  • Page 213 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Steer Relief Valve Figure 4-27. Location Of Port “M1” (Main Valve) a. Instrumentation/Setup: 1. Install a pressure gauge, 3000 PSI or higher, at the B. Steer Left Relief M1 port on the main control valve located in the 1.
  • Page 214 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. Pressure Setting Adjustment adjustment screw (highlighted red in Figure 4-28.) clockwise to increase pressure or A. Steer Right Relief counterclockwise to decrease pressure. 1. Follow steps of steer right relief pressure setting 3.
  • Page 215 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS B. Steer Left Relief adjustment screw (highlighted red in Figure 4-29.) clockwise to increase pressure or 1. Follow steps of steer left relief pressure setting counterclockwise to decrease pressure. checks above so that the gauge connected to the “M1”...

  • Page 216: Gear Pump

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS GEAR PUMP MAF42530 1. Inlet Port from Hydraulic Tank, 1-5/16-12 SAE J1926-1 2. Outlet Ports, 7/8-14 SAE J1926-1 Figure 4-30. Tandem Gear Pump (Dual Fuel - Gas/LPG) Table 4-13. Gear Pump Specs (Dual Fuel - Gas/LPG) I PUMP II PUMP Direction Of Rotation...
  • Page 217 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF42540 1. Inlet Port from Hydraulic Tank, 1-5/16-12 SAE J1926 2. Outlet Ports, 7/8-14 SAE J1926-1 Figure 4-31. Gear Pump (Diesel) Table 4-14. Gear Pump - Diesel I PUMP II PUMP Direction Of Rotation Clockwise Displacement 14,533 cm3/rev...

  • Page 218: General Repair Instructions

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS General Repair Instructions NOTE: Service information not available at the time of publishing. 4-42 31215923...

  • Page 219: Cylinder Repair

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CYLINDER REPAIR NOTE: Service information not available at the time of publishing. 31215923 4-43...

  • Page 220: 4.10 Cylinder Assemblies

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.10 CYLINDER ASSEMBLIES MAF46300 Figure 4-32. Steer Cylinder 4-44 31215923...
  • Page 221 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF46290 Figure 4-33. Lift Cylinder 31215923 4-45...
  • Page 222 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1. Bleeder Valve 2. Cartridge Valve 3. Barrel 4. Seal 5. Wiper 6. Wear Ring 7. Rod 8. Plug *Torque to 19-21 ft. lbs. (25.8-28.6 Nm) **Torque to 36-46 ft. lbs. 46-52 Nm). THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF THE BLEEDER VALVE IS LOOSENED.
  • Page 223 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF46280 Figure 4-35. Leveling Jack Cylinder 31215923 4-47...

  • Page 224: Oscillating Axle Cylinder Bleeding Procedure

    1. Oscillating Axle Cylinder 2. Bleed Port Figure 4-36. Oscillating Axle Cylinder Bleeding 1. With the machine on and running connect a JLG ana- 6. Continue bleeding the cylinder until a steady unbro- lyzer and enter “Level 1 Access” mode.
  • Page 225 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215923 4-49...

  • Page 226: Hydraulic Schematics (For Rt)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.11 HYDRAULIC SCHEMATICS (FOR RT) (OPTIONAL) FRONT BRAKES REAR BRAKES STEER CYLINDER DRIVE B* DRIVE A* 165 BAR 165 BAR 132 BAR 172 BAR 190 BAR 0.5 mm 0.5 mm STEER STEER LEFT PARK RIGHT...
  • Page 227 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FRONT AXLE CYLINDERS 190 BAR 27 BAR 0.5 mm OPTION OPTION OSC AXLE LIFT SHEET 1 1001236870-B MAF4 1520 Figure 4-38. Hydraulic Schematics (For RT) - Sheet 2 of 10 31215923 4-51...
  • Page 228 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFT CYL LIFT CYLINDER UPPERAUX LIFT DOWN 1.2 mm 214 BAR LIFT DOWN VALVE UPPER LIFT DOWN 2.2 mm LOWER LIFT LIFT DOWN 214 BAR V1 (EXT.) V2 (RET.) 26' , 33' , 40' LIFT SCHEMATIC V2 (RET.) V1 (EXT.) 47'LIFT SCHEMATIC...
  • Page 229 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFT CYLINDER UPPER AUX LIFT DOWN 1.2 mm 214 BAR UPPER LIFT DOWN LOWER LIFT CYLINDER LOWER AUX LIFT DOWN 1.7 mm 214 BAR LOWER LIFT DOWN V2 (RET.) 47' LIFT SCHEMATIC SHEET 2 1001236870-B 415 0...
  • Page 230 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT SPEED DRIVE MOTOR DRAIN* DRAIN* 4WD OPTION SHEET 3 Figure 4-41. Hydraulic Schematics (For RT) - Sheet 5 of 10 4-54 31215923...
  • Page 231 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS REAR RIGHT REAR LEFT 0.8 mm MOTOR DRAIN* AUX TRACTION 35 BAR DRIVE DRAIN* 2WD OPTION SHEET 3 1001236870-B MAF4 1540 Figure 4-42. Hydraulic Schematics (For RT) - Sheet 6 of 10 31215923 4-55...
  • Page 232 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS RIGHT FRONT JACK LEFT FRONT JACK retract sensor 180 BAR 8:1 PILOT retract sensor LEVEL JACK 150 BAR EXTEND OPTIONP* OPTIONT* RIGHT REAR JACK LEVEL JACK RETRACT 180 BAR LEFT REAR retract sensor 8:1PILOT JACK retract sensor...
  • Page 233 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS RL OSC AX EXTEND FROM PORT 8 MCV RR OSC AX EXTEND 32 BAR REAR AXLE OPTION P* ENAB LE OPTION T* DUAL AXLE OPTION SHEET 4 1001236870-B MAF4 1550 Figure 4-44. Hydraulic Schematics (For RT) - Sheet 8 of 10 31215923 4-57...
  • Page 234 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS REAR LEFT MOTOR DRAIN* DRIVE DRAIN* 0.094 in FRONT LEFT MOTOR DRAIN* SHEET 5 Figure 4-45. Hydraulic Schematics (For RT) - Sheet 9 of 10 4-58 31215923...
  • Page 235 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS REAR REAR LEFT RIGHT 0.8 MM 2 SPEED 13.8 BAR 0.094 in 1.8L PM TRACTION FRONT FRONT LEFT RIGHT MOTOR DRAIN* 40FT AND 47FT 4WD OPTION SHEET 5 1001236870-B MAF4 1560 Figure 4-46. Hydraulic Schematics (For RT) - Sheet 10 of 10 31215923 4-59...

