Oshkosh JLG 1500SJ Service And Maintenance Manual

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Service and Maintenance Manual

Model

1500SJ

P/N - 3121262

March 7, 2016

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Page 1 Service and Maintenance Manual Model 1500SJ P/N - 3121262 March 7, 2016...
Page 3: General
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
Page 4 INTRODUCTION REVISON LOG Original Issue - September 12, 2011 Revised - November 9, 2011 Revised - March 26, 2012 Revised - May 16, 2012 Revised - January 10, 2013 Revised - February 20, 2013 Revised - May 22, 2013 Revised - September 30, 2015 Revised - March 7, 2016...
Page 5: Table Of Contents
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires and Wheels ................. . . 3-1 Tire Inflation.
Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.14 Swing Brake ..................3-75 Pre-Installation Checks .
Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS ....... . . 3-143 List of Abbreviations in this Section .
Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 4 - BOOM & PLATFORM Boom Systems ..................4-1 Broken Cable Indicator System .
Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Boom Section Re-Positioning ..............4-78 Wire Rope Tensioning Procedure .
Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Jib Telescope Cylinder............... . . 5-93 Main Boom Telescope Cylinder .
Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ............6-1 Introduction.
Page 13 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
Page 14 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3121262...
Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-5 1-2.
Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-49. Swing Brake Assembly................3-78 3-50.
Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-24. Wire Rope Adjustment Tools (Optional) ............. 4-86 4-25.
Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-50. Rod Seal Installation ................5-65 5-51.
Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-107. Cylinder Cap Removal ................5-89 5-108.
Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3 ....... 6-26 6-8.
Page 21 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-33. Boom Length and Angle Harness - Sheet 2 of 2............7-26 7-34.
Page 22 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Dimensional Data .
Page 23 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 ........5-38 5-26 British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 .
Page 24 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3121262...
Page 25: Specifications
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-2. Dimensional Data Table 1-1. Operating Specifications Turning Radius (Axles Retracted) Capacity - ANSI Outside 22 ft. 6 in. (6.8 m) Unrestricted 500 lbs (227 kg) Inside 14 ft.
Page 26: Capacities
SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES 1.5 ENGINE DATA Table 1-3. Capacities Deutz Hydraulic Oil Tank 55 gal. (208 L) Table 1-5. Deutz TD2011L4 Specifications Fuel Tank - Standard 31 gal. (117 L) Type Liquid Cooled Number of Cylinders Fuel Tank - Optional 52.8 gal.
Page 27: Hydraulic Oil
SECTION 1 - SPECIFICATIONS 1.6 HYDRAULIC OIL Table 1-9. Mobil DTE 13M Specs ISO Viscosity Grade Table 1-7. Hydraulic Oil Specific Gravity 0.877 Hydraulic System S.A.E. Viscosity Pour Point, Max -40°F (-40°C) Operating Grade Temperature Range Flash Point, Min. 330°F (166°C) +0°...
Page 28: Major Component Weights
SECTION 1 - SPECIFICATIONS 1.7 MAJOR COMPONENT WEIGHTS Table 1-11. Mobil EAL H 46 Specs Type Synthetic Biodegradable ISO Viscosity Grade DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT- Specific Gravity .910 FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Page 29 SECTION 1 - SPECIFICATIONS 10,11 9,12 Figure 1-1. Maintenance and Lubrication Diagram 3121262 – JLG Lift –...
Page 30: Operator Maintenance
SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE 2. Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-14. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
Page 31 SECTION 1 - SPECIFICATIONS 4. A. Wheel Drive Hub - Bonfiglioli 5. Hydraulic Return Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 Lube Point(s) - Level/Fill Plug hours thereafter or as indicated by condition Capacity - 2.1 quarts (2 liters) ±...
Page 32 SECTION 1 - SPECIFICATIONS 7. Hydraulic Oil 9. Oil Change w/Filter - Deutz FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Fill Cap/Spin-on Element Capacity - 5 Quarts (4.5 L) Cooling System 11 Quarts (10.5 L) w/Filter Lube Point(s) - Fill Cap 16 Quarts (15 L) Total Capacity Capacity - 55 gallons (208 liters) Tank...
Page 33 SECTION 1 - SPECIFICATIONS 10. Fuel Filter - Deutz 12. Oil Change w/Filter - CAT Lube Point(s) - Replaceable Element Lube Point(s) - Fill Cap/Spin-on Element Interval - Every year or 600 hours of operation Capacity - 10.5 Quarts (10 L) 11.
Page 34 SECTION 1 - SPECIFICATIONS 14. Air Filter 16. Boom Lube Point(s) - Apply to wear pad contact paths Lube - Super Lube® Interval - Every year or 600 hours of operation. Refer to the Section 4 - Boom for detailed procedures Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator...
Page 35 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121262 – JLG Lift – 1-11...
Page 36 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-12 – JLG Lift – 3121262...
Page 37 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121262 – JLG Lift – 1-13...
Page 38 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-14 – JLG Lift – 3121262...
Page 39 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121262 – JLG Lift – 1-15...
Page 40 SECTION 1 - SPECIFICATIONS NOTES: 1-16 – JLG Lift – 3121262...
Page 41: General
SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures. MAINTENANCE Annual Machine Inspection General The Annual Machine Inspection must be performed on an This section provides the necessary information needed by annual basis, no later than thirteen (13) months from the date those personnel that are responsible to place the machine in of the prior Annual Machine Inspection.
Page 42: Service And Guidelines
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual At each Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic...
Page 43: Component Disassembly And Reassembly
SECTION 2 - GENERAL Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat- When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with the procedural steps in sequence.
Page 44: Hydraulic Oil
SECTION 2 - GENERAL 2. The design and manufacturing tolerances of the compo- Changing Hydraulic Oil nent working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a sys- 1. Filter elements must be changed after the first 50 hours tem can cause wear or damage to the components and of operation and every 300 hours (unless specified oth- generally results in faulty operation.
Page 45: Cylinder Drift
SECTION 2 - GENERAL Cylinder Drift 4. Re-assembly of pinned joints using filament wound bearings. Table 2-2. Cylinder Drift a. Housing should be blown out to remove all dirt and debris...bearings and bearing housings must be free Max. Acceptable Drift of all contamination.
Page 46 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings...
Page 47 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
Page 48 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications...
Page 49 SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F (49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F (43 C) 100 F (38 C) 90 F (32 C) 80 F (27 C) S U M M E R GR A D E 70 F (21 C) ENGINE F U E L...
Page 50 SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120 F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) 70 F(21 C) ENGINE 60 F(16 C) SPECIFICATIONS 50 F(10 C) 40 F(4 C) 30 F(-1 C) 20 F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS...
Page 51: Chassis & Turntable
SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE ers. If you do not have a torque wrench, tighten the fasteners 3.1 TIRES AND WHEELS with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tighten- Tire Inflation ing will result in breaking the studs or permanently deforming The air pressure for pneumatic tires must be equal to the air...
Page 52: Extending Axles
SECTION 3 - CHASSIS & TURNTABLE 3.2 EXTENDING AXLES control system will automatically reduce the wheel angle to 25 degrees during axle retraction. NOTE: The boom must be oriented between the rear wheels to NOTE: For more detailed information concerning system adjust- extend or retract the axles.
Page 53: Drive System
SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE SYSTEM The drive system utilizes 2 traction pumps so each side is pow- ered individually. This produces maximum tractive effort to wheels by minimizing flow divider losses. The maximum drive speed is modulated with the steered angle of the wheels to eliminate the whiplash effect of driving at full speed and maxi- mum steering lock.
Page 54: Drive/Steering Speed Control
SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE/STEERING SPEED CONTROL enabled, the DOS indicator will be illuminated continuously and a 3-second enable timer will be started and will continue The Drive/Steering Speed Control system uses the steering for 3 seconds after the end the last drive/steer command. If the sensors from the steering control system to increase operator timer expires, the DOS override switch must be re-engaged to control and comfort by reducing the effect of turning the...
Page 55 SECTION 3 - CHASSIS & TURNTABLE Press ENTER , the screen should read: Use the Left or Right arrow key until you see: To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press ENTER , the screen should read: Swing and drive functions can now be used to swing the turn-...
Page 56 SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Chassis Component Location - Sheet 1 of 2 – JLG Lift – 3121262...
Page 57 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Limit Switch (Right Front) 10. Steer Angle Sensor (Left Rear) 2. Steer Angle Sensor (Right Front) 11. Chassis Module 3. Steer Valve (Front) 12. Swivel/Collector Ring 4. Axle Lockout Valve 13. Axle Lockout Pressure Switch 5.
Page 58 SECTION 3 - CHASSIS & TURNTABLE Figure 3-7. Turntable Component Location - Sheet 1 of 2 – JLG Lift – 3121262...
Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Ground Control Box 15. Starter Relay 2. Headlight 16. Glow Plug Relay 3. Deutz EMR2 Module & Diagnostic Connector 17. Swivel 4. 110V / 220V Generator 18. Alarm 5. 110V / 220V Generator Control Box 19.
Page 60 SECTION 3 - CHASSIS & TURNTABLE DETAIL A * AXLE STOP SHIMMING PROCEDURE: ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM.
Page 61 SECTION 3 - CHASSIS & TURNTABLE 11,12,B,G 11,12,A,G 11,12,C,G DETAIL A 11,12,D,G 11,12,E,G 11,12,F,G A - Assemble to Axle Box Mid Plate; Typical 8 Places DETAIL B B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 inches (12.7 ±...
Page 62 SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Axle Loctite Application 3-12 – JLG Lift – 3121262...
Page 63 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Steering Assembly Notes Apply JLG Threadlocker P/N 0100011 Apply JLG Threadlocker P/N 0100019 Apply Loctite #222 Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut Spindle Steer Cylinder Pivot Pin Angle Sensor Assembly King Pin Steer Cylinder Axle...
Page 64: Oscillating Axle System
SECTION 3 - CHASSIS & TURNTABLE 3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST The oscillating front axle is attached to the frame by a pivot pin, which allows all four wheels to remain on the ground Lockout Cylinder Bleeding when traveling on rough terrain.
Page 65: Oscillating Axle Lockout Test
SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position. The front axles will oscillate when the boom is in the transport 12. Drive machine off of block and ramp back onto the level position (i.e.
Page 66: Drive Hub - Bonfiglioli
SECTION 3 - CHASSIS & TURNTABLE 3.11 DRIVE HUB - BONFIGLIOLI Installation of the Wheel Drive on the Machine 1. Clean the mating surfaces from oils or paint and fit the NOTE: Machines may be built with either Bonfiglioli or Reggiana wheel drive on the machine frame.
Page 67: General Information
SECTION 3 - CHASSIS & TURNTABLE Connecting the Brake After having finished running-in the gearbox, follow the steps given below. The gearbox is fitted with a negative multi disk safety brake with hydraulic control release (parking brake). For information 6. Check that there are no oil leaks. If leaks are present, regarding the characteristics of the brake refer to the installa- fix them before proceeding.
Page 68 SECTION 3 - CHASSIS & TURNTABLE 1= M18x1,5......Filling, draining and oil level plugs 2= 7/16" - 20 UNF - 2B..Brake port Figure 3-14. Hub Assembly 3-18 – JLG Lift – 3121262...
Page 69: Gearbox Disengagement
SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade Ambient temperature -20°C / +30°C +10°C / +45°C Oil viscosity SAE 80W/90 SAE 85W/140 Manufacturer Oil Brand SHELL SPIRAX HD SPIRAX HD AGIP ROTRA MP ROTRA MP...
Page 70 SECTION 3 - CHASSIS & TURNTABLE 3. Take out the cap nut (5). THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25 REV/MIN. 4. Turn the cap nut (5) upside down. As result the pin (3) will be pushed inside in order to permit disengagement of the gearbox.
Page 71: Maintenance Information
SECTION 3 - CHASSIS & TURNTABLE 6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade- quate solution.
Page 72: Troubleshooting
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting The following table is provided to help locate problems in the gearbox. Table 3-5. Troubleshooting Symptom Causes Remedies External oil leakage: From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal From the end cover a) O-ring seal damaged a) Replace O-ring seals...
Page 73 SECTION 3 - CHASSIS & TURNTABLE 1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for (31) and turn the screw until it compresses the springs the reassembly. (45).
Page 74 SECTION 3 - CHASSIS & TURNTABLE 1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring 2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring 3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43.
Page 75 SECTION 3 - CHASSIS & TURNTABLE 7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39). 11.
Page 76 SECTION 3 - CHASSIS & TURNTABLE 13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the splined shaft (14). 14. Place the disengagement shaft kit (15) inside the special tool (6689960240). 17. Remove the special tool and remove the spring (13) and the washers (12).
Page 77 SECTION 3 - CHASSIS & TURNTABLE 19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male hex head wrench. 20. Remove the pin (3). 23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the end cover (7).
Page 78 SECTION 3 - CHASSIS & TURNTABLE 25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17). (7). 29. Remove the 2nd reduction assembly (18). 26. Remove the 1st stage sun gear (10). 30.
Page 79 SECTION 3 - CHASSIS & TURNTABLE 31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier (ATZ.09.016.0) on the ring nut (22). 3rd reduction (20). 35. By using the torque multiplier (ATZ.09.016.0) loosen the 32.
Page 80: Inspection Of Parts
SECTION 3 - CHASSIS & TURNTABLE 37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29) flanged hub (31) from the gearbox housing (23). from the flanged hub (31). 38.
Page 81: Assembly
SECTION 3 - CHASSIS & TURNTABLE 4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate seals to make reassembly easier.
Page 82 SECTION 3 - CHASSIS & TURNTABLE 5. Carefully clean the metallic faces of the lifetime seal (29) 8. By using a hoist, place the gearbox housing (23) on the and lube the surfaces with oil. flanged hub (31). 9. By using a press and a metallic stopper, push the gear- 6.
Page 83 SECTION 3 - CHASSIS & TURNTABLE 10. By using a hoist place the torque multiplier NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm). (ATZ.09.016.0) on the ring nut (22). 13. Assemble correctly the spacers (21) on the pins of the 11.
Page 84 SECTION 3 - CHASSIS & TURNTABLE 15. By using a rubber hammer and a metal stopper push the 18. Insert the 2nd stage sun gear (17). planet assemblies of the 3rd reduction (20) against the shoulder until assembly is complete. 19.
Page 85 SECTION 3 - CHASSIS & TURNTABLE 21. Assemble the O-ring seal (9) into its seat in the end 24. Insert the plugs (6) into the oil draining-filling holes of cover (7). the end cover (7). Torque the plugs to 52 ± 7 ft.lbs. (70±10 Nm).
Page 86 SECTION 3 - CHASSIS & TURNTABLE 27. Assemble the cap nut (5). 30. Insert the spring (13) in the splined shaft (14). 31. Insert the splined shaft (14) in the equipment 28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. (6689960240).
Page 87 SECTION 3 - CHASSIS & TURNTABLE 33. Torque the 2 screws M5x16, grade 8.8, of the cover to 35. Insert the disengagement shaft kit (15) in the flanged 18.4 ft.lbs. (25 Nm). hub (31). 36. By using pliers assemble the circlip (36) into its seat in 34.
Page 88 SECTION 3 - CHASSIS & TURNTABLE 38. Assemble the brake discs package according to the fol- 41. Fit the external O-ring seal (38) and the backup ring (37) lowing order: first, insert one sintered bronze disc with into their seats in the spacer (39). external teeth (33).
Page 89 SECTION 3 - CHASSIS & TURNTABLE 44. Lube the seal seats into the flanged hub (31) and assem- 45. Insert the brake piston (44) inside the flanged hub (31), ble the O-ring seal (42) and the backup ring (43). paying attention not to damage the seals already fitted. 46.
Page 90 SECTION 3 - CHASSIS & TURNTABLE 47. Insert the springs (45) into the holes in the brake piston 49. Install the special tool (6689960310) on the flanged hub (44) marked previously. (31) and turn the screw until it compresses the springs (45).
Page 91: Final Test And Reinstallation
SECTION 3 - CHASSIS & TURNTABLE Final Test and Reinstallation 2. Open the flow valve and release the brake with the pilot pressure of 50 bar. Check the product by remounting it to the machine. 3. Close the flow valve and keep the brake released 3 min- utes or longer.
Page 92 SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Drive Hub Special Tools - Sheet 1 of 4 3-42 – JLG Lift – 3121262...
Page 93 SECTION 3 - CHASSIS & TURNTABLE Figure 3-19. Drive Hub Special Tools - Sheet 2 of 4 3121262 – JLG Lift – 3-43...
Page 94 SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Drive Hub Special Tools - Sheet 3 of 4 3-44 – JLG Lift – 3121262...
Page 95 SECTION 3 - CHASSIS & TURNTABLE Figure 3-21. Drive Hub Special Tools - Sheet 4 of 4 3121262 – JLG Lift – 3-45...