  • Page 236: Hydraulic Schematics (For Ert)

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.12 HYDRAULIC SCHEMATICS (FOR ERT) STEERCYLINDER STEER 132BAR 172BAR STEER STEER LEFT RIGHT LIFTUP ENABLE FLOW 190BAR CONTROL LIFT MAINCONTROL VALVE RETURNFILTER 5 MICRON SHEET 1 Figure 4-47. Hydraulic Schematics (For ERT) - Sheet 1 of 6 4-60 31215923...
  • Page 237 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 27BAR FRONTAXLE OPTIONP* OPTIONT* LIFT OSCAXLE SHEET 1 1001247271-B MAF4 7 B 15 0 Figure 4-48. Hydraulic Schematics (For ERT) - Sheet 2 of 6 31215923 4-61...
  • Page 238 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFTCYLINDER LIFTCYLINDER UPPERAUXLIFT DOWN 1.2 mm 214BAR LIFTDOWN VALVE UPPERLIFT DOWN 2.2 mm LIFT DOWN 214BAR V1(EXT.) V2(RET.) 26' , 33' , 40'LIFTSCHEMATIC V1(EXT.) 47'LIFTSCHEMATIC SHEET 2 Figure 4-49. Hydraulic Schematics (For ERT) - Sheet 3 of 6 4-62 31215923...
  • Page 239 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFTCYLINDER UPPERAUXLIFT DOWN 1.2 mm 214BAR UPPERLIFT DOWN LOWERLIFTCYLINDER LOWERAUX LIFTDOWN 1.7 mm 214BAR LOWERLIFT DOWN V2(RET.) 47'LIFTSCHEMATIC SHEET 2 1001247271-B MAF4 8 B 15 0 Figure 4-50. Hydraulic Schematics (For ERT) - Sheet 4 of 6 31215923 4-63...
  • Page 240 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS LEFT FRONT JACK 180 BAR 8:1PILOT 150 BAR retract sensor LEVEL JACK EXTEND OPTION P* OPTION T* LEFT LEVEL JACK REAR RETRACT JACK 180 BAR 8:1 PILOT retract sensor LEVEL JACK OPTION SHEET 3 Figure 4-51.
  • Page 241 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS RIGHT FRONT JACK retract sensor RIGHT REAR JACK retract sensor SHEET 3 1001247271-B MAF4 9 B 15 0 Figure 4-52. Hydraulic Schematics (For ERT) - Sheet 6 of 6 31215923 4-65...
  • Page 242 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4-66 31215923...

  • Page 243: Section 5 - Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM ANALYZER MENU: Analyzer Display HELP:PRESS ENTER Enter Key Escape Key Stores and selects Top Level, To return home or Sub Level, and item menus access previous menu Left & Right Arrow Keys Up &...

  • Page 244: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer If ENTER is pressed again, the display moves to the fol- lowing display: With the machine power on and the analyzer connected properly, the analyzer will display the following: HELP: 1 STARTUP (2/1)

  • Page 245: Changing The Access Level

    SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- When the analyzer is first connected, you will be in word was entered correctly:...

  • Page 246: Adjusting Parameters

    SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Machine Setup Once you have gained access to level 1, and a personal- When a machine digit item is selected, press the UP or ity item is selected, press the UP or DOWN arrow keys to...

  • Page 247: System Fault/Dtc Indication

    System Fault indicator on the face of the LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM- platform control box. PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/...

  • Page 248: Analyzer Menu Flow Chart (For Rt)

    SECTION 5 - JLG CONTROL SYSTEM ANALYZER MENU FLOW CHART (FOR RT) ANALYZER MENU STRUCTURE MENU : DIAGNOSTICS : DIAGNOSTICS: DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS GROUND SYSTEM PLATFORM ELEV SENSOR GROUND VOLTAGE: DRIVE SEL: LIFT UP: 12.0V OPEN OPEN PLAT VOLTAGE:...
  • Page 249 SECTION 5 - JLG CONTROL SYSTEM From DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS: DIAGNOSTICS : DIAGNOSTICS : CAN STATISTICS ELEV SENSOR OUTPUTS ENGINE LOAD SYSTEM DATALOG From ARM SENSOR ANG: FLOW CONTROL VLV ENGINE STATE: OVERLOADED?: CAN1 STATISTICS: SYSTEM: RAW XX.X DEG...
  • Page 250 SECTION 5 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DATALOG VERSIONS CAN STATISTICS DATALOG TIME ON: GROUND MODULE XXXXH XXm SOFTWARE: PX.X DATALOG TIME: GROUND MODULE DATALOG TIME: DATALOG CYCLES: ENGIN: XXXXh XXm CNST. DATA: PX.X...
  • Page 251 SECTION 5 - JLG CONTROL SYSTEM FROM MENU SYSTEM TEST MENU : ACCESS LEVEL: ACCESS LEVEL X CODE XXXXX MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES JOYSTICK PERSONALITIES DRIVE LIFT ENGINE LIFT: ENGINE: FWD MAX: DRIVE : UP ACCEL X.Xs LOW IDL XXXXRPM 0.00V...
  • Page 252 SECTION 5 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MODEL: MARKET: ENGINE: DRIVE TYPE: DRIVE CUTOUT: KBD1305E5X-18 MACHINE SETUP UNKNOWN ANSI USA LEVELING JACKS: LOAD SYSTEM: ENGINE SHUTDOWN: ELEC ARM GUARD: BEACON: CUTOUT PLT LOW TEMP CUTOUT: WHT. NOISE...
  • Page 253 SECTION 5 - JLG CONTROL SYSTEM FROM CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: ELEVATION SENSOR JOYSTICK REAR AXLE TILT CALIBRATE ELEV CALIBRATE ELEV: CALIBRATE CAL JOYSTICK: SENSOR? YES:ENTER;NO:ESC JOYSTICK? YES:ENTER;NO:ESC CALIBRATE ELEV: CAL JOYSTICK: COMPLETE! FWD TO MAX ARM SENSOR: CAL JOYSTICK: RAW TILT:...