Page 96: Drive Hub - Reggiana Riduttori
SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE HUB - REGGIANA RIDUTTORI 9. Socket wrench for M6 hexagonal screw. NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec- M- 1326 tion 3.11, Drive Hub - Bonfiglioli.
Page 97 SECTION 3 - CHASSIS & TURNTABLE Ø210 Ø130 Ø30 M- 1321 LOCTITE 2701 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-24. Bearing Spacer Mounting CO16117 Figure 3-25. Assembly Diagram 1 3121262 – JLG Lift – 3-47...
Page 98 SECTION 3 - CHASSIS & TURNTABLE M- 1316 M- 1020 M- 1317 M- 1317 N° 4 M- 1317 216.5 Ø11 Ø230 10x45° M- 1316 Ø17 M- 1317 M- 1317 Figure 3-28. Anti-rotation Block M- 1317 16 n° 8 Routing to 45° Ø205 Figure 3-26.
Page 99 SECTION 3 - CHASSIS & TURNTABLE M- 1126 M- 1126 M- 1125 VTCEI M6X12 n°12 M- 1020 VTCEI M10X60 n°4 Figure 3-30. Assembly Diagram 2 3121262 – JLG Lift – 3-49...
Page 100 SECTION 3 - CHASSIS & TURNTABLE M- 1546 M- 1548 Ø105 Ø93.5 Ø48 +0.1 Ø20 +0.2 Ø46 Ø8.5 Ø13.5 Ø40.5 Ø46 M- 1547 Ø39.5 Ø20 -0.1 VTCEI M8X16 n°1 Figure 3-31. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram 3-50 –...
Page 101: Disassembly
SECTION 3 - CHASSIS & TURNTABLE Disassembly 3. Release the screws from the release cover and pull the pin out. 1. Remove the plugs and pour the lubricant in a container. 4. Remove the BR250 ring and pull the cover out avoiding to damage the O-Ring.
Page 102 SECTION 3 - CHASSIS & TURNTABLE 3-52 – JLG Lift – 3121262...
Page 103 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-53...
Page 104 SECTION 3 - CHASSIS & TURNTABLE 6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also the planetary ring without damaging the O-Ring. remove the 3/16" balls. 7. Remove the release joint together with the spring. 10.
Page 105: Assembly
SECTION 3 - CHASSIS & TURNTABLE 12. Disassemble the Ø160 inner snap ring and pull the Assembly spring holder spacer out. Remove the springs and using a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are piston out of the spindle.
Page 106 SECTION 3 - CHASSIS & TURNTABLE 4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner the brake discs making sure to centre them on the spin- track.
Page 107 SECTION 3 - CHASSIS & TURNTABLE 9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on lowing order: the spindle thread by the M6 holes of the ring nut. 10.
Page 108 SECTION 3 - CHASSIS & TURNTABLE dle pins. Lock with a ÿ40 outer snap ring. Lubricate the 15. Place the hub onto the support making the two holes bearings. coincide for tightening the M10x25 flathead socket screws at the torque of 5daNm. 16.
Page 109 SECTION 3 - CHASSIS & TURNTABLE 17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor coupling flange S-D LC/KC. Mount the flange on the ably greased and lock it with the shimming ring. Lubri- spindle with 6 M8x25 socket cap screws at the torque of cate the bearings.
Page 110 SECTION 3 - CHASSIS & TURNTABLE 1. Swing Drive 4. Outer Race Bearing Bolt 2. Inner Race Bearing Bolt 5. Turntable Lock Pin 3. Swing Bearing 6. Remote Bearing Lubrication Fittings Figure 3-34. Swing System 3-60 – JLG Lift – 3121262...
Page 111: Swing Drive
SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened Roll and Leak Testing beyond their specified torque.
Page 112: Motor Control Valve Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36) and remove fittings from Brake (26) and Motor Control Valve (32). 1. Place unit on bench with the motor end up. 5.
Page 113: Motor And Brake Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor (10). 1. With unit resting on bench with Motor (10) end up, 4. Remove Brake (26) from Main Torque-Hub Assembly loosen Hex Bolts (29) and remove Lift Lugs (28) from the and dump oil out of Brake (26).
Page 114: Main Disassembly
SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15) from between Input Cover (6) and Carrier (3A) Subas- sembly. 1. With the unit resting on the Output Shaft (Pinion) (1A), remove the eight Bolts (17), four Shoulder Bolts (18) and 7.
Page 115: Hub-Shaft Disassembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G). 5. Invert the Housing (1G) and remove the Lip Seal (1B) if 1. Using retaining ring pliers, remove Retaining Ring (1I) not already removed when Output Shaft (1A) was from groove in Output Shaft (1A) and discard.
Page 116: Carrier Disassembly
SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust Washers (3H) and the two Thrust Washers (3B) out of the 1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).
Page 117: Hub-Shaft Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly 9. Install Bearing Spacer (1H) onto Output Shaft (1A) and against Bearing Cone (1F). 1. Press Bearing Cone (1D) onto Shaft (1A). 10. Install Retaining Ring (1I) into the groove in the Output Shaft (1A).
Page 118: Carrier Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE Carrier Sub-Assembly 8. Slide the second Thrust Washer (3E) between the Cluster Gear (3F) and the Carrier (3A) with the tang of the washer located in the cast slot of the Carrier (3A). Slide 1.
Page 119 SECTION 3 - CHASSIS & TURNTABLE 3A. Carrier 3E. Planet Shaft 3B. Tanged Thrust Washer 3F. Cluster Gear 3C. Needle Bearing 3G. Roll Pin 3D. Thrust Washer 3H. Ball Indented Washer Figure 3-41. Swing Drive - Carrier Sub-Assembly 3121262 – JLG Lift – 3-69...
Page 120 SECTION 3 - CHASSIS & TURNTABLE 3A. Carrier 3E. Planet Shaft 3B. Tanged Thrust Washer 3F. Cluster Gear 3C. Needle Bearing 3G. Roll Pin 3D. Thrust Washer 3H. Ball Indented Washer Figure 3-42. Swing Drive - Carrier Sub-Assembly 3-70 – JLG Lift – 3121262...
Page 121: Main Assembly
SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in mesh, place small end of Cluster Gears (3F) into mesh with the Internal Gear (2) and Input Gear (13). On the 1.
Page 122 SECTION 3 - CHASSIS & TURNTABLE 2. Internal Gear 15. Thrust Bearing 4. Ring Gear 16. Thrust Washer 5. O-Ring 17. Hex Bolt 6. Input Cover 18. Shoulder Bolt 8. Hex Bolt 19. Lockwasher 13. Sun Gear 20. Pipe Plug Figure 3-43.
Page 123: Motor And Brake Assembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble Hex Bolts (29) with Lift Lugs through the Motor (10) and 1. Place O-ring (27) onto end of Brake (26) and locate brake Brake (26) against the motor flange.
Page 124: Motor Control Valve Assembly
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque 13 to 15 ft-lbs. (18 to 21 Nm). 1. Lay assembly down with motor ports facing up. Remove 5. Install O-ring Plugs (21) into Motor Control Valve (32) the two plastic plugs in the motor ports, being careful and torque 30 to 31 ft-lbs.
Page 125: Swing Brake
SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BRAKE HYDRAULIC/MECHANICAL To check brake release, connect an appropriate hydraulic pres- Pre-Installation Checks sure supply set to the required level up to a maximum of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. MECHANICAL Check, That in the handling prior to assembly, the mounting Remove hydraulic supply from brake, checking to ensure that...
Page 126: Installation
SECTION 3 - CHASSIS & TURNTABLE 6. Remove springs (8). Take note of quantity and orien- Installation tation of springs. Position 1-off gasket (5) over male pilot on brake housing (4). 7. Should it be necessary to replace ball bearing (10) Locate brake shaft (1) and secure brake in position using 2-off or shaft seal (12), reverse remainder of brake sub- 1/2”...
Page 127 SECTION 3 - CHASSIS & TURNTABLE 2. Apply ring of Loctite 641 or equivalent adhesive to 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or equivalent) silicone grease and assemble full circumference of housing (2) bearing recess together with backing rings (16 & 18) to piston (9). adjacent to shoulder.
Page 128 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 8. Cylinder 15. O-Ring 2. Housing 9. Piston 16. Backing Ring 3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring 4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring 5.
Page 129: Swing Motor
SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING MOTOR Disassembly and inspection 1. Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
Page 130 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing 2. End Cover 8C. Vane 16. Seal 3. Seal Ring-Commutator 8D. Stator Half 17. Back-up Washer 4. Seal Ring 9. Wear Plate 18. Housing 5.
Page 131 SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into blow dry. Be sure the end cover valve apertures, includ- ring groove until seal ring is lifted out and discard seal ing the internal orifice plug, are free of contamination.
Page 132 SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disas- sembly for service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.
Page 133 SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur- link for cracks and worn or damaged splines.
Page 134 SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is ment of retained rollers.
Page 135 SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the Torqlink™ is com- NOTE: The depth or location of bearing/bushing (13) in relation to pleted. the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings.
Page 136: Assembly
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
Page 137 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).
Page 138 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15) the coupling shaft bore down, clamping against the that was removed from the Torqlink™. mounting flange.
Page 139 SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID.
Page 140 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and original rotor-drive link spline contact. A rotor set without alignment studs onto the housing (18). a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down.The rotor set seal ring groove faces toward the wear...
Page 141 SECTION 3 - CHASSIS & TURNTABLE 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 19. If shuttle valve components items #21, were removed 17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one onto the manifold.
Page 142 SECTION 3 - CHASSIS & TURNTABLE NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight.
Page 143: One Piece Stator Construction
SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.
Page 144: Procedure For Setting Gear Backlash
SECTION 3 - CHASSIS & TURNTABLE 3.16 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 foot- pounds (122 Nm) with Loctite #271. 1. Set backlash to 0.010 to 0.015" using the following pro- cedure. 2. Place shim (JLG p/n 4071041) between pinion and bear- ing on the bearing high spot.
Page 145: Swing Drive Lubrication
SECTION 3 - CHASSIS & TURNTABLE 8. Tighten the jam nut (shown below) with Loctite #271. The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API Service Classification GL-5 Extreme Pressure Gear Lube. Fill to cover the ring gear. 1.195 IN.
Page 146: Swing Bearing
SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not pene- trate under the bolt head to the bolt shank. d. Swing the turntable 90 degrees, and check some Turntable Bearing Mounting Bolt Condition selected bolts at the new position.
Page 147 SECTION 3 - CHASSIS & TURNTABLE Figure 3-53. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 3121262 – JLG Lift – 3-97...
Page 148 SECTION 3 - CHASSIS & TURNTABLE 3-98 – JLG Lift – 3121262...
Page 149: Wear Tolerance
SECTION 3 - CHASSIS & TURNTABLE 3. If the measurement is greater than 0.094 in. (2.387 mm), the swing bearing should be replaced. 4. If the measurement is less than 0.094 in. (2.387 mm), and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the fol- lowing: a.
Page 150: Turntable/Swing Bearing Removal
SECTION 3 - CHASSIS & TURNTABLE Turntable/Swing Bearing Removal It may be necessary to disconnect additional lines to gain access to certain fittings. Cap or plug all openings. The following procedure was accomplished using two over- head cranes with the jib assembly and the boom removed prior to un-decking the turntable.
Page 151 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-101...
Page 152 SECTION 3 - CHASSIS & TURNTABLE 3-102 – JLG Lift – 3121262...
Page 153 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-103...
Page 154 SECTION 3 - CHASSIS & TURNTABLE 3-104 – JLG Lift – 3121262...
Page 155 SECTION 3 - CHASSIS & TURNTABLE 6. Lay the jib control valve aside on the jib. Secure it in 8. Remove the bolt and keeper pin securing the jib level cylinder pivot pin and remove the pin. Place blocking or place so it does not fall.
Page 156 SECTION 3 - CHASSIS & TURNTABLE 9. Attach an adequate supporting device to the jib to sup- 11. At the rear of the turntable, tag and disconnect all wir- ing harnesses that run from the powertrack to the port its weight. Remove the bolt and keeper pin secur- ground control station.
Page 157 SECTION 3 - CHASSIS & TURNTABLE 13. Have a container or absorption material ready to catch 15. Remove the cover from the rear of the boom and dis- residual hydraulic fluid. Disconnect the telescope hoses connect the wiring harnesses and hoses running from from the bottom of the hydraulic control valve.
Page 158 SECTION 3 - CHASSIS & TURNTABLE 17. Using the Main Lift Crackpoint option under the Calibra- NOTE: To assist in determining when the lift cylinder is properly tions menu on the JLG Analyzer, lift the boom enough to supported, use the JLG Analyzer and select Diagnostics > access the boom lift cylinder rod pivot pin.
Page 159 SECTION 3 - CHASSIS & TURNTABLE 24. Disconnect the negative battery terminal from the bat- 27. Remove the attaching hardware securing the side of the tery. hood. 25. Place a container under the machine to catch escaping 28. Remove the attaching hardware securing the top of the hydraulic fluid.
Page 160 SECTION 3 - CHASSIS & TURNTABLE 31. Tag and disconnect the hoses from the top of the swivel. NOTE: The complete swing drive assembly weighs approximately 290 lbs. (132 kg). Cap or plug all openings. Use a tie strap to secure the hoses together.
Page 161 SECTION 3 - CHASSIS & TURNTABLE NOTE: The turntable assembly weighs approximately 20,650 lbs. 37. Lift the turntable assembly off of the swing bearing and (9370 kg). place it on adequate supports. 35. Using the lifting lugs and the center support, attach a lifting device to the front and rear of the turntable to support its weight.
Page 162: Turntable/Swing Bearing Installation
SECTION 3 - CHASSIS & TURNTABLE 40. Install lifting eyes into the swing bearing for removal. Turntable/Swing Bearing Installation 1. Remove the attaching hardware securing the swivel and lay it off to the side. NOTE: The swing bearing weighs approximately 300 lbs. (136 kg). 41.
Page 163 SECTION 3 - CHASSIS & TURNTABLE 3. Locate the high spot on the swing bearing. This will be 7. Install grease fittings into the bearing and also install marked by blue paint and two X’s on the bearing teeth. two pins to facilitate turning the bearing by hand and for alignment of the turntable.
Page 164 SECTION 3 - CHASSIS & TURNTABLE 12. Lift the turntable into place on the bearing using the 15. Connect the hoses to the top of the swivel as tagged previously installed guide pins for alignment. during removal. Secure the hoses together with a tie strap as shown.
Page 165 SECTION 3 - CHASSIS & TURNTABLE 17. Position the swing drive mounting bolts and backlash 19. Lift the boom from its supports. adjusting shim, JLG p/n 4071041. Set backlash following the procedures in this section. 18. Attach the swing bearing remote lubrication lines to the turntable.
Page 166 SECTION 3 - CHASSIS & TURNTABLE 20. While lifting the boom into position, begin to route the 22. Raise the boom enough to gain access to the lift cylin- hoses into position so they can be inserted into the der rod pivot fitting. powertrack.
Page 167 SECTION 3 - CHASSIS & TURNTABLE 25. Connect the hoses to the main valve and pressure filter 29. Place something under the front of the jib that will allow as tagged during removal. it to slide or move along the ground easily. Attach a lift- ing device to the rear of the jib, allowing the front to pivot on the ground.
Page 168 SECTION 3 - CHASSIS & TURNTABLE 31. Attach a lifting device to the front of the jib and align 33. Install the wiring harnesses and hydraulic hoses on the the jib level cylinder attachment fittings. Install the pivot jib valve as tagged during removal. pin.
Page 169: Swing Bearing Torque Values
SECTION 3 - CHASSIS & TURNTABLE 36. Position the hoods in place on the turntable and secure Swing Bearing Torque Values in place with the mounting hardware. 1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite. 2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite. 3.
Page 170: Swing Speed Proportioning
SECTION 3 - CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-60. Swing Bearing Torque Sequence 3.19 SWING SPEED PROPORTIONING Beyond Transport - Drive Speed Cutback System, the tilt sen- sor will cause an alarm to sound, and automatically put all Swing Speed Proportioning uses the boom length and angle functions in the creep speed mode.
Page 171: Generator
SECTION 3 - CHASSIS & TURNTABLE 3.21 GENERATOR Every 500 hours Every 500 hours of operation, service the generator brushes Every 250 hours and slip rings. Hostile environments may require more fre- quent service. Every 250 hours of operation, check the drive belt for proper tension.
Page 172: Overload Protection
SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings Refer to Figure 3-61., Inspecting Generator Brushes, Replacing STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings. BREAKER. INSPECTING BRUSH POSITION Inspect brush alignment with slip rings.
Page 173 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2.
Page 174: Auxiliary Power System
SECTION 3 - CHASSIS & TURNTABLE 3.22 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres- sure to the lift cylinder allowing gravity to lower the boom. The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to of moving the boom in the event of primary power loss.