  • Page 254: Analyzer Menu Flow Chart (For Ert)

    SECTION 5 - JLG CONTROL SYSTEM ANALYZER MENU FLOW CHART (FOR ERT) ANALYZER MENU STRUCTURE MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS : DIAGNOSTICS PLATFORM GROUND SYSTEM ELEV SENSOR OUTPUT DRIVE SEL: LIFT UP: MAIN CONTACTOR: ARM SENSOR ANG: OPEN OPEN ENABLED/DISABLED RAW XX.X DEG...
  • Page 255 SECTION 5 - JLG CONTROL SYSTEM From DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS : DIAGNOSTICS : OUTPUTS VOLTAGE/CUR CHARGER LOAD CAN STATISTICS ELEV SENSOR DATALOG FLOW CONTROL VLV BATTERY SOC: AC CONNECTED: NO OVERLOADED?: CAN1 STATISTICS: COMMAND: XXXXmA XXX%/DISCHARGED/ RX/SEC: X...
  • Page 256 SECTION 5 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DATALOG VERSIONS CAN STATISTICS DATALOG TIME ON: GROUND MODULE XXXXH XXm SOFTWARE: PX.X DATALOG TIME: GROUND MODULE DATALOG TIME: DATALOG CYCLES: RENTL: XXXXh XXm CNST. DATA: PX.X...
  • Page 257 SECTION 5 - JLG CONTROL SYSTEM FROM MENU SYSTEM TEST MENU : ACCESS LEVEL: ACCESS LEVEL X CODE XXXXX MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES DRIVE LIFT PUMP JOYSTICK GROUND MODE DRIVE: LIFT: PUMP: MIN XXX% FWD MAX: HORN: ACCEL X.Xs...
  • Page 258 SECTION 5 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MODEL: MARKET: BATTERY: FLA DRIVE CUTOUT: LEVELING JACKS: LOAD SYSTEM: MACHINE SETUP UNKNOWN ANSI USA CUTOUT PLT GROUND ALARM: ELEC ARM GUARD: BEACON: LOW TEMP CUTOUT: WHT. NOISE CLEARSKY: MOTION...
  • Page 259 SECTION 5 - JLG CONTROL SYSTEM FROM CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: JOYSTICK LOAD SET ARM GUARD ELEVATION SENSOR CALIBRATE CAL JOYSTICK: CAL LOAD: CALIBRATE SET ARM GUARD: JOYSTICK? YES:ENTER;NO:ESC YES:ENTER;NO:ESC ARMGUARD? LIFT TO HEIGHT CAL JOYSTICK: CAL LOAD: SET ARM GUARD:...

  • Page 260: Diagnostic Troubleshooting Codes (Dtc's) And Flash Codes Description (For Rt)

    SECTION 5 - JLG CONTROL SYSTEM DIAGNOSTIC TROUBLESHOOTING CODES (DTC’S) AND FLASH CODES DESCRIPTION (FOR RT) Flash Description Action Item Check List Code Code 0 0 “Everything OK” No Restrictions • Machine in PLT Mode and no faults active. 0 0 “Ground Mode OK”...
  • Page 261 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 0064 0 0 “Drive Speed Restricted - Rear Axle Not Drive Speed is Restricted to Elevated. • The UGM has determined that the Rear Axle is Not Aligned Aligned”...
  • Page 262 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 2 4 “Front Left Leveling Jack Pressure Trans- No Restrictions. • The Front Left Leveling Jack Pressure Transducer Voltage is ducer Failure” reading Greater than 4.75V or Less than 0.25V at UGM pin J7-4.
  • Page 263 • The Machine's Arm Angle Sensor is reading as Elevated and the Platform Stow Switch is reading as Stowed. • Check the platform stow switch status in the JLG Analyzer > Diagnostics > Elev Sensor. The NO status should be Open and the NC status should be Closed.
  • Page 264 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 23269 2 3 “Left Rear Ram Cylinder Pressure Switch If the Machine is Elevated, Drive is • The Ground Module has determined that the Rear Left Ram Disagreement”...
  • Page 265 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 33319 3 3 “Drive Forward Valve - Short to Ground” Drive and Lift Up are Prevented in • UGM Detects that the Drive Forward Valve (J14-9) is reading Platform Mode.
  • Page 266 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 33754 3 3 "Lower Lift Down Valve - Short to Ground" Lift Up and Down Prevented. • UGM Detects that the Lower Lift Down Valve (J2-35) is read- ing a Short to Ground Circuit.
  • Page 267 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 33781 3 3 "Rear Left Oscillating Axle Unlock Valve - Lift Up and Quik Level Prevented. • UGM Detects that the RL OSC Axle Unlock Valve (J2-5) is Short To Ground"...
  • Page 268 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 33794 3 3 "Rear Axle Enable Valve - Open Circuit" Lift Up Prevented. • UGM Detects that the Rear Axle Enable Valve (J2-11) is read- ing as an Open Circuit.
  • Page 269 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 3525 3 5 "Rear Left Leveling Jack Open Circuit" No Response. • UGM Detects that the RL Leveling Jack Valve (J2-21) is read- ing as an Open Circuit.
  • Page 270 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 3 “Engine Trouble Code (190:0 - Engine Engine Will Shutdown. • ECU is detecting the Engine Speed is higher than 2990 rpm. Overrun)” 4 3 "Engine Trouble Code (3509:4 - Sensor No Response.
  • Page 271 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 3 "Engine Trouble Code (51:4 - TPS1 Signal Engine Will Shutdown. • ECU is detecting the TPS 1 Voltage is less than or equal to Voltage Low)"...
  • Page 272 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 3 "Engine Trouble Code (1270:2 - Ignition No Response. • ECU is detecting LSI System has an Open Circuit or Short to Coil3 Error)" Battery.
  • Page 273 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 3 “Engine Trouble Code (523729:2 - LPG Fuel Engine Will Limit RPM to 2500 and • The ECU is detecting the Gaseous Solenoid is Higher than System Error)”...
  • Page 274 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 4 “Battery Voltage too Low - System Shut All UGM Valve Outputs are turned off. • UGM detects the Machine's System Voltage is less than 9V.
  • Page 275 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 6651 6 6 “CANBUS Failure - Ground Display” No response. • UGM is detecting that CAN Communication has been lost with the Ground Display. • Check ground display connector for damage and faulty wir- ing.
  • Page 276 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 8124 8 1 “Rear Axle Tilt Sensor Has Not Been Cali- Lift Up and Quik Level Functions Pre- • The UGM is detecting that the Rear Axle Tilt Sensor does not brated”...

  • Page 277: Diagnostic Troubleshooting Codes (Dtc's) And Flash Codes Description (For Ert)

    SECTION 5 - JLG CONTROL SYSTEM DIAGNOSTIC TROUBLESHOOTING CODES (DTC’S) AND FLASH CODES DESCRIPTION (FOR ERT) Flash Description Action Item Check List Code Code 0 0 “Everything OK” No Restrictions • Machine in PLT Mode and no faults active. 0 0 “Ground Mode OK”...
  • Page 278 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 2 2 “Function Problem - Steer Left Perma- If Machine is in Platform Mode, All • The Platform Steer Left Digital Input Signal at the Platform nently Selected"...
  • Page 279 • The Machine's Arm Angle Sensor is reading as Elevated and the Platform Stow Switch is reading as Stowed. • Check the platform stow switch status in the JLG Analyzer > Diagnostics > Elev Sensor. The NO status should be Open, and the NC status should be Closed in the stowed platform position.
  • Page 280 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 2512 2 5 “Elev Angle Sensor Not Detecting Lift Up Prevented. • The Arm Angle Sensor Value is not Changing while a Lift Up Change” Function is being Commanded.
  • Page 281 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 3121 3 1 “Main Contactor Coil - Voltage Feedback Lift Up, Drive and Leveling Jacks are • UGM is detecting that the Power Module is communicating a Incorrect”...
  • Page 282 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 33750 3 3 “Upper Lift Down Valve - Short To Battery” Lift Up and Down are Restricted to • UGM Detects that the Upper Lift Down Valve (J2-34) is read- Creep Speed.
  • Page 283 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 3 3 "Steer Left Valve - Open Circuit" Drive Speed Restricted to Elevated • UGM Detects that the Steer Left Valve (J2-2) is reading as an Speed.
  • Page 284 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 3529 3 5 "Leveling Jack Extend Valve - Short To No Response. • UGM Detects that the Leveling Jack Extend Valve (J2-32) is Ground" reading a Short to Ground Circuit.
  • Page 285 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4232 4 2 “Rear Left Motor Too Hot - Please Wait” Drive Speed Restricted to Elevated • UGM is detecting that the Left Drive Motor Temperature is Speed if the Temperature is greater greater than 125C.
  • Page 286 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 44136 4 4 "BATTERY CHARGER - FAULT (524037:31 - No Response. • The Battery Charger is detecting that one of the external Button Stuck Down)" buttons are permanently closed.
  • Page 287 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 44136 4 4 "BATTERY CHARGER - FAULT (524167:31 - No Response. • The Battery Charger is detecting an internal charger fault. Hardware Fault)" • Remove AC and battery for a minimum of 30 seconds and retry charger.
  • Page 288 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 4 4 "LSS Battery Voltage High" No Response. • The LSS Supply Voltage is Greater than 34V. • Check battery supply and wiring to the LSS Control Module.
  • Page 289 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 46100 4 6 "Rear Left Brake Return - Short To Battery" Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Left Power Module is communi- tions are Prevented.
  • Page 290 • Check the temperature on the Module, if the temperature is higher than 85C then allow the module to cool. If the tem- perature is not high, then contact JLG Support 46188 4 6 "Rear Left Module - Current Too High"...
  • Page 291 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 46192 4 6 "Rear Left Module - Phase Voltage Too Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Left Power Module is communi- High"...
  • Page 292 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 46199 4 6 "Rear Right Module - Brake Coil Voltage Drive is Prevented. • UGM is detecting that the Right Power Module is communi- Feedback Incorrect"...
  • Page 293 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 6 6 “CANBUS Failure - Platform Module” Machine Functions from Platform • UGM is detecting that CAN Communication has been lost are Prevented. with the Platform Module.
  • Page 294 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 7725 7 7 "Pump Motor - Not Respondng" Lift Up, Leveling Jacks and Steer • UGM is detecting that the Right Power Module is communi- Functions are Prevented.
  • Page 295 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 7758 7 7 "Rear Right Motor Output - Out Of Range Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Right Power Module is communi- High"...
  • Page 296 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 7773 7 7 "Rear Left Motor - Open Circuit" Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Left Power Module is communi- tions are Prevented.
  • Page 297 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 8 2 "Functions Cutout - Platform Overloaded" Machine will behave as if it is over- • UGM is detecting that a LSS fault is active. Remove excessive loaded.
  • Page 298 Prevented. cating that there is an issue with Module's Capacitor charge voltage. • Contact JLG Support. The charging resistance or PTC may be broken. The charging circuit might have a failure or there is a problem in the power circuit.
  • Page 299 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 99248 9 9 "Rear Right Module - Eeprom Failure" Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Right Power Module is communi- tions are Prevented.
  • Page 300 Prevented. cating that there is an issue with Module's Capacitor charge voltage. • Contact JLG Support. The charging resistance or PTC may be broken. The charging circuit might have a failure or there is a problem in the power circuit.
  • Page 301 • Check the battery voltage and 48V connections to the mod- ule. If no issues found, then contact JLG Support. 99354 9 9 "Rear Right Module - Internal Error (239 - Drive, Lift Up and Leveling Jack Func- •...
  • Page 302 • Check the battery voltage and 48V connections to the mod- ule. If no issues found, then contact JLG Support. 99355 9 9 "Rear Left Module - Internal Error (239 - Drive, Lift Up and Leveling Jack Func- •...
  • Page 303 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 99355 9 9 "Rear Left Module - Internal Error (199 - Drive, Lift Up and Leveling Jack Func- • UGM is detecting that the Left Power Module is communi- Param Transfer)"...
  • Page 304 SECTION 5 - JLG CONTROL SYSTEM Flash Description Action Item Check List Code Code 9 9 “EEPROM Failure - Check All Settings” All Machine Functions Prevented. • UGM is detecting an internal EEPROM error. • This is likely due to a software update that requires a Machine Setup Model and Market Toggle.