Page 175: Engine
SECTION 3 - CHASSIS & TURNTABLE 3.23 ENGINE Check the oil level, and if necessary, top the oil level up to the MAX mark with an approved grade and type of oil as outlined in the engine manufacturer’s operator’s NOTE: Refer to the engine manufacturer’s manual for detailed manual.
Page 176: Changing Engine Oil
SECTION 3 - CHASSIS & TURNTABLE Changing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-64., Engine Oil Viscosity for the 1. Allow the engine to warm up. The engine oil should proper grade.
Page 177: Replacing The Fuel Filter
SECTION 3 - CHASSIS & TURNTABLE 2. Using a suitable oil filter removal tool, loosen the lube oil Replacing the Fuel Filter filter cartridge and spin off. 3. Catch any escaping oil. 4. Clean any dirt from the filter carrier sealing surface. 5.
Page 178: Cleaning The Fuel Strainer
SECTION 3 - CHASSIS & TURNTABLE Cleaning the Fuel Strainer 3.24 DEUTZ EMR 2 The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control Sys- tem are connected by means of separate cable harnesses to the EMR control unit.
Page 179 SECTION 3 - CHASSIS & TURNTABLE CONTROL ROD POSITION SENSOR/ACTUATOR POWER SUPPLY COOLANT TEMPERATURE FLYWHEEL SPEED SENSOR SENSOR JLG SYSTEM HANDLES ENGINE START/STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS;...
Page 180 SECTION 3 - CHASSIS & TURNTABLE 3-130 – JLG Lift – 3121262...
Page 181 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-131...
Page 182 SECTION 3 - CHASSIS & TURNTABLE 3-132 – JLG Lift – 3121262...
Page 183 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-133...
Page 184 SECTION 3 - CHASSIS & TURNTABLE Figure 3-70. EMR 2 Engine Plug Pin Identification 3-134 – JLG Lift – 3121262...
Page 185 SECTION 3 - CHASSIS & TURNTABLE Figure 3-71. EMR 2 Vehicle Plug Pin Identification 3121262 – JLG Lift – 3-135...
Page 186 SECTION 3 - CHASSIS & TURNTABLE 3-136 – JLG Lift – 3121262...
Page 187 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-137...
Page 188 SECTION 3 - CHASSIS & TURNTABLE 3-138 – JLG Lift – 3121262...
Page 189 SECTION 3 - CHASSIS & TURNTABLE 3121262 – JLG Lift – 3-139...
Page 190 SECTION 3 - CHASSIS & TURNTABLE 3-140 – JLG Lift – 3121262...
Page 191: Bio Fuel In Deutz Engines
SECTION 3 - CHASSIS & TURNTABLE 3.25 BIO FUEL IN DEUTZ ENGINES The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20 weight-%. The US bio-diesel used for the mixture must General comply with the ASTM D6751-07a (B100) standard.
Page 192: Biological Contamination In Fuels
SECTION 3 - CHASSIS & TURNTABLE PLANT OIL PREVENTIVE MEASURES • Keep the storage tank clean, regular cleaning of the tank by specialist companies PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH...
Page 193 SECTION 3 - CHASSIS & TURNTABLE 3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE This section is organized in the following manner: CODE DEFINITIONS 1st page of Diagnostic Information for a Given Fault (See Fig- ure 3-77.) then: This section defines the diagnostics and recommended trou- 2nd Page of Diagnostic Information for a Given Fault (See Fig- bleshooting procedures associated with the engine control ure 3-78.)
Page 194 SECTION 3 - CHASSIS & TURNTABLE DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Troubleshooting flow chart Figure 3-78. 2nd Page of Diagnostic Information for a Given Fault 3-144 – JLG Lift – 3121262...
Page 195: List Of Abbreviations In This Section
SECTION 3 - CHASSIS & TURNTABLE List of Abbreviations in this Section Adaptive Learn Light Emitting Diode Barometric Pressure Liquefied Propane Gas Controller Area Network Manifold Absolute Pressure CAN Calibration Protocol MGCP Marine Global Control Platform Cylinder Head Temperature μP Microprocessor Closed Loop Manufacture...
Page 196 SECTION 3 - CHASSIS & TURNTABLE Universal Exhaust Gas Oxygen Sensor Fuel Pressure UEGO (also called wide-range EGO) Foot Pedal Position Voltage, Direct Current Fuel Rail Pressure Variable Reluctance Fuel Rail Temperature Switched, Ignition Voltage Fault Snapshot Waste-Gate Pressure Fuel Temperature Global Control Platform Heavy-Duty Global Control Platform HDGCP...
Page 197: Diagnostic Trouble Codes
SECTION 3 - CHASSIS & TURNTABLE Diagnostic Trouble Codes Resetting active and previously active DTCs is handled through DM11 and DM3, respectively DM1 and DM2 lamp The numeric diagnostic trouble codes assigned to the faults in indicators are assigned to each fault based on the fault.s diag- this section are cross-referenced to SAE’s "Recommended nostic action as defined in the calibration.
Page 198: Dtc 116- Ect Higher Than Expected Stage 1
SECTION 3 - CHASSIS & TURNTABLE DTC 116- ECT Higher Than Expected Stage 1 TAN/WHITE BLACK/GREEN Diagnostic Aids • Engine Coolant Temperature Sensor • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the trou- bleshooting procedures for that fault as it may have caused •...
Page 199: Dtc 117- Ect/Cht Low Voltage
SECTION 3 - CHASSIS & TURNTABLE DTC 117- ECT/CHT Low Voltage TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor This fault will set if the signal voltage is less than the limit defined in the diagnostic calibration anytime the engine is •...
Page 200 SECTION 3 - CHASSIS & TURNTABLE · Key On, Engine Running · System Mode = “Running” · Key Off Does DST display an ECT · Disconnect ECT sensor from harness voltage less the limit · Key On, Engine Off defined in calibration? ·...
Page 201: Dtc 118- Ect/Cht High Voltage
SECTION 3 - CHASSIS & TURNTABLE DTC 118- ECT/CHT High Voltage TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor This fault will set if the signal voltage is higher than the high voltage limit as defined in the diagnostic calibration anytime •...
Page 202 SECTION 3 - CHASSIS & TURNTABLE 3-152 – JLG Lift – 3121262...
Page 203: Dtc 122- Tps1 Signal Voltage Low
SECTION 3 - CHASSIS & TURNTABLE DTC 122- TPS1 Signal Voltage Low PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Position Sensor 1 condition while the engine is cranking or running. The limit is generally set to 4.90 VDC. In many cases, this condition is •...
Page 204 SECTION 3 - CHASSIS & TURNTABLE 3-154 – JLG Lift – 3121262...
Page 205: Dtc 123- Tps1 Signal Voltage High
SECTION 3 - CHASSIS & TURNTABLE DTC 123- TPS1 Signal Voltage High PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Position Sensor 1 There are two types of throttle actuators, 1) actuator with ana- log position feedback and 2) actuator with digital position •...
Page 206 SECTION 3 - CHASSIS & TURNTABLE 3-156 – JLG Lift – 3121262...
Page 207: Dtc 217- Ect Higher Than Expected 2
SECTION 3 - CHASSIS & TURNTABLE DTC 217- ECT Higher Than Expected 2 TAN/WHITE BLACK/GREEN • Engine Coolant Temperature Sensor Diagnostic Aids • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the trou- • Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused estimate greater than the stage 2 limit when operating at a "ECT Higher Than Expected 2."...
Page 208: Dtc 219- Rpm Higher Than Max Allowed Governed Speed
SECTION 3 - CHASSIS & TURNTABLE DTC 219- RPM Higher Than Max Allowed Governed Speed PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Max Govern Speed Override- Crankshaft Position Sensor Diagnostic Aids • Check Condition-Engine Running NOTE: If any other DTCs are present, diagnose those first. •...
Page 209: Dtc 336- Crank Signal Input Noise
SECTION 3 - CHASSIS & TURNTABLE DTC 336- Crank Signal Input Noise WHITE/PURPLE PURPLE/WHITE WHITE/PURPLE 1 PURPLE/WHITE • Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run- ning. If no signal is present, the signal amplitude is too high •...
Page 210 SECTION 3 - CHASSIS & TURNTABLE • Key On, Engine Running • System Mode= “Running” Operate engine at condition that set fault based on fault snapshot Is crank sensor a VR/ Check wiring and electrical connections Does DTC 336 reset ? magnetic pick-up? between crankshaft position sensor and ECM Is the wiring OK?
Page 211: Dtc 337- Loss Of Crank Input Signal
SECTION 3 - CHASSIS & TURNTABLE DTC 337- Loss of Crank Input Signal WHITE/PURPLE PURPLE/WHITE WHITE/PURPLE 1 PURPLE/WHITE • Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run- ning. If no signal is present while x cam pulses continue the •...
Page 212: Dtc 521- Oil Pressure Sender/Switch High Pressure
SECTION 3 - CHASSIS & TURNTABLE DTC 521- Oil Pressure Sender/Switch High The ECM can be configured to monitor oil pressure through a proportional transducer or through a switch. Oil pressure Pressure monitoring is important to prevent engine damage due to low oil pressure resulting in higher friction and lack of lubrication.
Page 213: Dtc 524- Oil Pressure Low
SECTION 3 - CHASSIS & TURNTABLE DTC 524- Oil Pressure Low For systems that use a transducer, this fault sets if the engine oil pressure is less than x psia and engine speed is greater than y RPM after the engine has been running for z seconds as defined in the diagnostic calibration.
Page 214 SECTION 3 - CHASSIS & TURNTABLE Normally Closed Switch • Key-On, Engine On • System Mode= “Running” • Key Off • Disconnect harness from Oil Pressure switch • Jumper Oil Pressure signal wire to ground • Clear DTC 524 • Warm engine at idle to normal •...
Page 215: Dtc 562- Battery Voltage (Vbat) Low
SECTION 3 - CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low BLACK RED/TAN • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle actuator, power supplies, and • Check Condition- Key on, Engine on other powered devices that the ECM controls.
Page 216 SECTION 3 - CHASSIS & TURNTABLE 3-166 – JLG Lift – 3121262...
Page 217: Dtc 563- Battery Voltage (Vbat) High
SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High BLACK RED/TAN • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle acutator, power supplies, and • Check Condition- Key on, Engine Cranking or Running other powered devices that the ECM controls.
Page 218 SECTION 3 - CHASSIS & TURNTABLE 3-168 – JLG Lift – 3121262...
Page 219: Dtc 601- Microprocessor Failure - Flash
SECTION 3 - CHASSIS & TURNTABLE DTC 601- Microprocessor Failure - FLASH Microprocessor • Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 220 SECTION 3 - CHASSIS & TURNTABLE 3-170 – JLG Lift – 3121262...
Page 221: Dtc 604- Microprocessor Failure - Ram
SECTION 3 - CHASSIS & TURNTABLE DTC 604- Microprocessor Failure - RAM Microprocessor • Engine Control Module- Random Access Memory This fault will set if the ECM detects a problem accessing or writing information to RAM and should be configured to set a •...
Page 222 SECTION 3 - CHASSIS & TURNTABLE 3-172 – JLG Lift – 3121262...
Page 223: Dtc 606- Microprocessor Failure - Cop
SECTION 3 - CHASSIS & TURNTABLE DTC 606- Microprocessor Failure - COP Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 224 SECTION 3 - CHASSIS & TURNTABLE 3-174 – JLG Lift – 3121262...
Page 225: Dtc 642- 5 Volt External Low Voltage
SECTION 3 - CHASSIS & TURNTABLE DTC 642- 5 Volt External Low Voltage PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Engine Control Module Diagnostic Aids • Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key on and the engine stopped.
Page 226: Dtc 643- 5 Volt External High Voltage
SECTION 3 - CHASSIS & TURNTABLE DTC 643- 5 Volt External High Voltage PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Engine Control Module Diagnostic Aids • Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key on and the engine stopped.
Page 227: Dtc 1612- Microprocessor Failure - Rti 1
SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 228: Dtc 1613- Microprocessor Failure - Rti 2
SECTION 3 - CHASSIS & TURNTABLE DTC 1613- Microprocessor Failure - RTI 2 Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 229 SECTION 3 - CHASSIS & TURNTABLE SFC 555- RTI 2 Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 555 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...
Page 230: Dtc 1614- Microprocessor Failure - Rti 3
SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 231 SECTION 3 - CHASSIS & TURNTABLE SFC 556- RTI 3 Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 556 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...
Page 232: Dtc 1615- Microprocessor Failure - A/D
SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 233 SECTION 3 - CHASSIS & TURNTABLE SFC 513- A/D Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 513 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...
Page 234: Dtc 1616- Microprocessor Failure - Interrupt
SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure - interrupt Microprocessor • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen • Check Condition- Key on within the microprocessor that will cause this fault.
Page 235 SECTION 3 - CHASSIS & TURNTABLE SFC 512- Invalid Interrupt Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 512 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...
Page 236: Dtc 1625- Can J1939 Shutdown Request
SECTION 3 - CHASSIS & TURNTABLE DTC 1625- CAN J1939 Shutdown Request BLUE/RED or PINK BLUE/WHITE • Controller Area Network Diagnostic Aids • Check Condition- Key On, Engine Off and/or Running • The ECM has shutdown the engine upon command by a external controller.
Page 237: Dtc 1626- Can J1939 Transmit (Tx) Fault
SECTION 3 - CHASSIS & TURNTABLE DTC 1626- CAN J1939 Transmit (Tx) Fault BLUE/RED or PINK BLUE/WHITE • Controller Area Network Diagnostic Aids • Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly grounded •...
Page 238: Dtc 1627- Can J1939 Receive (Rx) Fault
SECTION 3 - CHASSIS & TURNTABLE DTC 1627- CAN J1939 Receive (Rx) Fault BLUE/RED or PINK BLUE/WHITE • Controller Area Network Diagnostic Aids • Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly grounded •...
Page 239: Dtc 1628- Can Address Conflict Failure
SECTION 3 - CHASSIS & TURNTABLE DTC 1628- CAN Address Conflict Failure BLUE/RED or PINK BLUE/WHITE • CAN device(s) The Controller Area Network serves as a communication portal between intelligent devices. These devices may be but are not • Check Condition- Key On, Engine on limited to other engine ECMs (slave), diagnostic tools, "smart"...
Page 240 SECTION 3 - CHASSIS & TURNTABLE 3-190 – JLG Lift – 3121262...
Page 241: Dtc 1629- J1939 Tsc1 Message Reciept Loss
SECTION 3 - CHASSIS & TURNTABLE DTC 1629- J1939 TSC1 Message Reciept Loss BLUE/RED or PINK BLUE/WHITE • Controller Area Network Diagnostic Aids • Check Condition- Key On, Engine Running • Verify that that the CAN device generating the TSC1 mes- sage is powered and properly grounded •...
Page 242: Dtc 1652- Tps1 Loss Of Communications
SECTION 3 - CHASSIS & TURNTABLE DTC 1652- TPS1 Loss of Communications PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Actuator (with serial/digital position feedback) Diagnostic Aids • Check Condition- Key On, Engine Running and/or Stopped • Verify that the throttle actuator 5V supply voltage is pres- ent at the actuator.
Page 243: Dtc 2111- Unable To Reach Lower Tps
SECTION 3 - CHASSIS & TURNTABLE DTC 2111- Unable to Reach Lower TPS PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor and voltage divider circuit or 2) a non-contact hall-effect sen- •...
Page 244 SECTION 3 - CHASSIS & TURNTABLE 3-194 – JLG Lift – 3121262...
Page 245: Dtc 2112- Unable To Reach Higher Tps
SECTION 3 - CHASSIS & TURNTABLE DTC 2112- Unable to Reach Higher TPS PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor and voltage divider circuit or 2) a non-contact hall-effect sen- •...
Page 246: Dtc 9999- Throttle Actuator Failsafe Spring Failure
SECTION 3 - CHASSIS & TURNTABLE DTC 9999- Throttle Actuator Failsafe Spring Failure PINK/WHITE TAN/ORANGE GREEN/RED PURPLE/BLUE BLACK/GREEN • Throttle Actuator Diagnostic Aids • Check Condition- Key Off, Engine Stopped • Disconnect the throttle actuator from the wire harness. • Fault Condition- When the key is off (or the actuator is Remove the throttle actuator from the engine and manu- unpowered), the ECM is expecting the failsafe spring in the ally move it.
Page 247: Dtc To Spn/Fmi Table
SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT DESCRIPTION INDEX DTC 118: ECT voltage high DTC 117: ECT voltage low DTC 116: ECT higher than expected stage 1 DTC 563: Vbat voltage high DTC 562: Vbat voltage low DTC 643: Sensor supply voltage 1 high 1079 DTC 642: Sensor supply voltage 1 low...
Page 248: Counterweight
SECTION 3 - CHASSIS & TURNTABLE 3.27 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-79., Counterweight Bolt Torque. APPLY THREADLOCKER P/N 0100019 TO BOLT AND THREADS IN COUNTERWEIGHT. TORQUE TO 400 FT LBS (542 Nm).
Page 249: Boom & Platform
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM SYSTEMS Transport Position Sensing System The transport position sensing system uses the main boom NOTE: For more detailed information concerning system adjust- angle sensors, the main boom length sensor mounted in the ment and operation, refer to Section 6 - JLG Control Sys- pivot end of the main base boom in addition to the boom tem.
Page 250 SECTION 4 - BOOM & PLATFORM 1. Boom Angle Sensor #1 (Right) 2. Boom Cable Proximity Sensor 3. Boom Length Sensor 4. Boom Angle Sensor #2 (Left) 5. Boom Length & Angle Module 6. Lift Cylinder Pivot Pin Figure 4-1. Boom Component Location - Sheet 1 of 2 –...
Page 251 SECTION 4 - BOOM & PLATFORM 7. Jib Level Rotary Sensor 12. Platform Level Sensor #1 (Right-Primary) 8. Lock Pin Proximity Sensor (Bottom Side) 13. Jib Transport Proximity Sensors 9. Jib Control Module 14. Jib Swing Rotary Sensor (Bottom Side) 10.
Page 252: Drive/Steer - Boom Function Interlock System (Ce Only)
SECTION 4 - BOOM & PLATFORM Drive/Steer – Boom Function Interlock System (CE Envelope Tracking System ONLY) The Envelope Tracking System uses the envelope control sen- sors to enhance the control of the boom within the working The Drive/Steer – Boom Function Interlock System uses the envelope.
Page 253: Boom Control System (Bcs) Functional Check (Push To Test) System
SECTION 4 - BOOM & PLATFORM Boom Control System (BCS) Functional Check Jib Leveling During Automatic/Manual Envelope (Push to Test) System Control The machine is equipped with a system for the operator to There are no function switches in the platform or ground con- daily verify the proper functioning of the Boom Control Sys- trols to manually adjust the jib level function.
Page 254 SECTION 4 - BOOM & PLATFORM Press ENTER , the screen should read: Press ENTER , the screen should read: To enable the level override mode 58237 must be entered as the code. When the code is entered, the screen will show: Using the UP and DOWN arrow keys will toggle...
Page 255: Jib Lift Functionality
SECTION 4 - BOOM & PLATFORM Attempts to lift the main boom while this override is on will Jib Telescope Functionality result in a JIB LEVELING SYSTEM FAULT because during the override automatic jib leveling is disabled. To adjust the jib Jib Telescope out will only be allowed if the axles are back to level go into override mode for the jib leveling.
Page 256 SECTION 4 - BOOM & PLATFORM Jib Lock Pin override is accessible in Access Level 1. Using the Press ENTER , the screen should read: Left and Right arrow keys until the screen shown below is reached. To enable the override mode 58237 must be entered as the code.
Page 257: Jib Swing Deploy Sequence (Jib Pin Lock)
SECTION 4 - BOOM & PLATFORM Use the Left or Right arrow key until you see: Using the Up and Down arrow keys will allow the following modes: • OFF • EXTEND • RETRACT Once the desired mode is selected, stepping into the foot- switch with the machine running will perform extension or retraction of the jib lock pin.
Page 258: Swing/Axle Extend Retract Restrictions
SECTION 4 - BOOM & PLATFORM Swing/Axle Extend Retract Restrictions Boom Recovery override is accessible in Access Level 1. Using In addition to the Direction Of Steer proximity switch in the the Left and Right arrow keys until the screen chassis, a 360 degree dual rotary sensor is also used to calcu- shown below is reached.
Page 259 SECTION 4 - BOOM & PLATFORM To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press Enter . Once Enter is pressed using the Up or Down arrow key will turn the boom recovery on or off.
Page 260: Boom Removal And Installation
SECTION 4 - BOOM & PLATFORM 4.3 BOOM REMOVAL AND INSTALLATION 4. Disconnect the telescope hoses from the bottom of the hydraulic control valve. Pull the hoses out so the can be lifted away from the machine with the boom. Removal 1.
Page 261 SECTION 4 - BOOM & PLATFORM 6. Remove the cover from the rear of the boom and dis- 8. Using the Main Lift Crackpoint option under the Calibra- connect the wiring harnesses and hoses running from tions menu, lift the boom enough to access the boom the turntable to the boom.
Page 262: Installation
SECTION 4 - BOOM & PLATFORM 11. Remove the bolt and keeper pin securing the boom lift Installation cylinder rod pivot pin and drive out the pivot pin. 1. Lift the boom from its supports. 12. Lower the lift cylinder until it rests on the turntable. 13.
Page 263 SECTION 4 - BOOM & PLATFORM 2. While lifting the boom into position, begin to route the 4. Raise the boom enough to gain access to the lift cylin- hoses into position so they can be inserted into the der rod pivot fitting. powertrack.
Page 264 SECTION 4 - BOOM & PLATFORM 7. Connect the hoses to the main valve and pressure filter 11. Position the hoods in place on the turntable and secure as tagged during removal. in place with the mounting hardware. 8. Reconnect the negative battery terminal. 12.
Page 265: Boom Disassembly/Assembly & Cable Replacement
SECTION 4 - BOOM & PLATFORM 4.4 BOOM DISASSEMBLY/ASSEMBLY & CABLE 6. Remove the bolt and keeper pin securing the jib pivot pin and remove the pin. REPLACEMENT It is not necessary to completely remove the entire boom assembly from the machine to replace the cables. In the fol- lowing procedure, the base boom section will remain on the machine.
Page 266 SECTION 4 - BOOM & PLATFORM 8. Attach a lifting device to the powertrack for support and 9. Unbolt the lower powertrack tube from the outer mid unbolt the upper powertrack tube from the fly boom. boom section and the mounting bracket from the inner Pull the disconnected tube back to allow room to dis- mid boom section..
Page 267 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-19...
Page 268 SECTION 4 - BOOM & PLATFORM 4-20 – JLG Lift – 3121262...
Page 269 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-21...
Page 270 SECTION 4 - BOOM & PLATFORM 4-22 – JLG Lift – 3121262...
Page 271 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-23...
Page 272 SECTION 4 - BOOM & PLATFORM 4-24 – JLG Lift – 3121262...
Page 273 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-25...
Page 274 SECTION 4 - BOOM & PLATFORM 11. Remove the bolts securing the side wear pads to the 13. Remove the cover over the boom length limit switch at front of the base boom and remove the pads and shims. the front of the boom base section. Remove the switch. 12.
Page 275 SECTION 4 - BOOM & PLATFORM 15. Tag and disconnect the wiring harness running to the 18. Remove the keepers for the outer mid retract cable boom length sensor. Remove all the bolts and washers adjustment nuts at the front of the boom base section. securing the sensor, including those that secure the measuring cable to the telescope cylinder, and remove the length sensor.
Page 276 SECTION 4 - BOOM & PLATFORM 21. Remove the adjustment nuts for the for the outer mid 23. Remove the cover plate from the bottom of the boom extend cables along with the Broken Cable proximity and remove the sheave blocks. switch, spring, and adjustment plate.
Page 277 SECTION 4 - BOOM & PLATFORM 25. Remove the outer mid retract cables from the attach- 27. Pull the inner mid, outer mid, and fly boom sections out ment fixtures at the front of the boom base section. of the base boom section. Use additional lifting devices and reposition any lifting straps as necessary as the sec- tions are withdrawn.
Page 278 SECTION 4 - BOOM & PLATFORM 28. Remove the trunnion blocks that secure the telescope 30. Remove the hardware attaching the outer mid extend cylinder barrel to the inner mid boom section. block and remove the block and outer mid extend cables.
Page 279 SECTION 4 - BOOM & PLATFORM 32. Remove the rear bottom wear pad. 34. Pull the fly boom extend cables from their mounting receptacles. 33. Remove the lock plates from the fly boom retract cable adjustment nuts and remove the adjustment nuts from the fly boom retract cables and from the fly boom extend cables at the front of the inner mid boom sec- tion.
Page 280 SECTION 4 - BOOM & PLATFORM 36. Attach a strap to pull the outer mid and fly boom sec- NOTE: When pulling the outer mid and fly boom sections out of tions out of the inner mid boom section. Secure the rear the inner mid boom section, make sure the outer mid of the inner mid boom section so it doesn’t move as the retract cables do not catch at the rear of the boom section.
Page 281 SECTION 4 - BOOM & PLATFORM 40. Remove the cable retract retainer plates, cable retainer 42. Remove the upper rear wear pads from the fly boom blocks, sheaves, and bushings from the rear of the outer section. mid boom section. 43.
Page 282 SECTION 4 - BOOM & PLATFORM 44. Pull the fly boom extend cables out enough to have NOTE: When pulling the fly boom section out of the outer mid clearance to remove the sheave, and remove the retain- boom section, make sure the fly boom retract cables do not ing bolt, keeper pin, pin, bushings, and sheave from the catch at the rear of the boom section.
Page 283: Assembly
SECTION 4 - BOOM & PLATFORM 46. Remove the tape from the fly boom section and remove Assembly the fly boom retract cables. NEVER HANDLE WIRE ROPE WITH BARE HANDS. NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all four inner surfaces of both ends of each boom section to a minimum depth of 3 to 4 feet (1 to 1.25 m).
Page 284 SECTION 4 - BOOM & PLATFORM wire rope and place them into the fly boom, tape the slots to keep the rope from jumping out. TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY PROCEDURE. 1. Install the fly extend wire rope button ends into the slots on the bottom of the fly boom section.
Page 285 SECTION 4 - BOOM & PLATFORM Ft-Lbs. Figure 4-7. Boom Assembly Torque Values 3121262 – JLG Lift – 4-37...
Page 286 SECTION 4 - BOOM & PLATFORM #0100019 #0100011 #0100011 #0100019 #0100019 #0100011 #0100011 SECTION A-A Figure 4-8. Locations for Threadlocker Application - Sheet 1 of 4 4-38 – JLG Lift – 3121262...
Page 287 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-9. Locations for Threadlocker Application - Sheet 2 of 4 3121262 – JLG Lift – 4-39...
Page 288 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-10. Locations for Threadlocker Application - Sheet 3 of 4 4-40 – JLG Lift – 3121262...
Page 289 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 Figure 4-11. Locations for Threadlocker Application - Sheet 4 of 4 3121262 – JLG Lift – 4-41...
Page 290 SECTION 4 - BOOM & PLATFORM 4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain- boom section. ing bolt to the front of the outer mid boom section. DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES 8.
Page 291 SECTION 4 - BOOM & PLATFORM 10. Apply JLG Threadlocker P/N 0100011 to the bolts and 12. Apply a thin coat of moly paste lubricant to the inside install the rear upper and side wear pads on the outer diameter of the sheave composite bearings. Install the mid boom section as marked during disassembly.
Page 292 SECTION 4 - BOOM & PLATFORM 16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid section from the front. boom section to the receptacles at the rear of the outer mid boom section.
Page 293 SECTION 4 - BOOM & PLATFORM 21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the pulling the boom cables out the back fo the inner mid inner mid boom section. section at the same time.
Page 294 SECTION 4 - BOOM & PLATFORM 25. Apply JLG Threadlocker P/N 0100011 to the bolts and 27. Apply a thin coat of moly paste lubricant to the inside install the side and top wear pads into the inner mid diameter of the sheave composite bearings. Install the boom section.
Page 295 SECTION 4 - BOOM & PLATFORM 29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and install the cable retainer block. 30. Install the outer mid extend cables into the cable pulley at the rod end of the telescope cylinder.
Page 296 SECTION 4 - BOOM & PLATFORM 34. Apply JLG Threadlocker P/N 0100019 to the bolts and 37. Using Super Lube®, lubricate all wear surfaces on the attach the cable guide to the inner mid boom section inside of the boom base section and the outside of the with the mounting hardware.
Page 297 SECTION 4 - BOOM & PLATFORM 40. Push the inner mid boom assembly the rest of the way 46. Install the outer mid retract cable adjustment nuts at the into the boom base section, adjusting the lifting device front of the boom base section. as necessary to keep the weight balanced.
Page 298: Load Sensing Pin Removal And Installation
SECTION 4 - BOOM & PLATFORM 4.5 LOAD SENSING PIN REMOVAL AND size (as shown below). If excessive force is necessary to move the pin, it may be necessary to carefully activate INSTALLATION lift using the auxiliary power switch to relieve lift cylin- der weight from the load sensing pin.
Page 299 SECTION 4 - BOOM & PLATFORM Figure 4-12. Load Pin Removal Tool, JLG P/N 4846765 3121262 – JLG Lift – 4-51...
Page 300: Jib
SECTION 4 - BOOM & PLATFORM 4.6 JIB It may be necessary to disconnect additional lines to gain access to certain fittings. Cap or plug all openings. Removal 1. Lower the platform to the ground or onto blocking to support the weight of the jib. 2.
Page 301 SECTION 4 - BOOM & PLATFORM 7. Disconnect the jib protractor sensor linkage from the NOTE: The jib and platform assembly weighs approximately 2100 boom. lbs. (953 kg.). 9. Attach an adequate supporting device to the jib to sup- port its weight. Remove the bolt and keeper pin secur- ing the jib pivot pin and remove the pin.
Page 302: Installation
SECTION 4 - BOOM & PLATFORM Installation 3. Lift the jib into position on the boom fly section and install the jib pivot pin. Secure the pin in place with the 1. Attach an adequate lifting device to the jib and position keeper pin and bolt.
Page 303 SECTION 4 - BOOM & PLATFORM 4. Attach a lifting device to the front of the jib and align 5. Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section. the jib level cylinder attachment fittings. Install the pivot pin.
Page 304 SECTION 4 - BOOM & PLATFORM ROTARY JIB LIFT CYLINDER ACTUATOR PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR JIB BASE BOOM JIB LOCK CYLINDER JIB POWER TRACK JIB FLY BOOM PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR 1001118868-A Figure 4-13. Jib Assembly - Sheet 1 of 3 4-56 –...
Page 305 SECTION 4 - BOOM & PLATFORM Figure 4-14. Jib Assembly - Sheet 2 of 3 3121262 – JLG Lift – 4-57...
Page 306 SECTION 4 - BOOM & PLATFORM BOLT LOCKPIN CYLINDER CAP ALIGN CUTOUT IN CAP INWARD AS SHOWN ALIGN LOCK CYL WITH (SEE SECTION A-A BELOW) PROTRUSIONS CAP (SEE SECTION A-A BELOW) JIB LOCK CYLINDER LOCKNUT TORQUE 220 FT.LBS. (298 Nm) LOCK PIN ALIGN CUTOUT IN CAP CYLINDER...
Page 307: Boom Lubrication Application
SECTION 4 - BOOM & PLATFORM 4.7 BOOM LUBRICATION APPLICATION 4.8 PLATFORM LEVELING CYLINDER This procedure applies to booms after assembly or during Removal annual application using Super Lube® lubricant (JLG p/n 3020042). 1. Ensure the platform is supported by blocking or an ade- quate lifting device.
Page 308: Installation
SECTION 4 - BOOM & PLATFORM 4. Lift the platform to allow enough room for removal of Installation the cylinder. 1. Attach a lifting or jacking device to the platform and position the platform to provide adequate room to install the platform leveling cylinder. 2.
Page 309: Jib Telescope Cylinder
SECTION 4 - BOOM & PLATFORM 5. Secure the pivot pin in place with the keeper pin. 4.9 JIB TELESCOPE CYLINDER Loosely install the bolt, but do not tighten it at this time. Removal 1. Remove the guide pad at the rear of the jib to provide more room for cylinder removal.
Page 310 SECTION 4 - BOOM & PLATFORM 4. Remove the retaining rings securing the retaining pins 8. Tag and disconnect the hoses going to the jib telescope on the powertrack side of the jib and remove the pins. cylinder. 5. Attach a strap or similar device between the jib base boom and the jib fly boom to ensure the jib fly boom 9.
Page 311: Installation
SECTION 4 - BOOM & PLATFORM 4. Connect the hydraulic hoses to the cylinder as tagged during removal. Installation 5. Lower the jib enough to enable easier access to the 1. If installing a new cylinder, test fit the retaining pins that attachment holes in the jib fly boom.
Page 312: Jib Lift Cylinder
SECTION 4 - BOOM & PLATFORM 4.10 JIB LIFT CYLINDER 3. Remove the bolt and keeper pin that secure the jib lift cylinder barrel pivot pin. Remove the jib lift cylinder bar- rel pin. Removal 1. Ensure the weight of the jib is fully supported. 4.
Page 313: Installation
SECTION 4 - BOOM & PLATFORM 5. Remove the bolt and keeper pin that secure the jib lift Installation cylinder rod pivot pin. Remove the jib lift cylinder rod pivot pin. 1. If installing a new cylinder, test fit the pivot pins in the cylinder to ensure they fit properly.