  • Page 305: Chassis Tilt Sensor Installation

    SECTION 5 - JLG CONTROL SYSTEM CHASSIS TILT SENSOR INSTALLATION MAF42450 MAF42440 1. Tilt Sensor 3. Angle Chassis Harness 1. Tilt Sensor 3. Washer 2. Frame 4. Gasket 2. Bolt 4. Gasket Figure 5-13. Chassis Tilt Sensor Location Figure 5-14. Chassis Tilt Sensor Removal NOTE: Refer to Figure 5-14., Chassis Tilt Sensor Removal for...

  • Page 306: Location Of Additional Sensors

    SECTION 5 - JLG CONTROL SYSTEM LOCATION OF ADDITIONAL SENSORS MAF42740 1. Arm Tilt Sensor 4. Front Axle Tilt Sensors (CE Market Only or Quiklevel equipped machines) 2. Rear Axle Tilt Sensors (Quiklevel equipped machine) 5. Rear Axle Ram Cylinder Pressure Switch 3.
  • Page 307 SECTION 5 - JLG CONTROL SYSTEM 31215923 5-65...

  • Page 308: Calibration Procedures

    SECTION 5 - JLG CONTROL SYSTEM CALIBRATION PROCEDURES For the following troubleshooting steps, a bubble level (smaller is better) will be needed and the machine must be on a level surface: Chassis Tilt Sensor - Non QuikLevel Equipped 1. On the Analyzer, go to Diagnostics/System and read Machine the tilt angle.

  • Page 309: Chassis Tilt Sensor - Quiklevel Equipped Machine

    SECTION 5 - JLG CONTROL SYSTEM Chassis Tilt Sensor - QuikLevel Equipped Machine other axis. If either axis is greater than ±2.0°, replace the tilt sensor. Some possible reasons 1. Drive the machine onto a measured level surface that the tilt sensor will not calibrate are: (±0.5°...

  • Page 310: Troubleshooting Steps

    SECTION 5 - JLG CONTROL SYSTEM Front Oscillating Axle Tilt Sensor (CE or Quiklevel sensor or ground control board failure (observe any cracks in the box). Equipped Machines Only) Elevation Sensor 1. Place machine on flat level surface 2. Start with machine in the stow position 1.

  • Page 311: Rear Axle Tilt Sensor (Quiklevel Equipped Machines Only)

    SECTION 5 - JLG CONTROL SYSTEM Rear Axle Tilt Sensor (Quiklevel Equipped Machines a. Machine mounting and/or grade: With a digital level, measure the front and rear Only) axles for levelness. The machine must be on flat level ground. 1. Place machine on flat level surface.

  • Page 312: Joystick

    SECTION 5 - JLG CONTROL SYSTEM Joystick Set Charger (ERT Family Only) 1. In the platform at the platform control box, ensure NOTE: This procedure allows for changing the charger algo- the joystick is in the center (neutral) position. rithm based on the type of batteries and the battery stack size installed on the machine.

  • Page 313: Service Mode Procedures

    SECTION 5 - JLG CONTROL SYSTEM SERVICE MODE PROCEDURES 5. The Analyzer will display L/J RETRACTED? Select Enter. Elevation Service 6. The Analyzer will display DRIVE ALLOWED. Select Escape to leave menu. This procedure allows a service technician to elevate the...

  • Page 314: Qla Pressure Set

    SECTION 5 - JLG CONTROL SYSTEM QLA Pressure Set This mode allows a service technician to activate the QLA pressure set mode which will allow for easy adjust- ment of the QLA pressure set procedure. 1. Using the Analyzer, navigate to SERVICE MODE > QLA Pressure Set 2.

  • Page 315: Machine Configuration And Programming Settings (For Rt)

    SECTION 5 - JLG CONTROL SYSTEM 5.10 MACHINE CONFIGURATION AND PROGRAMMING SETTINGS (FOR RT) The Machine Configuration Programming must be completed before any Personality settings (Table 5-8) can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.

  • Page 316: Machine Configuration And Programming Settings (For Ert)

    SECTION 5 - JLG CONTROL SYSTEM 5.11 MACHINE CONFIGURATION AND PROGRAMMING SETTINGS (FOR ERT) The Machine Configuration Programming must be completed before any Personality settings (Table 5-9) can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 317 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Blue Numbers indicate the default setting for Table 5-5. Machine Configuration Programming Information that market. Plain text indicates another available selection. SHADED CELLS indicates hidden menu or Configuration RT3369 selection in that market.
  • Page 318 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Numbers indicate the default setting for that Table 5-7. Machine Configuration Programming Information market. Plain text indicates another available selec- tion. SHADED CELLS indicates hidden menu or selec- Configurati ERT3369 tion in that market.
  • Page 319 SECTION 5 - JLG CONTROL SYSTEM Table 5-8. Machine Model Personality Adjustment (For RT) Model Default Values Adjustment Adjustment Range RT2669 RT3369 DRIVE Accel X.Xs 0.1 - 5.0 sec Decel X.Xs 0.1 - 2.5 sec Min XXXXmA 0 - 600mA...