Page 314: Jib Straight Shimming Procedure
SECTION 4 - BOOM & PLATFORM 4. Raise the cylinder into position to allow the jib lift barrel 4.11 JIB STRAIGHT SHIMMING PROCEDURE pivot pin to be installed and install the pin. See Figure 4-16., Jib Straight Shimming. 5. Secure the pin in place with the keeper pin. Apply JLG 1.
Page 315 SECTION 4 - BOOM & PLATFORM PIVOT PAD MOUNT JIB ROTATOR BOTTOM PLATE TORQUE 20 FT.LBS. (27 Nm) WEAR PAD SHIMS (NOMINAL QTY SHOWN) Figure 4-16. Jib Straight Shimming 3121262 – JLG Lift – 4-67...
Page 316: Boom Cleanliness Guidelines
SECTION 4 - BOOM & PLATFORM 4.12 BOOM CLEANLINESS GUIDELINES 4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest exiting point from the boom. Make The following are guidelines for internal boom cleanliness for sure that all debris is removed before operating the machines that are used in excessively dirty environments.
Page 317 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-69...
Page 318 SECTION 4 - BOOM & PLATFORM 4-70 – JLG Lift – 3121262...
Page 319 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-71...
Page 320: Powertrack Maintenance
SECTION 4 - BOOM & PLATFORM 4.14 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of the powertrack. One Piece Bracket Maintenance 1. Place the powertrack on a workbench. 4. Pull up on the loose side of the round bar to allow the poly roller to slide off.
Page 321 SECTION 4 - BOOM & PLATFORM 5. Slide the poly roller off of the round bar. 7. Slide the flat bar out. 6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket. 9.
Page 322: Two Piece Bracket Maintenance
SECTION 4 - BOOM & PLATFORM 10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance bracket side up and over the extrusion on the link. 1. Loosen the screw. 11. Repeat the previous step on the other side. 2.
Page 323: Snap Rings And Screws
SECTION 4 - BOOM & PLATFORM 4. Hold the flat bar and remove the screws. 7. Slide the link out. 5. Remove the snap rings and pins. Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO DISCARD AND REPLACE ALL OLD SCREWS.
Page 324 SECTION 4 - BOOM & PLATFORM Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below. CLOSED OPEN 10-24 x 0.812 button torx socket head with blue locking patch: • Tighten to 45-50 in.lbs. (5-5.6 Nm). An open snap ring is shown below.
Page 325: Wire Rope
SECTION 4 - BOOM & PLATFORM 4.15 WIRE ROPE Three Month Inspection 1. Remove boom covers and visually (with flashlight) Inspection inspect the ropes for rust, broken wires, frays, abuse, or any signs of abnormalities. NOTE: The pictures in this paragraph are just samples to show the 2.
Page 326: Wire Rope Tensioning Adjustment
SECTION 4 - BOOM & PLATFORM 4.16 WIRE ROPE TENSIONING ADJUSTMENT INNER MID BOOM SECTION REPOSITIONING The inner mid section of the boom is positioned by the hydraulic cylinder. No adjustments can be made to this sec- tion. The wire ropes within the assembly only control the movement of the Outer Mid Boom and Fly Boom sections.
Page 327 SECTION 4 - BOOM & PLATFORM 3. Remove the lock plates and nylon collar locknuts from a. If the Outer Mid Boom still does not fall within the the wire rope adjustment nuts. dimension and tolerance of Figure 4-21., repeat the Outer Mid Boom positioning procedure.
Page 328: Wire Rope Tensioning Procedure
SECTION 4 - BOOM & PLATFORM 4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope adjustment nuts. a. Loosen the Fly Boom Retract Adjustment Nuts by an amount equal to twice the distance the boom needs to move to be in tolerance.
Page 329 SECTION 4 - BOOM & PLATFORM 6. Using tool JLG p/n 4120043, torque the Outer Mid Boom 9. Using tool JLG p/n 4120043, torque the Outer Mid Boom Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton ing between the two ropes until both maintain the meters), alternating between the two ropes until both required torque.
Page 330 SECTION 4 - BOOM & PLATFORM 11. Repeat the following boom movement steps three 18. Install all covers. times. This is to ensure that the wire rope tension has equalized on both sides of the sheaves and the ropes are seated properly in the sheave grooves.
Page 331 SECTION 4 - BOOM & PLATFORM 9.5 ± 0.5” 241 ± 13 mm 3.5 ± 0.5” 90.5 ± 13 mm FLY BOOM OUTER MID BOOM BASE BOOM INNER MID BOOM NOTE: Boom shown in fully retracted position. Figure 4-21. Wire Rope Tensioning 3121262 –...
Page 332 SECTION 4 - BOOM & PLATFORM 4-84 – JLG Lift – 3121262...
Page 333 SECTION 4 - BOOM & PLATFORM 3121262 – JLG Lift – 4-85...
Page 334 SECTION 4 - BOOM & PLATFORM 2" Socket 3/4” Socket Retaining Bolt Figure 4-24. Wire Rope Adjustment Tools (Optional) 4-86 – JLG Lift – 3121262...
Page 335: Broken Boom Cable Proximity Switch
SECTION 4 - BOOM & PLATFORM 4.17 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust after assembling the switch block, compression spring, and This system uses a proximity switch to detect excessive move- torquing the wire ropes. ment of the cable block.
Page 336: Normal Operation
SECTION 4 - BOOM & PLATFORM PLATFORM VALVES In order to obtain acceptable performance while performing all hydraulic functions, five sets of parameters are used. These The platform specific valves are located in a manifold at the “zones” allow compensation for differences in how the basket platform.
Page 337: Rotary Actuator
SECTION 4 - BOOM & PLATFORM 4.19 ROTARY ACTUATOR As hydraulic pressure is applied, the piston is displaced axially within the housing - similar to the operation of a hydraulic cyl- inder - while, simultaneously, the splines cause the shaft to Each actuator is individually serial numbered.
Page 338: Tools Required
SECTION 4 - BOOM & PLATFORM Tools Required 9. PLASTIC MANDREL 10. PRY BAR Removal of end cap and manual rotation of shaft. 11. FELT MARKER Highlights timing marks and outlines troubled areas. Permanent ink is recommended. 12. T-HANDLE SCREW EXTRACTOR 13.
Page 339: Disassembly
SECTION 4 - BOOM & PLATFORM Disassembly 4. Remove the lock pins using a screw extracting tool such as an "Easy Out" (a size #2 is shown). Inspect the actuator for corrosion prior to disassembly. Severe corrosion can make it difficult to remove the lock pins (109) If the pin cannot be removed with the screw extractor, and unthread the end cap (04).
Page 340 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing 3. Piston Sleeve 106.1. Port Plug 204.
Page 341 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 401 Counterbalance Valve 3. Piston Sleeve 106.1. Port Plug 204.
Page 342 SECTION 4 - BOOM & PLATFORM 7. Remove the end cap (4) and carefully set aside for later marks with a marker before disassembly as outlined in inspection. the steps below. 8. Remove the stop tube (400) if the actuator is equipped with one.
Page 343 SECTION 4 - BOOM & PLATFORM 11. Remove the shaft (2) by rotating counterclockwise. As 14. At the point when the piston gear teeth come out of the shaft is rotated, it will disengage from the piston engagement with the housing gear teeth, mark the pis- sleeve (3) and can be removed.
Page 344: Inspection
SECTION 4 - BOOM & PLATFORM 17. Remove the main pressure seal (205). 20. Remove the outside diameter piston seal (202) from the piston. 18. Remove the thrust washer (304) from the end cap (4) and shaft (2). 21. Remove the inside diameter piston seal (200). 19.
Page 345: Assembly
SECTION 4 - BOOM & PLATFORM Assembly 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular 1. Gather all the components and tools into one location motion.
Page 346 SECTION 4 - BOOM & PLATFORM 7. Install the inner T-seal (200) into the appropriate groove 8. Insert the piston (3) into the housing (1) as shown, until in the piston (3). Use a circular motion to ensure the seal the outer piston seal (202) contacts the inside housing is correctly seated in the groove.
Page 347 SECTION 4 - BOOM & PLATFORM 10. Looking into the bore from the opposite end of the 12. Looking at the actuator from the end opposite the shaft flange, use the existing timing marks to align the gear housing (1) be sure the timing marks align correctly. teeth on the shaft (2) with the gear teeth on the inside of Rotate the piston as necessary until aligned, then gently the piston (3).
Page 348 SECTION 4 - BOOM & PLATFORM 14. Install the stop tube (400) onto the shaft end if neces- 17. Tighten the end cap (4) using a metal bar. In most cases sary. Stop tubes are an available option to limit the rota- the original holes for the lock pins will align.
Page 349: Greasing Thrust Washers
SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Installing Counterbalance Valve Refer to Figure 4-29., Rotator Counterbalance Valve. 1. After the actuator is assembled but before it is put into 1. Make sure the surface of the actuator is clean, free of any service, the thrust washer area must be packed with contamination and foreign debris including old Loctite.
Page 350 SECTION 4 - BOOM & PLATFORM Figure 4-29. Rotator Counterbalance Valve 4-102 – JLG Lift – 3121262...
Page 351: Installation And Bleeding
SECTION 4 - BOOM & PLATFORM Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diame- ter x 5 foot clear, vinyl drain tube to each of the two After installation of the actuator on the equipment, it is impor- bleed nipples.
Page 352: Troubleshooting
SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.
Page 353: Jib Rotator Torquing Procedure
SECTION 4 - BOOM & PLATFORM 4.20 JIB ROTATOR TORQUING PROCEDURE 3. Torque the top bolts in a crossing star pattern to 300 ft.lbs. (410 Nm). See Figure 4-30., JIb Rotator Torque 4. Torque the center bolt to a final torque of 700 ft.lbs. (950 1.
Page 354 SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Torque to 40 ft.lbs. (55 Nm) JLG Threadlocker P/N 0100011 Torque 85 ft. lbs. (116 Nm) Torque 480 ft. lbs. (340-365 Nm) Check torque every 150 hours of operation Figure 4-31.
Page 355: Basic Hydraulic Information & Hydraulic Schematics
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.
Page 356: Dip Method
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.
Page 357: Hydraulic Connection Assembly And Torque Specification
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512 TORQUE SPECIFICATION Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.
Page 358: Straight Thread Types, Port Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Straight Thread Types, Port Connections Flange Connection Types ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162 MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162 6149, DIN 3852 Figure 5-10.
Page 359: Assembly And Torque Specifications
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.
Page 360: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED Thread Tapered (NPTF) Connections. TURNS AND USE THE LAST TURN FOR ALIGNMENT. 1.
Page 361: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for British Standard Pipe TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR ALIGNMENT. Thread Tapered (BSPT) Connections 5. Rotate male fitting the number of turns per Table 5-2, 1.
Page 362: Assembly Instructions For 37° (Jic) Flare Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37° Flare (JIC)Thread - Steel or Table 5-4, 37° Flare 1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double centricity issues with the tube OD.
Page 363 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-3. 37° Flare (JIC)Thread - Steel Type/Fitting Identification Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
Page 364 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
Page 365: Assembly Instructions For 45° Sae Flare Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using 1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
Page 366 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Thread ØA* ØB* [Ft-Lb] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16...
Page 367: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
Page 368 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in)
Page 369: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
Page 370 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-9. DIN 24°Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...
Page 371: Assembly Instructions For Bulkhead (Bh) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2.
Page 372 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12...
Page 373 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5...
Page 374 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Table 5-17 while using the Double Wrench Method. Fittings a. The table headings identify the straight thread O- ring port and the type on the other side of the fit- 1.
Page 375 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size...
Page 376 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
Page 377 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
Page 378 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
Page 379 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52...
Page 380 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-17. O-ring Boss (ORB) - Table 6 of 6 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 3/8-24 0.37 9.52...
Page 381: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5- Metric (MFF) Fittings 23 while using the Double Wrench Method.
Page 382 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
Page 383 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
Page 384 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
Page 385 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
Page 386 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
Page 387 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...
Page 388: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the type on the other side of the fitting.
Page 389 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...
Page 390 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...
Page 391: Assembly Instructions For Adjustable Port End (Bspp) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5- (BSPP) Fittings 30 while using the Double Wrench Method.
Page 392 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 FORM A**(SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
Page 393 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-26. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS...
Page 394 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-27. British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS BSPP...
Page 395 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 FORM A** (SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end BSPP Torque...
Page 396 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-29. British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS...
Page 397 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end BSPP Torque...
Page 398: Assembly Instructions For Flange Connections: (Fl61 And Fl62)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See Figure for O-ring installation instructions. 3.
Page 399 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws...
Page 400 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws...
Page 401: Double Wrench Method
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.
Page 402: Ffwr And Tfft Methods
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: 1. Lubricate the o-ring with a light coat of hydraulic oil. 1.
Page 403: O-Ring Installation (Replacement)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads dur- ing replacement or installation.
Page 404: Hydraulic Cylinders
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.3 HYDRAULIC CYLINDERS inder head retainer capscrews, and remove capscrews from cylinder barrel. Axle Extension Cylinder DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 405 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2,3,16 1,2,21 1684102-D 1. Thread Locker 6. Head 11. Wear Ring 16. Rod Wiper 21. Bolt 2. Locking Primer 7. Barrel 12. Backup Ring 17. Seal 22. Holding Valve 3. Loctite RC 609 8.
Page 406 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Loosen and remove the capscrew which attach the CLEANING AND INSPECTION tapered bushing to the piston. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage.
Page 407 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 408 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 409 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Remove the cylinder rod from the holding fixture. 17. Secure the cylinder head gland using the washer ring, JLG Threadlocker (P/N 0100011) and socket head bolts. 13. Place a new t-seal and wear rings in the outer piston Torque to 35 ft.lbs.
Page 410: Axle Lockout Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Axle Lockout Cylinder inder head retainer capscrews, and remove capscrews from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 411 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8,9,21 7,8,13 1684081-E 1. Barrel 6. Counterbalance Valve 11. Bearing 16. Backup Ring 21. Wiper 2. Rod 7. Thread locking Compound 12. Plug 17. Lock Ring 22. Seal 3. Piston 8. Locking Primer 13.
Page 412 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 413 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 414 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 415 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Remove the cylinder rod from the holding fixture. 14. Position the cylinder barrel in a suitable holding fixture. WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE SEALS ARE INSTALLED PROPERLY.
Page 416: Jib Level Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Level Cylinder inder head retainer capscrews, and remove capscrews from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 417 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque 9 ft.lbs. (12 Nm) 1,6*** ** Torque 50-55 ft.lbs. (68-75 Nm) *** Torque 170 ft.lbs. (230 Nm) 1001118142-B 1. Threadlocker 7. Spacer 13. Piston 105. Seal 2. Bolt 8. Holding Valve 14.
Page 418 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 9.
Page 419 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 420 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 421 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Remove the cylinder rod from the holding fixture. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE CYLINDER ROD, HEAD, AND PISTON.
Page 422: Platform Level Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Platform Level Cylinder 7. Using a spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY 8. Attach a suitable pulling device to the cylinder rod end. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED CYLINDER ROD, HEAD, AND PISTON.
Page 423 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6,16 6,9* 18**** 18**** 14*** * Torque to 4 in.lbs. (0.5 Nm) ** Torque to 9 ft.lbs. (12 Nm) *** Torque to 200 ft.lbs. (271 Nm) **** 30 to 35 ft.lbs. (41-47.5 Nm) 1001117968-D 1.
Page 424 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 11.
Page 425 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 426 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 427 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. If removed, install the spacer sleeve, sensor magnet, and 16. Position the cylinder barrel in a suitable holding fixture. retaining ring. 14. Remove the cylinder rod from the holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
Page 428: Boom Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Boom Lift Cylinder inder head retainer capscrews, and remove capscrews from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 429 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 28*** 27*** 2,17 1,2,25**** * Torque 25-27 ft.lbs. (34-36.5 Nm) ** Torque to 60 ft.lbs. (81 Nm) *** Torque 30-35 ft.lbs. (40.5-47.5 Nm) **** Torque 300 ft.lbs. (410 Nm) 1001118442-B 1. Threadlocker 7.
Page 430 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 9.
Page 431 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 432 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 433 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Remove the cylinder rod from the holding fixture. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE CYLINDER ROD, HEAD, AND PISTON.
Page 434: Jib Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lift Cylinder inder head retainer capscrews, and remove capscrews from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 435 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque to 4 in.lbs. (0.5 Nm) **Torque to 9 ft.lbs. (12 Nm) *** Torque to 120 ft.lbs. (163 Nm) **** Torque 50-55 ft.lbs. (68-75 Nm) 1001118082-B 1. Threadlocker 8. Plug 15.
Page 436 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 10.
Page 437 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 438 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 439 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Remove the cylinder rod from the holding fixture. 15. Position the cylinder barrel in a suitable holding fixture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE CYLINDER ROD, HEAD, AND PISTON.
Page 440: Jib Lock Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lock Cylinder CLEANING AND INSPECTION 1. Clean all parts thoroughly in an approved cleaning sol- DISASSEMBLY vent. 2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED or equivalent.
Page 441 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001119313-B 1. Head 4. Rod 103. Wear Ring 106. Rod Wiper 2. Lubricant 101. Wear Ring 104. O-ring 107. Seal 3. Barrel 102. Backup Ring 105. O-ring 108. Seal Figure 5-102. Jib Lock Cylinder 3121262 –...
Page 442 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS ASSEMBLY 3. Place a new O-rings and backup ring in the outside diameter groove of the cylinder head and new wear rings and polyseal in the inside diameter grooves of the NOTE: Prior to cylinder assembly, ensure that the proper cylinder cylinder head.
Page 443: Steer Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for easy realignment. Unscrew the cylinder cap from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 444 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque to 400 ft.lbs. (542 Nm) Max 1684314-D 6. Piston 11. O-ring 1. Cylinder Cap 2. Rod 7. Backup Ring 12. Wiper 3. Head 8. Wear Ring 13. Piston Seal 4.
Page 445 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a c. Lubricate inside of the steel bushing with WD40 vise or holding fixture as close to the piston as possible. prior to bearing installation. d.
Page 446 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER 10. Place a new wear ring and t-seal in the outer piston CYLINDER OPERATION. diameter grooves. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the seal.) Figure 5-112.
Page 447: Jib Telescope Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Telescope Cylinder INSPECTION 1. Inspect all seals, backup rings, wipers, and wear rings for tears, grooves, foreign matter, and excessive wear. Deep grooves may be an indication of damage to the barrel USE CARE IN REMOVAL OF ANY, AND ALL, COMPONENTS bore, rod chrome, or the presence of large particle con- AS COUNTERBALANCE VALVES MAY RETAIN CONSIDER-...
Page 448 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max 1001118663-C 1. Barrel 7. Pad Support 13. Wear Ring 19. Lockwasher 2. Rod 8. O-ring 14. Plug 20.
Page 449 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS ASSEMBLY ROD, GLAND, PISTON ASSEMBLY 1. Lubricate I.D. of head gland assembly with hydraulic NOTE: Refer to Figure 5-115. and Figure 5-116. provided at the end fluid, and slide onto rod (rod wiper end first) using cau- of this procedure for the proper seal locations and orienta- tion not to damage rod wiper or seal on rod end.
Page 450 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-115. Jib Telescope Cylinder Head Gland Detail Figure 5-116. Jib Telescope Piston Detail 5-96 – JLG Lift – 3121262...
Page 451: Main Boom Telescope Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Boom Telescope Cylinder inder head retainer capscrews, and remove capscrews from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
Page 452 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque to 13 ft.lbs. (17.5 Nm) ** Torque to 120 ft.lbs. (163 Nm) 1. Loctite #242 8. Barrel 15. O-Ring 22. Piston 29. Flatwasher 2. Locking Primer 9. Rod 16. Backup Ring 23.
Page 453 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 454 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Inspect cylinder head outside diameter for scoring or ASSEMBLY other damage and ovality and tapering. Replace as nec- NOTE: Prior to cylinder assembly, ensure that the proper cylinder essary. seal kit is used. See your JLG Parts Manual. 13.
Page 455 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating der head gland groove. Install a new wear ring into the end of rod must be free of oil.
Page 456 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Remove the cylinder rod from the holding fixture. 18. Secure the cylinder head gland using the washer ring, JLG Threadlocker (P/N 0100011), and socket head bolts. 14. Place a new t-seal and wear rings in the outer piston Torque to 120 ft.lbs.
Page 457: Cylinder Length Sensor
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.4 CYLINDER LENGTH SENSOR 5. Remove the plug that is over the setscrew that secures the sensor in place. Both the jib lift cylinder and the platform level cylinder utilize a cylinder length sensor which communicates with the JLG control system.
Page 458 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Using an allen wrench, remove the bolts securing the 8. Pull sensor out of the cylinder. DO NOT use the wiring retaining cap and remove the cap. harness to pull the sensor out as this will cause damage to the wiring.
Page 459: Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Installation 3. Apply lubricant JLG P/N 3020039 to the setscrew and install the setscrew. Torque the setscrew to 4 in. lbs. (0.45 1. Carefully insert the sensor into the cylinder. It may be Nm).
Page 460 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-132. Platform Valve Identification 5-106 – JLG Lift – 3121262...
Page 461 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-33. Platform Valve Specifications Torque Item Ohms ft.lbs. Pressure Check Port 17-18 23-24.5 Pressure Compensa- 25-30 34-41 Relief Valve 25-30 34-41 Relief Valve 25-30 34-41 Pressure Compensa- 25-30 34-41 Relief Valve 25-30 34-41 Inlet Valve...
Page 462 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-2. Fitting Torque Specifications Torque ft.lbs. 32.5 32.5 Figure 5-134. Platform Valve Fitting Torque Specifications 5-108 – JLG Lift – 3121262...
Page 463 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-135. Jib Control Valve Identification - Sheet 1 of 2 3121262 – JLG Lift – 5-109...
Page 464 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-136. Jib Control Valve Identification - Sheet 2 of 2 5-110 – JLG Lift – 3121262...
Page 465 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-137. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2 3121262 – JLG Lift – 5-111...
Page 466 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-33. Platform Valve Specifications Torque Item Ohms ft.lbs. Pressure Compensa- 25-30 34-41 Pressure Compensa- 25-30 34-41 Jib Lift Valve 16-20 22-27 Jib Tele Valve 16-20 22-27 Jib Level Valve 16-20 22-27 Jib Swing Valve 16-20...
Page 467 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-4. Fitting Torque Torque ft.lbs. 32.5 32.5 47.5 Figure 5-139. Jib Control Valve Fitting Torque Specifications 3121262 – JLG Lift – 5-113...
Page 468 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief 2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief 3. Lift Up 7. Swing Left 11.
Page 469 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-5. Cartridge Torque Values Ft-Lbs. Ft-Lbs. 25-30 33.9-40.6 30-35 40.6-47.4 25-30 33.9-40.6 30-35 40.6-47.4 30-35 40.6-47.4 40.6 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.5 30-35 40.6-47.4 30-35 40.6-47.5...
Page 470: Oil Sampling
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.5 OIL SAMPLING 3. Locate the oil sampling valve on the front of the main control valve. See Figure 5-141., Oil Sampling Port. 4. Unscrew the knurled end which is attached to the chain. 5.
Page 471: Pressure Setting Procedure
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.6 PRESSURE SETTING PROCEDURE Cold temperatures have a significant impact on pressure read- ings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge.
Page 472: Adjustments Made At The Main Valve Bank
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. To make an adjustment to this pressure, go to the SWING engine compartment, locate the function pump. The NOTE: Left and right are done with one adjustment. stand by adjustment is the adjustment outside adjust- ment, closest to the turntable.
Page 473 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS STEERING, FRONT AND REAR 2. Install the Analyzer in the platform control box and scroll menu’s to Access Level 2 and insert password (33271) to NOTE: The following procedure requires 2 people to perform. One get into Access Level 1.
Page 474 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-142. Steer Pressure Adjustments 5-120 – JLG Lift – 3121262...
Page 475 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. Remove the front circular steer/axle access covers at the mounted next to the MS2 port, clockwise to increase or front of the chassis, and the rear square cover at the top counterclockwise to decrease pressure.
Page 476 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Checking the left rear steer cylinder is identical to the mounted next to MS2 port clockwise to increase or procedure for left front steer cylinder, except now we are counterclockwise to decrease pressure. checking pressures at the rear axle/steer valve location.
Page 477: Adjustments Made At The Platform Valve Bank
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Remove the gauge from MS3 port and install on MS4 16. The next step is identical to the left front step men- port, which is on the left side of the front axle/steer tioned above, make sure the right rear wheel spindle is valve, closest to the left front wheel spindle.
Page 478: Adjustments Made At The Jib Valve
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Adjustments Made at the Jib Valve 6. Using the arrow keys scroll until MENU: SERVICE MODE is JIB LEVEL UP reached. Press ENTER NOTE: To check or adjust the jib level up pressure setting the JLG Analyzer must be used to override the automatic jib level function.
Page 479 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 11. When the function bottoms out, pressure should read 2600 psi.(180bar). 8. Enter code 58237 and Press ENTER . The screen 12. If necessary to adjust pressure, CW increases and CCW should read SERVICE MODE: JIB &...
Page 480 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6. Using the arrow keys scroll until MENU: SERVICE MODE is 8. Enter code 58237 and Press ENTER . The screen reached. Press ENTER should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 7.
Page 481 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Once turned on, operate the Jib Lift Down function. This 14. Adjust the jib level using will activate the Jib Level Down function. the Jib Lift function switch until the jib level 11.
Page 482 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB TELESCOPE OUT JIB TELESCOPE IN 1. Install a high pressure gauge at the MTA port. 1. Install a high pressure gauge at the MTB port. 2. Fully retract the jib boom. 2.
Page 483 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB LIFT UP JIB LIFT DOWN 1. Install a high pressure gauge at the MJA port. 1. Install a high pressure gauge at the MJB port. 2. Fully extend the jib lift cylinder or cap port JB. 2.
Page 484: Drive Pumps
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.7 DRIVE PUMPS 2. Transmission does not propel the machine, diesel engine running properly - Charge Pump/Relief Valve Troubleshooting Procedure a. Is there any charge pressure at port G or indicated by measuring pressure at Ma and Mb? To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d...
Page 485 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS h. Remove charge pressure relief valve from the mid- f. Stroke pump in both directions, while measuring dle pump and inspect. Is it damaged? pressure at Ma & Mb ports of the pump. Does any No - Refit cartridge and proceed to step 2.i pressure greater than charge pressure alternate Yes - Clean &...
Page 486 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Transmission Does Not Find or Hold Neutral 5. Transmission Drives in one direction only a. Does pump remain in neutral with electrical con- a. Are electrical connections to pump control propor- nectors removed? tional solenoids correct, intact and without defects? No - proceed to step 7.b...
Page 487: Charge Pressure Relief Valve Adjustment
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse- sive speed? power (Flow & Pressure) Yes - Check minimum displacement stop screw adjustments on the motors.
Page 488: Mechanical Centering Of Pump
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules able in 0.3, 0.5, and 1.0 mm thickness. PREPARATION FOR ADJUSTMENT When control modules are exchanged or replaced, it is gener- ally necessary to center the new module.
Page 489: High Pressure Relief Valve Adjustments
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS trol spring are correctly located in the grooves near the end of Removal and inspection of charge pump the feedback lever arms. Before removing cap screws, mark the position of the charge pump housing and separator plate in relation to the port block.
Page 490: Routine Maintenance
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS sembly. Make sure 0-rings are completely seated in their Routine Maintenance grooves. The Variable Displacement Hydrostatic Transmission Pumps are relatively maintenance free. Maintenance work is confined to the system, by way of maintaining hydraulic fluid condition, the "life blood"...
Page 491 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS g. Under application conditions with a heavy occur- b. The air/oil cooler surfaces and engine radiator rence of dust or severe temperature fluctuations, should be cleaned at the same time. the intervals between fluid maintenance should be c.
Page 492: Removal And Installation Of Shaft Seal
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap ring. Remove the retaining ring with snap ring pliers. Screw in sheet metal screw into the holes fitted with rubber. Pull out shaft seal with pliers.
Page 493: Function Pump
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.8 FUNCTION PUMP Figure 5-143. Function Pump - Sectional View Spare Parts 2. Drive Shaft 1. Sealing kit, existing spare parts: shaft sealing ring, o- rings, and a circlip. 3. Bearing set, miscellaneous parts. 3121262 –...
Page 494: Sealing The Drive Shaft
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft bly, valve plate, retaining plate, and retaining ball. BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE REMOVAL OF THE SHAFT SEALING RING. 1.
Page 495: Disassembly And Assembly Of The Complete Unit
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the position of the sealing ring in the pump housing. socket screw of the port plate. 5.
Page 496 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow. 8. Loosen the fixing nut of the stopper max flow and disas- 12.
Page 497 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 14. Disassemble the control piston while moving the swash 18. Remove both bearing shells. plate. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disassemble the piston rod.
Page 498: Assembly
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas- housing. semble the three pressure pins inside the cylinder. 23. Remove the o-ring. Lifting of the valve plate isn’t shown. Assembly 1.
Page 499: Adjustments
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. Pumps clockwise driven must have a position of the Adjustments valve plate 4 degrees out of center in the same direction de-centered like drive direction. TAPER ROLLER BEARING INITIAL TENSION Cast Iron pump housing must have initial tension of the bear- ings: 0 to 0.05 mm.
Page 500 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-144. Function Pump, Pressure and Flow Control - Sheet 1 Figure 5-145. Function Pump, Pressure and Flow Control - Sheet 2 5-146 – JLG Lift – 3121262...
Page 501: Pump Control Disassembly For Cleaning
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-146. Function Pump, Pressure and Flow Control - Sheet 3 Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur- face clean and installing some adhesive tape should pre- vent oil from seeping from the pump control.
Page 502 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Remove the spring disc. 21. Inspect the housing for contamination or plugged ori- fices. Clean orifices carefully with a dead soft steel wire 11. Remove the adjusting springs (two springs, one to insure they are open.
Page 503: Start-Up Procedure
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.9 DRIVE & FUNCTION PUMP START UP The middle transmission pump also supplies oil to a hot oil flushing valve cartridge, #120, in the Traction Control Mani- PROCEDURES fold. This cartridge provides a means to obtain brake release oil pressure.
Page 504 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 10. Operate the drive system in the "turtle mode", forward 17. Check oil level & temperature. and reverse. 18. Remove and inspect charge pressure oil filter, replace with new element. 11. De-aerate the system by bleeding fluid from the Ma & Mb ports.
Page 505 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS This page left blank intentionally. 3121262 – JLG Lift – 5-151...
Page 506 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-147. Hydraulic Schematic - Sheet 1 of 10 5-152 – JLG Lift – 3121262...
Page 507 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001120628-F Figure 5-148. Hydraulic Schematic - Sheet 2 of 10 3121262 – JLG Lift – 5-153...
Page 508 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-149. Hydraulic Schematic - Sheet 3 of 10 5-154 – JLG Lift – 3121262...
Page 509 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001120628-F Figure 5-150. Hydraulic Schematic - Sheet 4 of 10 3121262 – JLG Lift – 5-155...
Page 510 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Front Rear Drive Drive Pump Pump F00B F00A F00B F00A To port B, Main control valve, page 1. To port T2, main control valve, Page 1 PORT PORT PORT PORT PORT PORT PORT SWIVEL PORTS...
Page 511 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Front Pump Fire coil C1; flow to port A, measure at port M4 CHARGE PUMP FILTER Fire coil C2; flow to port B; measure at port M5 B5 >= 200 Rear Pump BYPASS 50 PSI Fire coil C1;...
Page 512 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS FRONT DRIVE MIDDLE DRIVE CHARGE PUMP FILTER PUMP PUMP B10 >= 1000 2.75 in3 2.75 in3 BYPASS 43 PSI 5000psi 5000psi R,T1,T2 R,T1,T2 Suction Strainer 60 Mesh (238 Micron) Cooler 3 PSI Bypass PORT PORT PORT...
Page 513 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PORT FRONT AXLE LEFT MOTOR OSCILLATING AXLE CIRCUIT FRONT DRIVE BRAKES DRIVE SYSTEM REXROTH PUMPS 1001120628-F Figure 5-154. Hydraulic Schematic - Sheet 8 of 10 3121262 – JLG Lift – 5-159...
Page 514 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB STOW ROTATOR 66 CU IN 10:1 PILOT RATIO SPRING 3300 PSI JIB TELESCOPE CYLINDER BORE 2.5" 4.91 sq in 1.5" 1.78 sq in JIB LIFT CYLINDER ANNULAR 3.14 sq in JIB LEVEL CYLINDER BORE 5"...
Page 515 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PLATFORM ROTATOR 14.1 cu in 3:1 PILOT RATIO SPRING 3000 PSI PLATFORM LEVEL CYLINDER JIB LOCK CYLINDER BORE 3.5" 9.62 sq in BORE 2.5" 4.91 sq in 1.5" 1.76 sq in 1.75"...
Page 516 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTES: 5-162 – JLG Lift – 3121262...
Page 517: Jlg Control System
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep, min INSTRUCTIONS speed, and max.-speed for all boom, drive, and steering func- tions.
Page 518: To Connect The Jlg Control System Analyzer
SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer 1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop- analyzer, to the motor controller module located in the erly, the analyzer will display the following: platform box or at the power module and connect the remaining end of the cable to the analyzer.