  • Page 320: Machine Orientation When Setting Speeds

    SECTION 5 - JLG CONTROL SYSTEM Table 5-8. Machine Model Personality Adjustment (For RT) Model Default Values Adjustment Adjustment Range RT2669 RT3369 Rev MAX XXXV 3.90 - 5.00V 3.96 3.96 GROUND MODE : Horn: XXX% 1 - 100% Alarm: XXX%...
  • Page 321 SECTION 5 - JLG CONTROL SYSTEM Table 5-9. Machine Model Personality Adjustment (For ERT) Model Default Values Adjustment Adjustment Range ERT2669 ERT3369 DRIVE Accel X.Xs 0.1 - 5.0 sec Decel X.Xs 0.1 - 2.0 sec Decel To Stop X.XS 0.1 - 5.0 sec...
  • Page 322 SECTION 5 - JLG CONTROL SYSTEM Table 5-9. Machine Model Personality Adjustment (For ERT) Model Default Values Adjustment Adjustment Range ERT2669 ERT3369 Alarm: XXX% 1 - 100% LOAD : OVR DBNCE: XXs 0.0 - 5.0s OVR HOLD XXs 0.0 - 5.0s...

  • Page 323: Section 6 - Lss Setup/Calibration/Service

    Top Level Menu. Press the ENTER key to view the menu. NOTE: The cable has a four-pin connector at each end of the cable; The cable cannot be connected back- When accessing the Help Menu, the JLG Analyzer will wards. display EVERYTHING OK if the platform is not over- loaded and no difficulties are detected.

  • Page 324: Machine Setup Menu

    ANALYZER 1ST LINE) ANALYZER 2ND LINE) LOAD: 1 = CUTOUT PLT Displays/adjusts the LSS Module 2 =CUTOUT ALL Table 6-3. Calibration Value RT2669, RT3669, ERT2669 & Models ERT3669 Minimum Calibration Values 453 KG (1000 LB) Maximum Calibration Values 7771 KG...

  • Page 325: Service

    SECTION 6 - LSS SETUP/CALIBRATION/SERVICE SERVICE Description The system consists of the LSS Module, four Shear Pin Load Cells (sensors), Wire Harness, and various brackets and fas- teners. The LSS Module is mounted beneath the platform on a bracket. The Shear Pin Load Cells mount between the platform and the arm structure in such a way that all support force for the platform is applied through them (for mea- surement).

  • Page 326: 6.5 Calibration

    NOTE: Need to calibrate load sensing system every 3 months and also apply a thorough coat of Lithium Grease (JLG PN 3020029) added to the upper slide channel under the platform where the upper wear pads s through the upper slide channels. Refer to Figure 6-2., Lithium Grease Application.
  • Page 327 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE APPLY THOROUGH COAT OF LITHIUM GREASE (JLG PN 3020029) TO UPPER SLIDE CHANNELS MAF45680 Figure 6-2. Lithium Grease Application 31215923...

  • Page 328: Testing & Evaluation

    Place 120% of the machines rated load in the center of the platform and ensure that the 1. Plug the JLG Analyzer into the Host Control System. overload visual and audible warnings are active. 2. Park the vehicle on a level surface. The platform Reduce the platform load to 100% rated load and should be fully stowed and level within ±...

  • Page 329: 6.6 Troubleshooting

    3. There is a short circuit on the pre-regulated supply for the JLG Analyzer present on J2-1. Unplug J2’s connector and observe whether the module begins to function. If so, examine the Analyzer harness for defect.
  • Page 330 (this is normal). (±1 kg) (without the influence of vibration 2. Wiring leading to one of the Shear Pin Load Cells is damaged. Examine each sensor’s reading using the JLG Analyzer. or wind).
  • Page 331 2. The signal between the LSS Module and the Host Control System is shorted. The Platform Module’s J1-20 is an input, and it connected to the J1-5 output on the LSS Module To examine the status of this signal, plug the JLG Ana- lyzer into the Host Control System, enter the Access Level 1 password (33271), and examine the DIAGNOSTICS, SYS- TEM, LOAD display.
  • Page 332 Figure 6-3. LSS Module Load Cell Connector Communication (J1 - Black) Pinout (J5, J6, J7, J8) SIGNAL DESCRIPTION APWR Pre-Regulated Supply for JLG Analyzer (Analyzer Pin 1; approx. 12 V) RS-232 for JLG Analyzer (Analyzer Pin 3) TRP1 120 Ohm CANbus Terminator CANH-1...
  • Page 333 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE MAF44850 Figure 6-4. Wiring Diagram (For LSS) 31215923 6-11...
  • Page 334 SECTION 6 - LSS SETUP/CALIBRATION/SERVICE 6-12 31215923...

  • Page 335: Multimeter Basics

    LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM- nector terminal and measuring resistance. Do this after PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM giving each wire a gentle pull to ensure the wires are PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 still attached to the contact and contacts are seated in INCHES (30.5 CM) AWAY FROM THESE COMPONENTS.

  • Page 336: Voltage Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 7-2. Resistance Measurement Figure 7-1. Voltage Measurement (DC) • If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together. (See multimeter’s operation manual).

  • Page 337: Continuity Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC) • Some meters require a separate button press to • Set up the meter for the expected current range. enable audible continuity testing.

  • Page 338: Continuity Measurement Over Long Distances

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a prob- When trying to determine continuity of a harness or lem the third wire is used to troubleshoot the other wire, longer than the reach of standard instrument wires.

  • Page 339: Dielectric Grease Application

    The following connector systems are specifically addressed This connector system is typically used on control modules at because of their widespread use at JLG. However, this guid- JLG. Follow the general guidance for installation. ance may be applied to similar devices...

  • Page 340: Mini Fit Sr

    This connector system is typically used on control modules at nuity, due to silicone dielectric grease ingress when switching JLG. Follow the general guidance for installation. inductive loads. Therefore, dielectric grease shall not be applied to Carling switch mating connectors unless specifi- cally noted.

  • Page 341: Amp Connector

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS AMP CONNECTOR Figure 7-5. AMP Connector 1. To insert a contact, push it straight into the appropri- Assembly ate circuit cavity as far as it will go (See Figure 7-7., Check to be sure the wedge lock is in the open, or as- Connector Assembly Figure 2).
  • Page 342 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-9., Connector Assem- Release the locking latches by squeezing them bly Figure 4).

  • Page 343: Disassembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half 1. Insert a 4.8 mm (3/16 in.) wide screwdriver blade turn (1/4 turn in each direction), gently pull the wire between the mating seal and one of the red wedge until the contact is removed.

  • Page 344: Service - Voltage Reading

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading sharp point. This practice should be discouraged when dealing with the AMP SEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

  • Page 345: 7.6 Working With Deutsch Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.6 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-13. DT/DTP Contact Removal Figure 7-12. DT/DTP Contact Installation 1. Remove wedgelock using needlenose pliers or a 1. Grasp crimped contact about 25 mm behind the con- hook shaped wire to pull wedge straight out.

  • Page 346: Hd30/Hdp20 Series Assembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25 mm behind the contact 1. With rear insert toward you, snap appropriate size crimp barrel.

  • Page 347: Switches

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch”. 1. De-energize the circuit. Inductive proximity switches are actuated only by fer- 2.

  • Page 348: Automatic Switches

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches Switch Wiring - Low Side, High Side If the switch is actuated automatically, by temperature When controlling a load, a switch can be wired between or pressure for example, find a way to manually actuate the positive side of the power source and the load.

  • Page 349: Electrical Schematics (For Rt)

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS (FOR RT) SHEET 2: CHASSIS HARNESS, CHASSIS CABLE, LIFT DOWN CABLE, LIFT DOWN (47FT) HARNESS, REAR OSCILLATING AXLE SHEET 3: PLATFORM CABLE, ARMSTACK, 260MRT HARNESS, PLATFORM CABLE, PLATFORM BOX CABLE, ARM ANGLE HARNESS, PLATFORM BOX HARNESS, PLATFORM (MODULE BASED) HARNESS, LOAD SENSE...
  • Page 350 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS X145A YEL J7-29 LJ STOW PWR BLK J7-28 LJ STOW GND WHT J7-26 LJ PRES 5V BLK J2-17 LVL JAX GND LEVEL JACKS WHT J2-16 F RT LVL JX VLV WHT J2-12 F LT LVL JX VLV BLK J8-1 GND (14) OPT HARNESS WHT J2-23 R RT LVL JX VLV...
  • Page 351 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CHASSIS HARNESS BLK J8-1 GND (14) YEL J8-2 IGN (12) X88A YEL J7-30 ENG IGN RL WHT J3-9 ALT LAMP YEL CAN2H GRN CAN2L WHT 60-3 FUEL PUMP PWR WHT J1-2-2 BEACON BLK J8-1 GND (14) WHT J2-24 GLOW PLUG IND ENGINE...
  • Page 352 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CABLE PLATFORM PLATFORM PLATFORM BOX JOYSTIC ARMSTACK HARNESS BOX HARNESS CABLE X125A X127A ORG-BLK-CABLE WHT J4-26 RR LP PWR WHT-YEL CABLE FOOTSWITCH SIG YEL-BLK-CABLE WHT J4-27 RL LP PWR X126A ORG J9-27-2-3 PLT IGN BLU-BLK-CABLE WHT J4-13 FR LP PWR BLU CABLE DI SPARE 1...
  • Page 353 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS USB PROGRAMMING PORT CABLE PLATFORM PLATFORM BOX JOYSTICK BOX HARNESS 2-PORT USB CHARGER X127A WHT-YEL CABLE FOOTSWITCH SIG X126A ORG J9-27-2-3 PLT IGN BLU CABLE DI SPARE 1 RED J7-1 PLT EMS SIG RED-BLK CABLE RED J7-1 PLT EMS VIO CABLE DI SPARE 2...
  • Page 354 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BEACON GENERIC ALTERNATOR DIODE ALT EXCITE LAMP IGN YEL 2-1 IGN PWR (12) RED 1-2-3 PWR (12) BLK 00-17-2 IGN RL GND YEL J7-20 ENG IGN RL BLK 00-1-4 GEN CNTL BOX GND X88B BLK 00-16-3 GND S163...
  • Page 355 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BEACON GENERIC ALTERNATOR DIODE ALT EXCITE DIESEL ENGINE HARNESS LAMP IGN GROUND STUD BLK 00-1-4 GEN CNTL BOX GND BLK 00-16-3 GND GND TO ENG T1-1- BLK 00-1-4 GEN CNTL BOX GND X18 CONNECTOR TO HARNESS WHT J1-22 GEN ENBL YEL 2-1-2 GEN CNTL BOX PWR (16)
  • Page 356 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS KUBOTA KUBOTA POST O2 SNSR STARTER KUBOTA START START ALTERNATOR DIODE IGN FUSE ALT FUSE IGN LAMP S212 YEL 2-1 IGN PWR (12) YEL 2-1-4 IGN PWR RED 1-2-4 PWR (12) BLK 00-16-1 GND (18) YEL J7-30 ENG IGN RL X88B WHT J1-11 ENG STRT RL...
  • Page 357 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS KUBOTA KUBOTA KUBOTA POST O2 SNSR PRE O2 SNSR STARTER KUBOTA START START ALTERNATOR DIODE IGN FUSE T12- TO IGN LAMP AUX BLOCK DUAL FUEL ENGINE HARNESS GROUND STUD EC10 BLK 34-2 GND (14) BLK 34-3 GND (14) WHT 54-2 SN GND WHT 30 PRE 02 SN...
  • Page 358 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PROX SENSOR PROX SENSOR PROX SENSOR PROX SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT GENERIC GENERIC GENERIC GENERIC PRES SENSOR PRES SENSOR PRES SENSOR PRES SENSOR REAR LEFT REAR RIGHT FRONT LEFT FRONT RIGHT LEFT REAR...
  • Page 359 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PROX SENSOR PROX SENSOR PROX SENSOR PROX SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT PRES SENSOR PRES SENSOR PRES SENSOR PRES SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEVELING JACKS HARNESS 1001117025...
  • Page 360 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HARNESS INFORMATION: 26FT 33FT 40FT HARNESS 47FT CONNECTS TO BLK 00-112-3 GND RED 111-3 PWR WORKLIGHT 2 GND AUX BLOCK LB16 BLK CABLE GROUND BLK 00-112-1 GND T317 ORG FUSE LEAD (12) WHT CABLE POWER RED 111-1 PWR X397A...
  • Page 361 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HARNESS BLK 00-112-3 GND RED 111-3 PWR WORKLIGHT 2 WORKLIGHTS LB16 BLK 00-112-2 GND RED 111-2 PWR WORKLIGHT 1 LB15 HOC PWR HOC TEMP HYDRAULIC OIL COOLER RED 101-2-1 B+(12) RED 101-3-1 B+ S411 RED 101-3-2 HOC TEMP SW PWR WHT 102-1 HOC TEMP SW SIG...
  • Page 362 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7-28 31215923...