Page 519: Changing The Access Level Of The Hand Held Analyzer
SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS DRIVE ACTIVATE TEST BOOM ACCESS LEVEL SYSTEM PERSONALITIES DATALOG MACHINE SETUP...
Page 520: Adjusting Parameters Using The Hand Held Analyzer
SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.
Page 521: Machine Setup
SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press the UP DOWN arrow keys to adjust its value, for example: CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
Page 522 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT BOOM CONTROL SYSTEM JOYSTICK BOOM LENGTH ANGLE MODULE...
Page 523 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP VOLT VERSION VALVE...
Page 524 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal- ity settings first and then changing the model number of the machine configuration will cause the personality settings to return to default MODEL NUMBER: No Model...
Page 525 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI. TILT: 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation;...
Page 526 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. HYDRAULIC DRIVE: Hydraulic driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. MOTION CUTOUT: Motion cutout in platform mode only.
Page 527 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number FUNCTION CUTOUT: NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive cutout above elevation. DRIVE CUT E&T: Drive cutout above elevation and tilted. * Only visible under certain market selections.
Page 528 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings 1500SJ 1500SJ Function Cutout Model Number Envelope Height Market Ground Alarm Engine Glow Plug Oscillating Axle Starter Lockout Temperature Engine Shutdown Leveling Mode Tilt Clearsky BOLD TEXT...
Page 529 SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. FUNCTION SPEEDS Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON...
Page 530 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec DECEL X.Xs Displays/adjusts main lift deceleration...
Page 531 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) PLATFORM LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec DECEL X.Xs Displays/adjusts basket level deceleration...
Page 532 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec DECEL X.Xs Displays/adjusts jib lift deceleration...
Page 533 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speeds PARAMETER SUBMENU DEFAULT TIME RANGE (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 VALUES (SEC) ANALYZER 1ST LINE) LINE) JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec DECEL X.Xs Displays/adjusts jib level deceleration...
Page 534: Test Notes
SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN SETTING Test Notes FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum LIFT UP, from platform control, lowest elevation up to maxi- machine performance.
Page 535: Canbus Communications
SECTION 6 - JLG CONTROL SYSTEM 6.4 CANBUS COMMUNICATIONS The GROUND MODULE (UGM) is the master system controller. Most functions are dispatched and coordinated from this module, all other system modules (PLATFORM, JIB, BLAM, CANbus: CAN (Control Area Network) is a two wire differential CHASSIS) handle sub-tasks.
Page 536 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Control System Block Diagram 6-20 – JLG Lift – 3121262...
Page 537: Calibration Instructions
SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATION INSTRUCTIONS Table 6-5. Calibration Instructions This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement degree of function interaction. For safety and proper machine bration Telescope proportional valve replacement functionality, the calibration procedures must be repeated for Erratic controlled arc operation...
Page 538 SECTION 6 - JLG CONTROL SYSTEM 6-22 – JLG Lift – 3121262...
Page 539 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-23...
Page 540 SECTION 6 - JLG CONTROL SYSTEM 6-24 – JLG Lift – 3121262...
Page 541 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-25...
Page 542 SECTION 6 - JLG CONTROL SYSTEM 6-26 – JLG Lift – 3121262...
Page 543 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-27...
Page 544 SECTION 6 - JLG CONTROL SYSTEM 6-28 – JLG Lift – 3121262...
Page 545 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-29...
Page 546 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT SPARE (LP NOT USED) DIGITAL OUTPUT TOWER BOOM LIFT POWER DIGITAL OUTPUT GROUND GROUND INPUT GROUND GROUND INPUT TOWER TELESCOPE ENABLE DIGITAL OUTPUT SPARE (LP NOT USED) DIGITAL OUTPUT GROUND...
Page 547 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type PLATFORM EMS DIGITAL INPUT PLATFORM MODE DIGITAL INPUT GROUND MODE DIGITAL INPUT TOWER CYLINDER PRESSURE ANALOG INPUT REFERENCE VOLTAGE VOLTAGE OUTPUT CAN TERMINATION TERM SPARE ANALOG INPUT SPARE ANALOG INPUT 2 ANALOG INPUT GROUND...
Page 548 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type GROUND FROM BATTERY GROUND INPUT GROUND EMS GROUND INPUT (Black) GROUND TO PLATFORM GROUND OUTPUT GROUND EMS OUT TO PLATFORM GROUND OUTPUT Connector Function Type AXLES SET LAMP DIGITAL OUTPUT 500# CAPACITY LAMP DIGITAL OUTPUT BOOM CONTROL SYSTEM LAMP...
Page 549 SECTION 6 - JLG CONTROL SYSTEM Connector FUNCTION Type FUNCTION Connector Type Power Feed Thru to J1-1 Power Power Feed Thru to J1-2 Power Feed Thru to J2-1 Power Power Connector Type FUNCTION Power Feed Thru to J2-2 Power Ground Power Output Ignition Power...
Page 550 SECTION 6 - JLG CONTROL SYSTEM Connector FUNCTION Type FUNCTION Connector Type Power Feed Thru to J1-1 Power Power Feed Thru to J2-1 Power Power Feed Thru to J1-2 Power Connector Type FUNCTION Power Feed Thru to J2-2 Power Ground Power Output Ignition Power...
Page 551 SECTION 6 - JLG CONTROL SYSTEM Connector FUNCTION Type Connector Pin FUNCTION Type Power Feed Thru to J2-1 Power Power Feed Thru to J1-1 Power Connector Pin FUNCTION Type Power Feed Thru to J2-2 Power Power Feed Thru to J1-2 Power Signal Feed Thru to J2-4 Digital...
Page 552 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-17. Analyzer Connecting Points 6-36 – JLG Lift – 3121262...
Page 553: Control System Boom Sensors
SECTION 6 - JLG CONTROL SYSTEM 6.6 CONTROL SYSTEM BOOM SENSORS Sensor #2 - Main Boom Angle Sensors NOTE: Note: The machine is defined as being in transport mode if: Axles are retracted. Main boom lift is below elevation angle. Main boom telescope is fully retracted.
Page 554 SECTION 6 - JLG CONTROL SYSTEM MAIN BOOM LIMIT SWITCH MAIN BOOM STRING POT MAIN BOOM PROTRACTOR JIB TELESCOPE SENSOR PROXIMITY SENSORS MAIN BOOM ANGLE SENSORS PLATFORM WIRE ROPE PROXIMITY SENSOR LEVEL SENSORS JIB ROTATE SENSORS JIB LEVEL PROTRACTOR SENSOR JIB LOCK PIN PROXIMITY SENSORS Figure 6-18.
Page 555: Sensor #3 - Main Boom Length Sensor
SECTION 6 - JLG CONTROL SYSTEM Sensor #3 - Main Boom Length Sensor Sensor #4 - Main Boom Cylinder Angle Sensor This sensor's function is to measure Main Boom angle in rela- tionship to the turntable. A rotary type sensor is mounted to the Turntable and attached to the Main lift cylinder.
Page 556: Sensor #6 - Jib Level Angle Sensor
SECTION 6 - JLG CONTROL SYSTEM Sensor #6 - Jib Level Angle Sensor Sensor #7 - Jib Lock Pin Switch This sensor is used to indicate the Jib Lock Pin is fully engaged. It is an inductive proximity switch mounted to the Jib Pivot weldment with both Normally Open and Normally Closed con- tacts wired into the control system.
Page 557: Sensor #10 - Dual Capacity / Jib Transport Length Switches
SECTION 6 - JLG CONTROL SYSTEM Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Cylinder Angle Sensor Switches This sensor is used to measure Platform angle in relationship to the Jib. A linear position sensor is located inside the Plat- form Level cylinder to measure cylinder stroke and be trans- lated into Platform angle.
Page 558: Jib Control Module
SECTION 6 - JLG CONTROL SYSTEM 6.7 JIB CONTROL MODULE 6.8 CAN GATEWAY See Figure 6-16., Jib Control Module. The Jib Control Module is mounted at the end of the main boom to aid in control of Jib Lift, Jib Level, Jib Telescope, and The CAN gateway is located in the ground control box.
Page 559: System Test
SECTION 6 - JLG CONTROL SYSTEM 6.9 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat- form console are in the following positions: The Control System Incorporates a built-in system test to a. Drive speed switch is in the Middle position. (Turtle check the system components and functions.
Page 560 SECTION 6 - JLG CONTROL SYSTEM 4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter. engine. The analyzer will prompt you asking if you want to acti- vate the system test; hit Enter again to activate. 7.
Page 561 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-45...
Page 562: Test From The Ground Station
SECTION 6 - JLG CONTROL SYSTEM Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the engine. 1. Position the Platform/Ground select switch to the Ground position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector inside the Ground control box.
Page 563 SECTION 6 - JLG CONTROL SYSTEM 3121262 – JLG Lift – 6-47...
Page 564 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be reported include below messages. ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
Page 565 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor- mal”...
Page 566 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends. If ENTER is pressed or clicked, each operator input is prompted for in turn.
Page 567 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) DRIVE: DRIVE FOR/REV XXX% Displays drive joystick direction & demand STEER RIGHT/LEFT XXX% Displays steer switch direction &...
Page 568 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) BOOM: U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand SWING RIGHT/LEFT XXX% Displays swing joystick direction &...
Page 569 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) ENGINE: START ACTIVE/NOT ACTIVE Displays status of the engine start circuit AIR FILTER OP/CL Displays measured status of air filter by-pass switch.
Page 570 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) SYSTEM: GM BATTERY XX.XV Ground module battery voltage PM BATTERY XX.XV Platform module battery voltage AMB.
Page 571 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured) AUX POWER OP/CL Displays the status of the auxiliary power switch input...
Page 572 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING AXLE = 1) SKY WELDER YES/NO...
Page 573 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) MOMENT: Displayed if MODEL NUMBER = 7 or 8 (LB-IN) ACTUAL XXXXXXXX Displays current moment value...
Page 574 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) ENVELOPE: Displayed if MODEL NUMBER = 7 or 8 LENGTH XXXX.X Displays the current indicated boom length in inches.
Page 575 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) CALIBRATION DATA BASKET UP Displays the basket up calibration point BASKET DOWN Displays the basket down calibration point L FWD DRIVE...
Page 576 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) DATALOG: XXXXhXXm Displays total controller on (EMS) time ENGINE XXXXhXXm Display engine run time DRIVE...
Page 577: Calibrating Steer
SECTION 6 - JLG CONTROL SYSTEM 6.10 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat- form position. When calibrating steering, each individual wheel must be cali- brated in order to make the tire and wheel parallel with the frame.
Page 578 SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read: engine. 4. The analyzer screen should read: 9. Hit Enter. The screen will read: 5.
Page 579 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer. 15. Left Rear Steer Calibration will be followed by Right For- ward Steer Calibration which will be followed by Right Rear Steer Calibration.
Page 580: Calibrating Drive
SECTION 6 - JLG CONTROL SYSTEM 6.11 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the engine. 1. Position the Platform/Ground select switch to the Plat- form position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector at the base of the platform control box.
Page 581 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read: 9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate the Drive Joystick forward full stroke until the machine just begins to move, then leave off the joystick immediately.
Page 582 SECTION 6 - JLG CONTROL SYSTEM 13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read: the crack point is set to. The screen will show: 15. Repeat steps 10 thru 12 for left reverse drive. 16.
Page 583: Electronic Platform Leveling
SECTION 6 - JLG CONTROL SYSTEM 6.12 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS There are three possible level valve driver errors, short to bat- tery, short to ground, and open circuit. Platform Leveling Fault Warning 1. In the case of a short to ground or an open circuit, the The JLG Control System takes a snapshot of the two sensor val- platform valve cannot be turned on and the following ues and records the difference once on each power up.
Page 584: Calibrating Platform Level
SECTION 6 - JLG CONTROL SYSTEM TILT SENSOR ERRORS 6.13 CALIBRATING PLATFORM LEVEL If the secondary tilt sensor is faulty, the control system will STEP 1: SETTING THE PLATFORM VALVE MINIMUMS continue to utilize information from the primary sensor. 1. Position the Platform/Ground select switch to the If the primary sensor is faulty, the control system will switch to Ground position.
Page 585: Step 2: Bleeding The Platform Valves
SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: STEP 2: BLEEDING THE PLATFORM VALVES 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 5.
Page 586 SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.
Page 587: Calibrating Lift Crack Point
SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: 11. Using UP ARROW, increase the value until you see the basket up movement. 12. Hit ENTER again. CAL. COMPLETE message should appear 13. Engine should again return to idle. 14.
Page 588 SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector at the base of the 4. The analyzer screen should read: platform control box. 3. Pull out the Emergency Stop switch and Start the engine. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6.
Page 589 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach Upper Lift Crack Point 10. Hit Enter. The screen will read: (UPPER LIFT CRKPT). The screen will read: 11. Hit Enter again. The screen will read: 9. Hit enter. The screen will read: 12.
Page 590: Calibrating Telescope Crack Point
SECTION 6 - JLG CONTROL SYSTEM 13. Hit enter. The number displayed will be the value that 6.15 CALIBRATING TELESCOPE CRACK POINT the crack point is set to. The screen will show: 1. Position the Platform/Ground select switch to the Plat- form position.
Page 591 SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Upper Telescope Crack Point engine. (UPPER TELE CRKPT). The screen will read: 4. The analyzer screen should read: 9.
Page 592 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: NOTE: In the following step, a minimum value of 10 must be indi- cated on the analyzer before the crack point can be set. The JLG Control System will not accept a value less than 10 and the analyzer will not advance to "CAL COMPLETE"...
Page 593 SECTION 6 - JLG CONTROL SYSTEM 14. Hit Enter. The screen will read: 15. Hit Enter. The screen will read: 16. Repeat steps 10 thru 12 for the Tele In function. 17. After completing all the Tele Calibrations, hit ESC twice to go back to CALIBRATIONS.
Page 594: Calibrating Tilt Sensor
SECTION 6 - JLG CONTROL SYSTEM 6.16 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground control box. A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.
Page 595 SECTION 6 - JLG CONTROL SYSTEM 9. Use the arrow keys to reach the TILT SENSOR. The screen 11. When prompted, swing turntable 180° to opposite end of chassis. should read: 12. Press ENTER. The screen should read: 10. Press ENTER. 13.
Page 596: Jib Sensor Calibrations
SECTION 6 - JLG CONTROL SYSTEM 6.17 JIB SENSOR CALIBRATIONS 4. The analyzer screen should read: To calibrate the jib sensors, the analyzer must be in access level 1. All jib sensors can be calibrated at one time or each cal- ibration can be performed on an individual basis.
Page 597 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach the JIB SENSORS. The screen 10. Press ENTER. The screen should read as shown below. should read: When it does, activate boom lift until the control system stops it at 20 degrees boom angle.
Page 598 SECTION 6 - JLG CONTROL SYSTEM 11. Press ENTER. The screen should read as shown below. 12. If the operator presses enter at the jib lift sensor calibra- When it does, the operator can either press enter to tion prompt, the screen shown below will be displayed. begin the jib lift sensor calibration, or use the right or At this point, lift the jib up to the mechanical stop.
Page 599 SECTION 6 - JLG CONTROL SYSTEM 14. Once the jib is stopped the screen shown below will be 16. Hitting the ENTER key at this point will take the operator displayed. to the next jib sensor calibration. The screen will show: 15.
Page 600 SECTION 6 - JLG CONTROL SYSTEM 18. Operate jib lift down until the jib stops. When the jib is 20. Press ENTER. The screen should read: at the mechanical stop the operator must hit ENTER again. The screen will show: 21.
Page 601 SECTION 6 - JLG CONTROL SYSTEM 22. When the system completes this step, the next screen 24. When the system completes the previous step, the will show: screen will read: 23. Press ENTER. The screen should read as shown below. 25.
Page 602 SECTION 6 - JLG CONTROL SYSTEM 26. Hitting the ENTER key at this point will take the operator 28. When the jib reaches the mechanical stop, press ENTER. to the next jib sensor calibration. The screen will show: The screen will show: 27.
Page 603 SECTION 6 - JLG CONTROL SYSTEM 30. Press Enter. The screen shown below will be displayed. 32. At the finish of the jib swing lift calibration the jib lock At this point, use the platform rotate left function switch pin will be locked by the control system. The screen will to swing the jib left.
Page 604 SECTION 6 - JLG CONTROL SYSTEM NOTE: At this point the left or right arrow key may be used to skip 37. When the platform level up is at mechanical stop, Press to any of the other jib sensor calibrations. ENTER.
Page 605: Calibrating The Jib Level Up And Down Valve Crackpoints
SECTION 6 - JLG CONTROL SYSTEM 39. Press ENTER. The display will then show: 40. The control system will stop the platform level and the screen will show: 41. Pressing ENTER will take you back to the beginning and escape (ESC) will take you to the initial screen. Calibrating the Jib Level Up and Down Valve Crackpoints 1.