  • Page 363: Electrical Schematics (For Ert)

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS (FOR ERT) SHEET 1: TITLE PAGE SHEET 2: CHASSIS HARNESS, CHASSIS CABLE, LIFT DOWN CABLE, LIFT DOWN (47FT) HARNESS 47FT ELECTRONIC AUXILIARY DESCENT SHEET 3: PLATFORM CABLE, ARMSTACK, 260MRT HARNESS, PLATFORM CABLE, PLATFORM BOX CABLE, ARM ANGLE HARNESS, PLATFORM BOX...
  • Page 364 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS X145A YEL J7-29 LJ STOW PWR BLK J7-28 LJ STOW GND WHT J7-26 LJ PRES 5V BLK J2-17 LVL JAX GND YEL J8-2-3 IGN LEVEL JACKS S579 WHT J2-16 F RT LVL JX VLV YEL J8-2-2 IGN (12) WHT J2-12 F LT LVL JX VLV OPT HARNESS...
  • Page 365 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CHASSIS HARNESS YEL J8-2-3 IGN S579 YEL J8-2-2 IGN (12) IP482 ORG LEAD FUSE (12) BLK J8-1 GND (12) WHT J1-2-2 BEACON TO BATTERY WHT J4-29 48V PWR MOD IGN RELAY SIG YEL J8-2-2 48V IGN RELAY COMPARTMENT RED 2-1-2 DC 12V UNSW...
  • Page 366 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PLATFORM PLATFORM CABLE BOX HARNESS ARMSTACK HARNESS PLATFORM BOX JOYSTICK CABLE X125A X127A ORG-BLK-CABLE WHT J4-26 RR LP PWR WHT-YEL CABLE FOOTSWITCH SIG YEL-BLK-CABLE WHT J4-27 RL LP PWR X126A ORG J9-27-2-3 PLT IGN BLU-BLK-CABLE WHT J4-13 FR LP PWR BLU CABLE DI SPARE 1...
  • Page 367 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS USB PROGRAMMING PORT PLATFORM CABLE BOX HARNESS PLATFORM BOX JOYSTICK 2-PORT USB CHARGER X127A WHT-YEL CABLE FOOTSWITCH SIG X126A ORG J9-27-2-3 PLT IGN BLU CABLE DI SPARE 1 RED J7-1 PLT EMS SIG RED-BLK CABLE RED J7-1 PLT EMS VIO CABLE DI SPARE 2...
  • Page 368 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CONNECT TO NEGATIVE CONNECT TO POSITIVE POWER STUD POWER STUD IP399 IP389 RED 371-3-1 B+ RED 371-3-2 B+ RED 342-3-2 B+ 1001248066 CO371-J1 CO342-B+ ORG 371-2 BRAKE POS RED 1-55 B+ SPM(2) RED 1-56 B+ MPM(2) BRAKE POSITIVE RED 371-3-1 B+...
  • Page 369 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TRACTION HARNESS CONNECT TO NEGATIVE CONNECT TO POSITIVE POWER STUD POWER STUD STEER ANGLE SENSOR IP389 RED 342-3-2 B+ RED 342-3-1 B+ CO342-J1 CO342-B+ RED 1-55 B+ SPM(2) RED 1-56 B+ MPM(2) ORG 342-2 BRAKE POS BRAKE POSITIVE RED 342-3-1 B+...
  • Page 370 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PROX SENSOR PROX SENSOR PROX SENSOR PROX SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT GENERIC GENERIC GENERIC GENERIC PRES SENSOR PRES SENSOR PRES SENSOR PRES SENSOR REAR LEFT REAR RIGHT FRONT LEFT FRONT RIGHT LEFT REAR...
  • Page 371 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PROX SENSOR PROX SENSOR PROX SENSOR PROX SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT PRES SENSOR PRES SENSOR PRES SENSOR PRES SENSOR LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEVELING JACKS HARNESS (OPT)
  • Page 372 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CONNECT TO BATTERY DISCONNECT RED GENERATOR B+ 4EPDM X637 MS351-2 SHEET 4 B6 BLK GENERATOR B- 4EPDM CONNECT TO NEGATIVE POWER STUD X638 SHEET 4 H4 EC363B- EC363B+ UA103 UA131 48VDC UA108 DYNAMO GENERATOR ENGINE SCHEMATIC UA112...
  • Page 373 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS EC363B+ UA103 X658 UA131 48VDC PLUGS IN TO X460A SHEET 5, C5 EC104 GENERATOR ENGINE SCHEMATIC SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOID MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP.
  • Page 374 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7-40 31215923...
  • Page 376 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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