Page 606 SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector inside the Ground 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. control box. 6. Enter the Access Code, 33271. 7. Go to the CALIBRATIONS menu and hit ENTER. 8.
Page 607: Calibrating The Boom Sensors
SECTION 6 - JLG CONTROL SYSTEM 6.18 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the Ground position. DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR THE REAR WHEEL TO LIFT FROM THE GROUND APPROXIMATELY 1 INCH (2.5 CM).
Page 608 SECTION 6 - JLG CONTROL SYSTEM 5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 10. Hit Enter. The screen will read: 7.
Page 609 SECTION 6 - JLG CONTROL SYSTEM 11. After verifying all the conditions listed in step 1 are met, 13. After visually verifying that the jib is horizontal, hit Enter. hit Enter. The screen will read: The screen will read: 12. After verifying all load (personnel or material) is 14.
Page 610 SECTION 6 - JLG CONTROL SYSTEM 15. After visually verifying the platform is centered, hit 17. Use the up/down arrows to select YES if the accessory is Enter. The screen will read: installed, NO if it is not installed and hit enter. The screen will read: 16.
Page 611 SECTION 6 - JLG CONTROL SYSTEM 19. Use the up/down arrows to select YES if the accessory is 21. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter.
Page 612 SECTION 6 - JLG CONTROL SYSTEM 23. After making sure the machine is in Calibration Position The screen will read: 1, hit Enter. The screen will read: 24. Lift up to stop (full stroke of cylinder) for Calibration Position 2. When the machine is in that position, hit Enter.
Page 613 SECTION 6 - JLG CONTROL SYSTEM 25. Swing 180 degrees (centered over opposite end of chas- When Position 3 calibrating is complete the screen will sis) for Calibration Position 3. read: Figure 6-23. Boom Sensor Calibration Position 3 When the machine is in the proper position, hit Enter. The screen will read: 3121262 –...
Page 614 SECTION 6 - JLG CONTROL SYSTEM 26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: Swing the machine back 180 degrees (centered over When Position 4 calibrating is complete, the screen will original end of chassis) for Calibration Position 4.
Page 615 SECTION 6 - JLG CONTROL SYSTEM 27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: Telescope out to stop (boom must be fully extended) for Calibration Position 5. Figure 6-25.
Page 616 SECTION 6 - JLG CONTROL SYSTEM 28. Retract to stop (boom must be fully retracted) for Cali- 29. Lift down to stop (boom must be on boom rest) for Cali- bration Position 6. bration Position 7. Figure 6-27. Boom Sensor Calibration Position 7 When the machine is in the proper position, hit Enter.
Page 617 SECTION 6 - JLG CONTROL SYSTEM When Position 7 Calibrating is complete, the screen will 30. Lift until the function stops (controller will stop at 5 read: degrees above horizontal) for Calibration Position 8. Figure 6-28. Boom Sensor Calibration Position 8 When the machine is in the proper position, hit Enter.
Page 618 SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The screen will read: 31. Telescope to the yellow witness mark (controller will be close - operator must position the pointer to center line When Position 9 calibrating is complete, the screen will on decal within 0.25"...
Page 619 SECTION 6 - JLG CONTROL SYSTEM Press Enter. The screen will read: When the boom is in the proper position, the screen will read: 32. Telescope in to green witness mark (controller will find the position - operator must visually verify the position). Pressing enter will bring up: Figure 6-30.
Page 620 SECTION 6 - JLG CONTROL SYSTEM 33. Operate the Lift Up function switch. The control system 35. Operate the Jib Telescope Out function to the mechani- will stop the boom at the desired angle. The display will cal stop. Press ENTER. The display will read: read: 36.
Page 621 SECTION 6 - JLG CONTROL SYSTEM 37. Operate the Jib Telescope In function switch until the jib 39. When the calibration step is done, the display will read: is telescoped in to the mechanical stop. Press ENTER. The display will read: 40.
Page 622 SECTION 6 - JLG CONTROL SYSTEM 41. Operate the Main Boom Telescope function until the 43. Press ENTER. The display will read: main boom is telescoped in to the stop. The display will read: 44. After completing all the Boom Sensors Calibrations, hit ESC twice to go back to Calibrations.
Page 623: Boom Control System Check Procedure
SECTION 6 - JLG CONTROL SYSTEM Boom Control System Check Procedure 5. Push and hold the gray Boom Control System Test But- ton on the ground control panel. The lighting of the Perform the following check with no load (personnel or mate- green Boom Control System Calibrated indicator indi- rial) in the platform from the ground control station.
Page 624 SECTION 6 - JLG CONTROL SYSTEM FAULT CODE LIGHT 1705744 A 1702566 B 1702565 B 1001125195 B 1702938 1705170 A 1001125194 A PLATFORM CONTROL MODULE GROUND FAULT CONTROL CODE MODULE LIGHT Figure 6-31. Fault Code Light Location 6-108 – JLG Lift – 3121262...
Page 625 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Sequence Fault Message Fault Description Check Code EVERYTHING OK The normal help message in Platform Mode. GROUND MODE OK The normal help message in Ground Mode. 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE- VATED MAX"...
Page 626 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code <<< PLATFORM CONTROLS >>> STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are closed simultane- ously. 2211 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power- more then seven seconds.
Page 627 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code <<< OTHER CONTROLS >>> <<< FUNCTION PREVENTED >>> MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been changed.
Page 628 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3317 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi- Right Forward Drive Valve.
Page 629 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3343 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only. Cold Start Advance Solenoid.
Page 630 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3377 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles Head Light Relay. only.
Page 631 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Main Telescope Out Valve. 33130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the...
Page 632 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Main Telescope In Valve. 33207 HORN - OPEN CIRCUIT There is an Open Circuit to the...
Page 633 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system Open Circuit to the Platform equipped vehicles only.
Page 634 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading - Deutz engine only. is > 6.6V. OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only.
Page 635 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code CANBUS FAILURE - LOAD SENSING SYSTEM MODULE CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only. communication lost.
Page 636 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are not possible while the Load Sensing System indicates the Platform is overloaded AND is configured to prevent drive and boom functions while the Plat-...
Page 637 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8315 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the - Electronic leveling system sensor values at power-up. The equipped vehicles only.
Page 638 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi- changing during a boom tele- cles only.
Page 639 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 84102 MAIN CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE 84103 JIB LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 84104 JIB LIFT ANGLE SENSOR - NOT DETECTING CHANGE 84105 PLATFORM LEVEL ANGLE SENSOR - NOT DETECTING CHANGE 84106...
Page 640 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Right Front Steer Left Valve. 8610 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an...
Page 641 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8624 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has become decoupled. 8625 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has become decoupled.
Page 642 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code LSS INTERNAL ERROR - PIN EXCITATION LSS INTERNAL ERROR - DRDY MISSING FROM A/D EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has reported an EEPROM failure.
Page 643 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 9925 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software IMPROPER version is not compatible with the rest of the system. 9926 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER The BLAM software version is not compatible with the rest of...
Page 644 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 99159 JIB LIFT ANGLE SENSOR - INTERNAL ERROR 99160 FUNCTIONS LOCKED OUT - JIB CONTROL MODULE SOFTWARE VERSION IMPROPER 6-128 –...
Page 645: Basic Electrical Information & Electrical Schematics
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERAL that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the Ground This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port matics to be used for locating and correcting most of the oper-...
Page 646: Resistance Measurement
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing conti- Figure 7-2.
Page 647: Current Measurement
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Current Measurement APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...
Page 648: Installation Of Dielectric Grease
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3. Anderson connectors for the battery boxes and battery Deutsch HD, DT, DTM, DRC Series chargers should have silicone grease applied to the con- The Deutsch connector system is commonly used for harsh tacts only.
Page 649: Amp Mate-N-Lok
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs Exclusions AMP Mate-N-Lok A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application.
Page 650 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity. and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric mistakenly applied to this connector system, the low-force grease and create electrical contact.
Page 651: Amp Connector
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-9.). Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-7.).
Page 652 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).
Page 653: Disassembly
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 6.
Page 654 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-13. Connector Installation 7-10 – JLG Lift – 3121262...
Page 655: Deutsch Connectors
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 5. Remove wedgelock using needlenose pliers or a hook 1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
Page 656: Hd30/Hdp20 Series Assembly
SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp 11. With rear insert toward you, snap appropriate size barrel.
Page 657 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-13...
Page 658 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-21. Chassis Electrical Components - Sheet 1 of 2 7-14 – JLG Lift – 3121262...
Page 659 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-22. Chassis Electrical Components - Sheet 2 of 2 3121262 – JLG Lift – 7-15...
Page 660 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-23. Turntable Electrical Components - Sheet 1 of 2 7-16 – JLG Lift – 3121262...
Page 661 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-24. Turntable Electrical Components - Sheet 2 of 2 3121262 – JLG Lift – 7-17...
Page 662 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-18 – JLG Lift – 3121262...
Page 663 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-26. Console Box Harness - Sheet 2 of 2 3121262 – JLG Lift – 7-19...
Page 664 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-20 – JLG Lift – 3121262...
Page 665 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-21...
Page 666 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-29. Jib Valve Harness - Sheet 1 of 3 7-22 – JLG Lift – 3121262...
Page 667 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-23...
Page 668 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-31. Jib Valve Harness - Sheet 3 of 3 7-24 – JLG Lift – 3121262...
Page 669 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-25...
Page 670 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-33. Boom Length and Angle Harness - Sheet 2 of 2 7-26 – JLG Lift – 3121262...
Page 671 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-34. Main Terminal Box Harness - Sheet 1 of 4 3121262 – JLG Lift – 7-27...
Page 672 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-28 – JLG Lift – 3121262...
Page 673 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-36. Main Terminal Box Harness - Sheet 3 of 4 3121262 – JLG Lift – 7-29...
Page 674 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-37. Main Terminal Box Harness - Sheet 4 of 4 7-30 – JLG Lift – 3121262...
Page 675 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-31...
Page 676 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-32 – JLG Lift – 3121262...
Page 677 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-40. Turntable Harness - Sheet 3 of 3 3121262 – JLG Lift – 7-33...
Page 678 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-41. Pump Harness 7-34 – JLG Lift – 3121262...
Page 679 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121262 – JLG Lift – 7-35...
Page 680 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-36 – JLG Lift – 3121262...
Page 681 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-44. Chassis Harness - Sheet 3 of 3 3121262 – JLG Lift – 7-37...
Page 682 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL DIAGNOSITC DISPLAY KEY SWITCH EMERGENCY MOUNTED IN GROUND BOX TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH...
Page 683 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH MOMENT CONTROL TEST PUSH BUTTON (CE ONLY) 500# CAP AXLE SET GLOW PLUG...
Page 684 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS This page left blank intentionally. 7-40 – JLG Lift – 3121262...
Page 685 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-47. Electrical Schematic - Sheet 1 of 18 3121262 – JLG Lift – 7-41...
Page 686 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HORN AXLE EXTEND/RETRACT PLATFORM DISPLAY PUSH BUTTON JIB LOCK PIN SOFT TOUCH TOGGLE SWITCH LED BOARD LIGHT LIGHT HIGH DRIVE STEER MODE PLATF LEVEL OVERRIDE TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH GOLD PIN SILVER PIN PLTF LEVEL...
Page 687 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS AXLE EXTEND/RETRACT BOOM CONTROL SELECT START/AUX POWER CAPACITY SELECT DRIVE ORIENTATION JIB LOCK PIN SOFT TOUCH SOFT TOUCH HEAD/TAIL TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH OVERRIDE LIGHT LIGHT LIGHT GOLD PIN...
Page 688 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SENSOR #2 (LH) SENSOR #1 (RH) JIB LIFT PLATF LEVEL PLATF LEVEL PLATF ROT PLATF ROT JIB LOCK JIB LOCK PLATFORM PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR LENGTH SENSOR DOWN LEFT RIGHT PIN - IN PIN - OUT...
Page 689 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MOUNTED IN JCM BOX JIB LIFT JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING 3 x 4 Buss Bar LENGTH SENSOR JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN DOWN...
Page 690 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BROKEN CABLE PUMP PROXIMITY SENSOR CONNECTOR SEE SHEET 7 Boom Angle Sensor Boom Angle Sensor #1 Right Side #2 Left Side ZONE B-8 STROBE MAIN SWING SWING MAIN LIFT LIGHT DUMP RIGHT LEFT CO11-J2...
Page 691 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BROKEN CABLE BOOM LENGTH PROXIMITY SENSOR LIMIT SWITCH X244 X146 SEE SHEET 5 RED (12) ZONE D-8 BLK (12) ORN (12) BLU (12) STROBE MAIN SWING SWING MAIN LIFT MAIN LIFT LIFT MAIN TELE MAIN TELE...
Page 692 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER DIAGNOSITC DISPLAY KEY SWITCH EMERGENCY TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITC...
Page 693 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER (CE ONLY) TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH MOMENT CONTROL TEST GENERIC 500# CAP AXLE SET GLOW PLUG HIGH COOLANT LOW OIL NO ALTERNATOR...
Page 694 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SEE SHEET 4 ZONE B-6 SN176 SWIVEL LEFT FRONT AXLE OSC. AXLE LOCK-OUT BRAKE TWO SPEED COUPLING EXTEND LIMIT SWITCH TURNTABLE VALVE VALVE VALVE ANGLE SENSOR YEL/RED 2-1-3 S187 S188 ORN/RED 49-104 S189 YEL/RED 2-1-2 S190...
Page 695 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS LEFT FRONT AXLE RIGHT FRONT AXLE LEFT REAR AXLE RIGHT REAR AXLE EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH RETRACT LIMIT SWITCH RETRACT LIMIT SWITCH YEL/RED 2-1-3 S187 S188 ORN/RED 49-104 S189 YEL/RED 2-1-2 S190 S191...
Page 696 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS WHT/YEL 48-13 (8) EC91 GLOWPLUG START RELAY RELAY ENGINE TRAY ENGINE PIVOT PIN BLOCK EC204-B- WHT/YEL 48-12 (12) BLK (1/0) Sheet_4 (T/T & Boom)-[2,D] EC204 RED (1/0) RED (1/0) Sheet_4 (T/T & Boom)-[2,D] RED (8) EC204-B+ X266...
Page 697 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS This Page Left Blank Intentionally. 3121262 – JLG Lift – 7-53...
Page 698 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS LEFT FRONT RIGHT FRONT LIGHT LIGHT HEAD & TAIL LIGHT RELAY (OPTION) 7500W GENERATOR CONTROL BOX CONNECT TO X147 BLU/ORN 52-12 IN TURNTABLE X201 CONNECT TO B- BLACK YEL/RED 2-8-8 ENGINE ON ENGINE TRAY IP328 CONNECTOR #2...
Page 699 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS PLATFORM SENSOR (FOR PASSIVE SYSTEM, REMOVE PLATFORM SENSOR AND 2 RELAYS) (OPTION) 7500W GENERATOR RL502-87 CONTROL BOX SHEET 2 YEL/RED P3 YEL/RED P3 [F,4] RL502-30 YEL/RED P9-1 RL502-87A RL502-85 ORN/RED P5 ORN/RED P5-1 RL502-86 ORN/RED P4...
Page 700 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ECM-J2 X999 X1003 BUSSMANN DIODE PACK BLK 248-33 INJECTOR 1 BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT) (BLUE) BLK 248-16 INJECTOR 1 BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR GLOWPLUG SOLENOID BLK 248-48 INJECTOR 4...
Page 701 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BUSSMANN DIODE PACK FUEL PUMP 20A (SW), ECM 30A (CONT) Deutz Engine (BLUE) YELLOW CONNECTOR GLOWPLUG SOLENOID GLOWPLUGS GENERIC 150 AMP RELAY, POWER MODULE Tier 4 Final GENERIC GENERIC ALTERNATOR BATTERY POSITIVE BUSBAR EC971-B+...
Page 702 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ALERT BEACON OPTION HARNESS P/N 1001142736 RED - BEACON PWR BEACON MODULE BLK - GROUND RED - BEACON PWR WHT - IGNITION BLK - GROUND BLK - GROUND SHEET: 10 Figure 7-63. Electrical Schematic - Sheet 17 of 18 7-58 –...
Page 703 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS CRIBBING HARNESS OPTION TO CRIBBING MODULE- J1 TO CRIBBING MODULE - J2 CRIBBING ENABLE LAMP CRIBBING ENABLE SW SW374 CONNECT TO S369 GROUND CONTROLLER (SHEET 5) J7 33 S370 MS377-3 GRN CANL YEL CANH YEL CANH YEL CANH...
Page 704 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS NOTES: 7-60 – JLG Lift – 3121262...
Page 706 (717) 485-5161(Corporate) (800) 554-5438(Service) (717) 485-6417 JLG Worldwide Locations JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin) 358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi...