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JLG 680S Service And Maintenance Manual

JLG 680S Service And Maintenance Manual

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Service and Maintenance Manual

Model

680S

Prior to SN 0300189341

P/N - 3121234

December 05, 2017

AS/NZS

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Summary of Contents for JLG 680S

Page 1 Service and Maintenance Manual Model 680S Prior to SN 0300189341 P/N - 3121234 December 05, 2017 AS/NZS...
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. FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
Page 4 INTRODUCTION REVISON LOG Original Issue - August 28, 2006 Revised - January 7, 2013 Revised - November 8, 2016 Revised - December 05, 2017 3121234...
Page 5: Table Of Contents
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
Page 6 Do NOT Do the Following When Welding on JLG Equipment....... .
Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.11 Drive Motor (SN 0300183331 through 0300189341) ..........3-61 Description .
Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.23 Generator ..................3-149 Maintenance Schedule .
Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 4 - BOOM & PLATFORM Platform ................... 4-1 Platform Valve Removal (Prior to SN 0300141319) .
Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.12 Rotary Actuator ..................4-50 Theory of Operation .
Page 11 To Connect the JLG Control System Analyzer........
Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Operator Maintenance and Lubrication Diagram ........... . 1-6 1-2.
Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-46. Swashplate & Servo Piston ............... . . 3-64 3-47.
Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-103. EMR 2 Engine Side Equipment ..............3-172 3-104.
Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-1. Cylinder Barrel Support................5-3 5-2.
Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-58. Steer Cylinder (SN 0300142666 through 0300189340) ..........5-27 5-59.
Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4 ........6-28 6-6.
Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-34. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 1 of 10 ..............7-26 7-35.
Page 19 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Specifications and Performance Data .
Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. Machine Personality Settings and Function Speeds ..........6-22 Function Speeds (In Seconds) .
Page 21: Specifications
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 SPECIFICATIONS AND PERFORMANCE DATA Table 1-2. Specifications and Performance Data Table 1-1. Operating Specifications Swing 360° Maximum Work Load (Capacity) Tail Swing 4 ft. 8 in. (1.42 m) Unrestricted: 500 lbs.
Page 22: Component Data
SECTION 1 - SPECIFICATIONS 1.4 COMPONENT DATA Table 1-6. Deutz D2011L04 Specifications (SN 0300129454 to 0300189341) Engine Data Type Liquid Cooled (Oil) Fuel Diesel Table 1-4. Ford LRG-425 Specifications Oil Capacity Type Water-cooled Cooling System 5 Quarts (4.5 L) Fuel Gasoline Crankcase 11 Quarts (10.5 L) w/Filter...
Page 23: Battery
SECTION 1 - SPECIFICATIONS 1.6 TORQUE REQUIREMENTS Table 1-8. GM 3.0L Fuel Gasoline/LP Gas Table 1-11. Torque Requirements No. of Cylinders Description Torque Value (Dry) Interval Hours BHP Gasoline/LP 80 hp @ 3000 rpm Bore 4.0 in. (101.6 mm) Wheel Lugs 300 ft.
Page 24: Lubrication
Specific Gravity 0.922 Pour Point, Max -25°F (-32°C) NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain Flash Point, Min. 428°F (220°C) the same required additives or be of comparable viscosi- Operating Temp.
Page 25: Pressure Setting
SECTION 1 - SPECIFICATIONS 1.8 PRESSURE SETTING Table 1-16. UCon Hydrolube HP-5046 Type Synthetic Biodegradable Table 1-18. Pressure Settings Specific Gravity 1.082 Telescope Out 2500 psi (172 Bar) Pour Point, Max -58°F (-50°C) Swing, Left & Right 1700 psi (117 Bar) Steer 2500 psi (172 Bar) Viscosity...
Page 26 SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance and Lubrication Diagram 3121234...
Page 27: Operator Maintenance
SECTION 1 - SPECIFICATIONS 1.10 OPERATOR MAINTENANCE 2. Wheel Bearings NOTE: The following numbers correspond to those in Figure 1-1., Operator Maintenance and Lubrication Diagram. Table 1-20. 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 28 SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 7. Platform Filter a. Platform Filter (Prior to SN 0300141319) Interval - Change as necessary. Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indi- cator.
Page 29 SECTION 1 - SPECIFICATIONS 8. Suction Strainers 10. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7016331) Capacity - 11 Quarts(10.5 L) Crankcase; Lube - EO Interval - Every Year or 1200 hours of operation...
Page 30: Draining Oil Build Up From The Propane Regulator (Prior To Sn 0300134626)
SECTION 1 - SPECIFICATIONS 13. Fuel Filter - Ford 17. Air Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every Year or 1200 hours of operation. Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 14.
Page 31 SECTION 1 - SPECIFICATIONS 1.11 DRAINING OIL BUILD UP FROM THE PROPANE 6. Remove the retainer clip for the LPG fuel temperature sensor and remove the sensor from the regulator body. REGULATOR (PRIOR TO SN 0300134626) During the course of normal operation oils may build inside the primary and secondary chambers of the pro- pane pressure regulator.
Page 32: Propane Fuel Filter Replacement
SECTION 1 - SPECIFICATIONS 1.12 PROPANE FUEL FILTER REPLACEMENT 1. Electric Lock Off Solenoid 6. Seal 10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13.
Page 33: Propane Fuel System Pressure Relief
SECTION 1 - SPECIFICATIONS 1.13 PROPANE FUEL SYSTEM PRESSURE RELIEF 1.14 SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 machine serial number is stamped on the left side of the frame.
Page 34 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners)- Sheet 1 of 5 1-14 3121234...
Page 35 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners)- Sheet 2 of 5 3121234 1-15...
Page 36 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners)- Sheet 3 of 5 1-16 3121234...
Page 37 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (Metric Fasteners) - Sheet 4 of 5 3121234 1-17...
Page 38 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (Metric Fasteners) - Sheet 5 of 5 1-18 3121234...
Page 39: General
Service Technician as a person who has successfully com- cies corrected, this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG product model. Reference the machine Service and Mainte- Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor- mance of this inspection.
Page 40: Service And Guidelines
Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...
Page 41: Component Disassembly And Reassembly
SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING your work to assure that nothing has been overlooked.
Page 42: Lubrication
SECTION 2 - GENERAL Lubrication Hydraulic Oil Refer to Section 1 for recommendations for viscosity ranges. Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the speci- Changing Hydraulic Oil fied intervals. When recommended lubricants are not avail- able, consult your local supplier for an equivalent that meets Filter elements must be changed after the first 50 hours or exceeds the specifications listed.
Page 43: Cylinder Drift
SECTION 2 - GENERAL CYLINDER DRIFT Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...
Page 44: Pins And Composite Bearing Repair Guidelines
2. Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing.
Page 45 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
Page 46 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Drive Brakes Swing Brakes...
Page 47 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...
Page 48 SECTION 2 - GENERAL 4150548 E Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 3121234...
Page 49 SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 3121234 2-11...
Page 50 SECTION 2 - GENERAL 4150548 E Figure 2-3. Engine Operating Temperature Specifications - Caterpillar 2-12 3121234...
Page 51 SECTION 2 - GENERAL 4150548 E Figure 2-4. Engine Operating Temperature Specifications - GM 3121234 2-13...
Page 52 SECTION 2 - GENERAL NOTES: 2-14 3121234...
Page 53: Chassis & Turntable
The air pressure for pneumatic tires must be equal to the on the same axle should be the same. air pressure that is stenciled on the side of the JLG product Wheel Replacement or rim decal for safe and proper operational characteristics.
Page 54: Lockout Cylinder Bleeding
SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence: 3.2 LOCKOUT CYLINDER BLEEDING ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.
Page 55 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121234...
Page 56 SECTION 3 - CHASSIS & TURNTABLE 0258286 C 0274571 C 0272003 E Figure 3-1. Axle and Steering Installation without Tow Package - Sheet 1 of 2 3121234...
Page 57 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Weldment 9. Pivot Pin 17. Tanged Washer 25. Washer 2. Lockout Cylinder Assembly 10. Washer 18. Bearing Nut 26. Wear Shim 3. Tie Rod 11. Bushing 19. Dust Cap 27. Stud 4. Spindle Weldment 12.
Page 58 SECTION 3 - CHASSIS & TURNTABLE 14 3 13 9 0274572 C 0271352 H Figure 3-3. Axle and Steering Installation with Tow Package- Sheet 1 of 2 3121234...
Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 16. Axle Weldment 31. Hitch Pin 46. Bearing Nut 2. Bolt 17. Tie Rod 32. Connecting link 47. Bolt 3. Bolt 18. Bolt 33. Keeper Shaft 48. Hub Assembly 4. Garmax Bushing 19.
Page 60 SECTION 3 - CHASSIS & TURNTABLE 1. Drive Hub 5. Steer Cylinder 2. Drive Motor 6. Spindle 3. Axle Lockout Cylinder 7. Flow Divider Valve 4. Axle Figure 3-5. Chassis Component Location 3121234...
Page 61 SECTION 3 - CHASSIS & TURNTABLE 1. Swing Drive 6. Hydraulic Oil Tank 10. Piston Pump 2. Rotary Coupling 7. Return Filter Assembly 11. Gear Pump 3. Main Control Valve 8. Fuel Tank 12. Hydraulic Filter 4. Battery 9. Engine 13.
Page 62: Oscillating Axle Lockout Test (If Equipped)
SECTION 3 - CHASSIS & TURNTABLE 3.3 OSCILLATING AXLE LOCKOUT TEST EMERGENCY TOWING (IF EQUIPPED) RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- HIGHWAY TOWING NOT PERMITTED.
Page 63: Wheel Drive Assembly, 2Wd
SECTION 3 - CHASSIS & TURNTABLE 3.5 WHEEL DRIVE ASSEMBLY, 2WD 3. Through the access holes in the axle, tag and disconnect the hydraulic lines running to the drive motor and drive brake. Cap or plug all openings to ensure no dirt enters Removal the hydraulic system.
Page 64: Installation
1. If re-installing the existing studs or installing new ones, the washers and nuts to secure the assembly together coat the threads of the studs with JLG Threadlocker and torque the nuts to 75 ft. lbs. (102 Nm). PN 0100011 before screwing them into the drive hub.
Page 65: Drive Hub (4Wd Machines W/ Integral Brake)
SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE HUB (4WD MACHINES W/ INTEGRAL Tightening and Torquing Bolts BRAKE) If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque.
Page 66: Main Disassembly
SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove Input Sun Gear (17) from Input Carrier Sub- Assembly (3A). NOTE: Refer to Figure 3-9., Main Disassembly - Sheet 1 of 2 and 7. Remove Input Carrier Sub-Assembly (3A) from Housing Figure 3-10., Main Disassembly - Sheet 2 of 2.
Page 67 SECTION 3 - CHASSIS & TURNTABLE 7. Input Shaft 8. Output Sun Gear 17. Input Sun Gear Figure 3-10. Main Disassembly - Sheet 2 of 2 3121234 3-15...
Page 68: Input Carrier Disassembly
SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly 3. Remove the 14 needle Bearings (3C) from the bore of the Planet Gear (3F). NOTE: Refer to Figure 3-11., Input Carrier Disassembly. 4. Repeat steps 1 through 3 for each of the two remaining 1.
Page 69: Output Carrier Disassembly
SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 3. Slide the Planet Gear (4F) and the two Thrust Washers (4B) out of the Carrier (4A). NOTE: Refer to Figure 3-12., Output Carrier Assembly. 4. Remove the 15 needle Bearings (4C) from the bore of the Planet Gear (4F).
Page 70: Housing-Spindle Disassembly
SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Disassembly 5. Remove “A” position Bearing Cone (1D) from Bearing Cup (1D) in Housing (1E). NOTE: Refer to Figure 3-13., Housing-Spindle Disassembly. 6. Lift Housing (1E) off of Spindle (1A). 1. Place unit on bench with Spindle (1A) end down. 7.
Page 71: Spindle-Brake Disassembly
SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Disassembly NOTE: The Pressure Plug (12) requires a special tool for installa- tion. It is not recommended to remove this plug unless it is leaking. The plug is called a Koenig Expander. The installa- NOTE: Refer to Figure 3-14., Spindle Brake Disassembly.
Page 72: Input Carrier Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE 1. Compress the Compression Springs (2-13) by installing a 4. Insert a Planet Shaft (3E) into the planet shaft hole in the minimum of three M4 x 16 mm Socket Head Capscrews end of the Carrier (3A) opposite the splined end. (2-11) equally spaced through End Plate (2-7) and into 5.
Page 73 SECTION 3 - CHASSIS & TURNTABLE 3A. Carrier 3B. Thrust Washers 3C. Needle Bearings 3E. Planet Shaft 3F. Planet Gear Figure 3-15. Input Carrier Sub-Assembly 3121234 3-21...
Page 74: Output Carrier Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE Output Carrier Sub-Assembly 8. Insert a Planet Shaft (4E) into one of the planet shaft holes on the Carrier (4A). The end of the planet shaft that does NOT have the roll pin hole should be inserted NOTE: Refer to Figure 3-16., Output Carrier Sub-Assembly.
Page 75 SECTION 3 - CHASSIS & TURNTABLE 4A. Output Carrier 4B. Thrust Washer 4C. Needle Rollers 4E. Planet Shaft 4F. Planet Gear 4G. Roll Pin 4H. Thrust Washer 4I. Spring 4J. Washer 4K. Retaining Ring Figure 3-16. Output Carrier Sub-Assembly 3121234 3-23...
Page 76: Spindle Brake Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE Spindle Brake Sub-Assembly 11. Grease the small Backup Ring (2-4) and install in the small-diameter groove near the top of the Piston (2-8), on top of the small O-Ring (2-5). NOTE: Refer to Figure 3-17., Spindle Brake Sub-Assembly. NOTE: If piston comes pre-assembled with shipping bolts (2-11), NOTE: This procedure applies only to units with integral input skip to Step 15.
Page 77 SECTION 3 - CHASSIS & TURNTABLE 1-A. Spindle 2-7. End Plate 12. Pressure Plug 2-8. Piston 2-1. Internal Circlip 2-9. Stator 2-2. O-ring 2-10. Spacer 2-3. Backup Ring 2-11. Capscrew 2-4. O-ring 2-12. Rotor 2-5. Backup Ring 2-13. Compression Spring 2-6.
Page 78: Housing-Spindle Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Sub-Assembly DW2B Integral Brake Check 1. Using appropriate fittings, connect hydraulic line from NOTE: Refer to Figure 3-18., Housing-Spindle Assembly. hand pump to brake port. NOTE: Spray a light film of oil on all component parts during 2.
Page 79 SECTION 3 - CHASSIS & TURNTABLE 1B. Seal 1F. Bearing Spacer 1C. Bearing Cups 1G. Retaining Ring 1D. Bearing Cone 1H. Wheel Stud 1E. Housing Figure 3-18. Housing-Spindle Assembly 3121234 3-27...
Page 80: Main Assembly
SECTION 3 - CHASSIS & TURNTABLE Main Assembly 4. With the modified spline end facing up, place the Out- put Sun Gear (8) into mesh with the planet gears from the Output Carrier Sub-Assembly (4A). NOTE: Refer to Figure 3-19., Main Assembly - Sheet 1 of 2 and Fig- ure 3-20., Main Assembly - Sheet 2 of 2.
Page 81 SECTION 3 - CHASSIS & TURNTABLE 6. Cover 9. Input Coupling 10. Thrust Spacer 14. Cover Bolts 19. O-ring Figure 3-20. Main Assembly - Sheet 2 of 2 3121234 3-29...
Page 82 SECTION 3 - CHASSIS & TURNTABLE 3-30 3121234...
Page 83 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Lip Seal 4C. Needle Bearing 7. Input Shaft 1G. Retaining Ring - Ext 3A. Carrier 4I. Spring 9. Coupling 12. Pressure Plug 3F. Planet Gear 4K. Retaining Ring - Int 6. Cover Subassembly 16.
Page 84 SECTION 3 - CHASSIS & TURNTABLE 3-32 3121234...
Page 85 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1D. Tapered Bearing - Cone 4E. Planet Shaft 8. Sun Gear 2. Input Brake 1B. Lip Seal 4C. Needle Bearing 7. Input Shaft 1G. Retaining Ring - Ext 3A. Carrier 4I. Spring 9.
Page 86 SECTION 3 - CHASSIS & TURNTABLE 3-34 3121234...
Page 87 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-35...
Page 88 SECTION 3 - CHASSIS & TURNTABLE 3-36 3121234...
Page 89 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-37...
Page 90 SECTION 3 - CHASSIS & TURNTABLE 3-38 3121234...
Page 91 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-39...
Page 92: Drive Motor - 2Wd (Prior To Sn 0300083331)
SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE MOTOR - 2WD (PRIOR TO SN Rotary group complete 9 pistons, cylinder sub-assembly, valve plate (cw or ccw corresponding to the order) retaining plate 0300083331) and retaining ball. Spare Parts Kits Sealing kit, existing spare parts: shaft sealing ring, 6 different o-rings and a circlip (sealing mat.: perbunan) Swashplate Same sealing kit like shown above only seal material changed...
Page 93: Replacing The Drive Shaft Seal
SECTION 3 - CHASSIS & TURNTABLE Figure 3-31. Drive Motor Cutaway 2. Change the shaft seal and check its sliding surface (drive shaft) and housing. Grease the sealing ring. Replacing the Drive Shaft Seal 1. Remove snap ring. 3121234 3-41...
Page 94: Disassembly
SECTION 3 - CHASSIS & TURNTABLE 3. Be careful while you seal the drive shaft, use an adhesive 6. Assemble the snap ring in the correct position. tape. 4. Assemble the sealing ring, fitting tool holds the correct NOTE: This description shows how to change the drive shaft seal- position of the sealing ring in the pump housing.
Page 95 SECTION 3 - CHASSIS & TURNTABLE 3. Remove the port plate together with the valve plate 6. Remove the adjustment shim. (hold the valve plate so that the plate can’t fall down). 7. Unscrew the cap nut and remove it. 4.
Page 96 SECTION 3 - CHASSIS & TURNTABLE 9. Turn in the stopper max flow to get swivel angle zero. 13. Disassemble the plug. 14. Disassemble the control plate while moving the swash- 10. Disassemble the rotary group in horizontal position. plate. 11.
Page 97 SECTION 3 - CHASSIS & TURNTABLE 16. Disassemble the swashplate. 20. Disassemble the snap ring. 21. Disassemble the sealing ring. 17. Remove the spring. 22. The external front bearing ring is pulled out of the pump 18. Remove both bearing shells. housing.
Page 98: Assembly
SECTION 3 - CHASSIS & TURNTABLE 23. Remove the o-ring. Lifting of the valve plate isn’t shown. Assembly 1. Assemble the variable displacement pump in reverse order. 2. Measurement of the taper roller bearing pretension (see adjustment figure). 24. A usual commercial bearing puller is used to disassem- ble the external bearing ring of the taper roller bearing inside the port plate.
Page 99 SECTION 3 - CHASSIS & TURNTABLE 4. Pumps anti-clockwise driven must have a position of the 5. Assembly of the port plate and pump housing: valve plate 4° decentered in counter-clockwise position. NOTE: The correct position of the drilling that connects high pres- sure to the control valve.
Page 100 SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rota- tion is appr. 3,1 cm Figure 3-33. Flow Control Pilot Valves 3-48 3121234...
Page 101: Testing And Setup
SECTION 3 - CHASSIS & TURNTABLE Testing and Setup Mechanical flow limiter: While screwing in the threaded pin you will be able to reduce the flow from Vg max to 50% of Vg max. DR: When pressure line is closed adjust the pressure of the controller (if it’s DFR design then open the adjustable orifice and increase force of the spring - FR -).
Page 102: Wheel Drive Assembly
1. Use a jack to lift the frame enough so the tire and wheel assembly is off the ground. Place blocking strong 1. Apply a coat of JLG Threadlocker P/N 0100011 on cap- enough to support the weight of the machine under the screws.
Page 103: Drive Hub
SECTION 3 - CHASSIS & TURNTABLE 3.9 DRIVE HUB Cleaning and Inspection Disassembly 1. Thoroughly clean all parts in an approved cleaning sol- vent. 1. Position hub over suitable container and remove drain 2. Inspect bearing cups and cones for damage, pitting, cor- plugs (10) from unit.
Page 104 SECTION 3 - CHASSIS & TURNTABLE j. Place disconnect cap over cover cap with nipple fac- j. Place spacer into opposite side of cluster gear and against needle rollers. ing out and secure with two bolts. Torque bolts to 70-80 in. lbs. (7.9-9 Nm). k.
Page 105: Assembly
SECTION 3 - CHASSIS & TURNTABLE n. Line up cluster gear and thrust washers with hole in e. Install retaining ring into input shaft groove to carrier and slide planet shaft through. Ensure cham- secure spacers and spring to shaft. fered side of hole in planet shaft is lined up with pin hole in carrier.
Page 106 SECTION 3 - CHASSIS & TURNTABLE 3. Press new seal (2) into hub counterbore with flat metal side facing in. Use a flat object to ensure that seal is pressed evenly and is flush with hub face. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. 7.
Page 107 SECTION 3 - CHASSIS & TURNTABLE 10. Install retaining ring (34) into input shaft retaining ring 14. Place o-ring (22) into hub counterbore. Use petroleum groove. or grease to hold o-ring in place. Slight stretching of o-ring may be necessary to insure proper seating. 15.
Page 108 SECTION 3 - CHASSIS & TURNTABLE 17. While holding ring gear, input gear, and cluster gears in 20. Install thrust washers and thrust bearing (39, 40) into mesh, place small side of cluster gears into mesh with carrier counterbore. internal gear. On ring gear, locate hole marked ‘X’ over one of counterbore holes in hub.
Page 109 SECTION 3 - CHASSIS & TURNTABLE 23. Locate four shoulder bolts (42), 90 degrees apart into 25. Place coupling (1) into spindle and onto input shaft. counterbore holes in hub marked in step (13). Torque shoulder bolts to 47 ft. lbs. (64 Nm). 26.
Page 110 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 2. Seal 3. Bearing Cup 4. Bearing Cone 5. Bearing Cup 6. Bearing Cone 7. Hub 8. Spacer 9. Retaining Ring 10. Plug 11. Wheel Bolt 12. Internal Gear 13. Carrier 14. Thrust Washer 15.
Page 111: Drive Brake
SECTION 3 - CHASSIS & TURNTABLE 3.10 DRIVE BRAKE Assembly 1. Lightly lubricate rotary shaft seal (12) and assemble to Disassembly housing (2) taking care not to damage seal lip. 1. Supporting brake: remove the six socket head cap- 2. Apply ring of Loctite 641 or equivalent adhesive to full screws and washers (13 &...
Page 112 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug 2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural) 3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23.
Page 113 SECTION 3 - CHASSIS & TURNTABLE 3.11 DRIVE MOTOR (SN 0300183331 THROUGH Disassembly 0300189341) NOTE: Removal of the end cap voids warranty. Description During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated The drive motors are low to medium power, two-position axial during start-up.
Page 114 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 23. End Cap 24. O-ring Figure 3-41. End Cap 13. Using an 8 mm internal hex wrench, remove the end capscrews (22). 14. Remove the end cap (23). Remove o-ring (24) from the 14.
Page 115 SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring (30) from the housing. 31. Cylinder Kit Assembly Figure 3-43. Cylinder Kit 19. Turn the housing on its side and remove the cylinder kit assembly (31). Set the assembly aside, being careful not to scratch the running surface.
Page 116 SECTION 3 - CHASSIS & TURNTABLE 20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the Lift here support washer (33) and carefully pry out the shaft seal (34). Discard the seal. NOTE: To avoid damaging the shaft during seal removal.
Page 117 SECTION 3 - CHASSIS & TURNTABLE 28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the spring enough to safely remove the spiral retaining ring (51). While maintaining pressure, unwind the spiral retaining ring (51).
Page 118 SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK or scratched blocks. Blocks may be resurfaced to the specifica- tions shown in the drawing, provided resurfacing will not Measure the cylinder block height. Replace blocks worn reduce the block height below the minimum specification. beyond the minimum height specification.
Page 119 SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate 1. Install new o-ring (1) and piston seal (2) to the servo pis- the bearings while feeling for uneven movement. Bearings ton (3). Install the piston seal over the o-ring. should spin smoothly and freely.
Page 120 SECTION 3 - CHASSIS & TURNTABLE 4. Turn the block over and install the retaining ring (8), hold-down pins (9) and ball guide (10) to the cylinder block. RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO 5.
Page 121 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated. ing onto shaft with lettering facing out. Lubricate bear- Install the cylinder kit (19) onto the shaft. Install with the ing rollers.
Page 122 SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the end cap. Install 15. Install the end cap (25) onto the housing with the end the bearing with letters facing out. Press until bearing capscrews (26). Check to ensure the end cap will prop- surface is 0.08 ±0.01 in.
Page 123 SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation Press seal into housing until it bottoms out.
Page 124 SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). Initial Start-up Procedures Follow this procedure when starting-up a new motor or when installing a motor that has been removed. 11/16 in 27 ft.lbs. (37 Nm) UNINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE 5/8 in INJURY TO THE TECHNICIAN OR BYSTANDERS.
Page 125 SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-5. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.
Page 126 SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement INSPECT THE COMPONENTS Inspect the new seal, the motor housing seal bore and the sealing area on the shaft for rust, wear and contamination. Pol- REMOVAL ish the shaft and clean the housing if necessary. 1.
Page 127 SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT THE COMPONENTS Inspect new o-rings and the sealing area for rust, wear, or con- tamination. Also check springs and poppet for wear. REMOVAL 1. Using a 11/16 in. internal hex wrench remove plug (1) INSTALLATION and (2).
Page 128 SECTION 3 - CHASSIS & TURNTABLE 3.12 RE-ALIGNING DRIVE HUB INPUT COUPLING 2. Pressurize the brake release port 155 to 200 psi (10.6 to 13.8 bar) to release the brake. The following procedure applies to drive hubs with integral 3. Verify that the brake is released by rotating the input brakes.
Page 129 6. Place swing drive hub in the clean area. 7. Refer to Section 3.14 and Section 3.18 for swing drive maintenance. 3. Apply JLG Threadlocker P/N 0100019 and torque pivot bolt to 205 ft. lbs. (280 Nm) (shown below). PIVOT BOLT...
Page 130 23-25 ft. lbs. (31- 33 Nm). FILL PLUG 7. Apply JLG Threadlocker P/N 0100019 and torque set- screw 50 ft. lbs. (68 Nm). 8. Apply JLG Threadlocker P/N 0100019 to the jam nut and tighten. DRAIN PLUG 3-78 3121234...
Page 131 SECTION 3 - CHASSIS & TURNTABLE FRAME REF. 0272188 E 1001094899 D 1. Bolt 5. Setscrew 9. Turntable Bearing 13. Snap Pin 2. Bolt 6. Shim 10. Bolt 14. Quick Release Ring 3. Jam Nut 7. Flatwasher 11. Flatwasher 15. Chain 4.
Page 132 SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING HUB (PRIOR TO SN 0300134352) WHEN REBUILDING OR REPAIRING THE UNIT, THE RETAINING RING (1I), O- Disassembly RINGS (5) AND SEAL (1B) SHOULD ALWAYS BE REPLACED. 1. Loosen all 12 cover bolts (12) & (13) and drain the oil Main Assembly Procedure from the unit.
Page 133 SECTION 3 - CHASSIS & TURNTABLE 3. Place o-ring (5) into hub counterbore. Use petroleum 6. With shoulder side of ring gear (4) facing down, place jelly to hold o-ring in place. Also at this time locate and ring gear over (into mesh with) large gears. Be sure that mark the 4 counter beamed holes in the face of the hub punch marks remain in correct location during ring gear (1G).
Page 134 SECTION 3 - CHASSIS & TURNTABLE 8. Input gear (8) is installed, meshing with teeth of the 11. Place o-ring (5) into cover (6) counterbore. Use petro- large diameter cluster gear (3F). The counterbore on the leum jelly to hold o-ring in place. input gear (8) locates on the shoulder of the thrust spacer (9).
Page 135 SECTION 3 - CHASSIS & TURNTABLE 13. Install regular grade 8 bolts (12) into remaining holes. Hub Shaft Sub-Assembly 1. Press bearing cone (1D) onto shaft (1A). 14. Pipe plugs (20) are to be installed into cover (6) using a lubricant of some sort.
Page 136 SECTION 3 - CHASSIS & TURNTABLE 4. Returning the hub (1G) to locate on the large diameter 7. Pipe plugs (1J & 1K) should be checked and/ or installed end, the output shaft (1A) is carefully installed into the at this time in the assembly. hub (1G).
Page 137 SECTION 3 - CHASSIS & TURNTABLE 10. A soft metal punch should be used to ensure that this Carrier Sub-Assembly retaining ring (1I) is completely seated in the groove of the output shaft (1A). 1. Apply a coat of grease or petroleum jelly to cluster gear bore.
Page 138 SECTION 3 - CHASSIS & TURNTABLE 4. Place second set of sixteen needle rollers into cluster 7. Line up cluster gear and thrust washer with hole in car- rier and slide planet shaft through. Line up chamfered gear. side of hole in planet shaft with pin hole in carrier. 5.
Page 139 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-87...
Page 140 SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING BRAKE (PRIOR TO SN 0300134352) Assembly 1. Lightly lubricate rotary shaft seal (12) and assemble to Disassembly housing (2) taking care not to damage seal lip. 1. Supporting brake:, remove the six socket head cap- 2.
Page 141 SECTION 3 - CHASSIS & TURNTABLE 1. Shaft 6. Outer Plate 11. Retaining Ring 16. Backup Ring 21. Plug 2. Housing 7. Gasket 12. Shaft Seal 17. O-ring 22. Spring (Natural) 3. Friction Plate 8. Cylinder 13. Capscrew 18. Backup Ring 23.
Page 142 SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING DRIVE BRAKE NOTE: Be sure to use the same number of springs and the same spring pattern as recorded during disassembly. Disassembly 8. Position plate (12) on spring (13). NOTE: Discs (11 & 12) and return plate (13) must remain dry 1.
Page 143 SECTION 3 - CHASSIS & TURNTABLE Figure 3-64. Swing Brake 3121234 3-91...
Page 144 SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING MOTOR (PRIOR TO SN 0300134352) 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 145 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 16. Seal 2. End Cover 8C. Vane 17. Backup Washer 3. Seal Ring-Commutator 8D. Stator Half 18. Housing 4. Seal Ring 9. Wear Plate 18A. O-Ring 5.
Page 146 SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve com- 7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs. ponents, remove the two previously loosened plugs (21). 8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring.
Page 147 SECTION 3 - CHASSIS & TURNTABLE 9. Remove manifold (7) and inspect for cracks surface scor- NOTE: The rotor set (8) components may become disassembled during service procedures. Marking the surface of the rotor ing, brinelling or spalling. Replace manifold if any of and stator that is facing UP, with etching ink or grease pen- these conditions exist.
Page 148 SECTION 3 - CHASSIS & TURNTABLE NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets 14. Check exposed portion of coupling shaft (12) to be sure of seven vanes (8C & 8E) as shown in the alternate con- you have removed all signs of rust and corrosion which struction TG rotor set assembly view, check the rotor lobe might prevent its withdrawal through the seal and bear-...
Page 149 SECTION 3 - CHASSIS & TURNTABLE NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is 0.020 in.
Page 150 SECTION 3 - CHASSIS & TURNTABLE 21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely.
Page 151 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 152 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 in. (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing man- drel that was used to press in the outer bearing/bushing (19).
Page 153 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™. the coupling shaft bore down, clamping against the mounting flange.
Page 154 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 155 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the original rotor-drive link spline contact.
Page 156 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 from the end cover (2) turn a plug (21), loosely into one end of the valve cavity in the end cover.
Page 157 SECTION 3 - CHASSIS & TURNTABLE NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.
Page 158 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 159 SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING HUB (SN 0300134352 THROUGH Tightening and Torquing Bolts 0300189341) If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened Roll, Leak And Brake Testing beyond their specified torque.
Page 160 SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32). NOTE: Refer to Figure 3-66., Motor Control Valve. 5.
Page 161 SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 4. Remove the Springs (8L) from the piston. 5. Apply less than 50 psi (3.45 bar) air to the “brake port” to NOTE: Refer to Figure 3-67., Motor and Brake. remove Brake Piston (8A).
Page 162 SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly 5. Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Subassembly. NOTE: Refer to Figure 3-68., Main Drive Assembly. 6. Remove Ring Gear (4) from Housing (1G). 7. Remove O-ring (5) from between Ring Gear (4) and 1.
Page 163 SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by the Bearing Cone (1D) during this step. NOTE: Refer to Figure 3-69., Hub-Shaft. 4. Remove the Bearing Cone (1E) from the Housing (1G). 1.
Page 164 SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E). NOTE: Refer to Figure 3-70., Carrier. 3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).
Page 165 SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-70. Carrier. NOTE: Refer to Figure 3-69., Hub-Shaft. 1. Apply a liberal Coat of grease to the bore of Cluster Gear 1. Press Bearing Cup (1C) into Housing (1G) taking care to (3F).
Page 166 SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing. NOTE: Refer to Figure 3-68., Main Drive Assembly. 9.
Page 167 SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-67., Motor and Brake. NOTE: Refer to Figure 3-66., Motor Control Valve. 1. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. 1.
Page 168 SECTION 3 - CHASSIS & TURNTABLE 1001101060 A 1. Housing 1F. Thrust Washer 3B. Tanged Washer 4. Ring Gear 10. Bolt 1A. Output Shaft 1G. Retaining Ring 3C. Needle Bearing 5. O-ring 11. Dowel Pin 1B. Lip Seal 1H. Pipe Plug 3D.
Page 169 SECTION 3 - CHASSIS & TURNTABLE 1001101060 A 8A. Piston 13. Bolt 23. Valve Assembly 32. Ring 40. Thrust Bearing 8B. 0-Ring 14. Lock washer 24. Tube 33. Manifold 41. Inner Seal 8C. Backup Ring 15. Pipe Plug 26. O-ring 34.
Page 170 SECTION 3 - CHASSIS & TURNTABLE 3.19 SWING MOTOR (SN 0300134352 TO 0300189341) Disassembly 1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
Page 171 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8. Rotor Set 12. Coupling Shaft 18A. O-Ring 2. End Cover 8A. Rotor 13. Bearing/Bushing, Inner 19. Bearing/Bushing, Outer 3. Seal Ring-Commutator 8B. Stator or Stator Vane 14. Thrust Washer 20. Dirt & Water Seal 4.
Page 172 SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve com- NOTE: A polished pattern (not scratches) on the cover from rota- ponents, remove the two previously loosened plugs tion of the commutator (5) is normal. Discoloration would (21).
Page 173 SECTION 3 - CHASSIS & TURNTABLE 10. Remove rotor set (8) and wear plate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wear plate.You may have to shift the rotor set on the wear plate to work the drive link out of the rotor (8A) and wear plate.
Page 174 SECTION 3 - CHASSIS & TURNTABLE NOTE: Series TG and TH may have a rotor set with two stator NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets halves (8B & 8D) with a seal ring (4) between them and two of seven vanes (8C &...
Page 175 SECTION 3 - CHASSIS & TURNTABLE 14. Check exposed portion of coupling shaft (12) to be sure NOTE: Minor shaft wear in seal area is permissible. If wear exceeds you have removed all signs of rust and corrosion which 0.020 in. (0.51 mm) diametrically, replace coupling shaft. might prevent its withdrawal through the seal and bear- ing.
Page 176 SECTION 3 - CHASSIS & TURNTABLE 19. Remove seal (16), backup ring (17) and backup washer 21. Inspect housing (18) assembly for cracks, the machined (25) from large frame, housing by working them around surfaces for nicks, burrs, brinelling or corrosion. Remove unseated thrust washers (14) and thrust bearing (15) burrs that can be removed without changing dimen- and out of the housing.
Page 177 SECTION 3 - CHASSIS & TURNTABLE 22. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of the two thrust washers (14) and thrust bearing (15).
Page 178 SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
Page 179 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 in. (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing man- drel that was used to press in the outer bearing/ bush- ing (19).
Page 180 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the ORIGINAL DESIGN LARGE FRAME, TF & TG TORQMOTORS™ THAT DO NOT HAVE mounting flange. BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
Page 181 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- tant grease has been applied to the lower (outer) hous- ing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings.
Page 182 SECTION 3 - CHASSIS & TURNTABLE 10. Install drive link (10) the long splined end down into the 12. Apply a small amount of clean grease to a new seal ring coupling shaft (12) and engage the drive link splines (4) and assemble it into the seal ring groove on the wear into mesh with the coupling shaft splines.
Page 183 SECTION 3 - CHASSIS & TURNTABLE 14. Apply clean grease to a new seal ring (4) and assemble it 16. Apply grease to a new seal ring (4) and insert it in the in the seal ring groove in the rotor set contact side of seal ring groove exposed on the manifold.
Page 184 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).
Page 185 SECTION 3 - CHASSIS & TURNTABLE NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required.
Page 186 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 187 NOTE: This check is designed to replace the existing bearing bolt d. Swing the turntable 90 degrees, and check some torque checks on JLG Lifts in service. This check must be selected bolts at the new position. performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
Page 188 SECTION 3 - CHASSIS & TURNTABLE BOOM FULLY ELEVATED MEASURING POINT Figure 3-75. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 3-136 3121234...
Page 189 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-137...
Page 190 SECTION 3 - CHASSIS & TURNTABLE 3-138 3121234...
Page 191 SECTION 3 - CHASSIS & TURNTABLE Figure 3-79. Swing Bearing Tolerance Measuring Point. Figure 3-78. Swing Bolt Feeler Gauge Check. Swing Bearing Removal Wear Tolerance 1. From Ground Control station, operate the boom ade- quately to provide access to frame opening to rotary coupling.
Page 192 7. Spray a light coat of Safety Solvent 13 on the new bear- Swing Bearing Installation ing bolts. Then apply a light coating of JLG Threadlocker P/N 0100019 to the new bearing bolts, and install the 1. Using suitable lifting equipment, carefully lower the bolts and washers through the turntable and inner race swing bearing into position on the frame.
Page 193 SECTION 3 - CHASSIS & TURNTABLE 3.21 ROTARY COUPLING (PRIOR TO SN 0300137913) Table 3-8. Coupling Port Information Table (Prior to SN 0300137913) Use the following procedure to install the seal kit. Operating Proof Port Port 1. If not already removed, remove the axle oscillation valve Description Pressure Pressure...
Page 194 SECTION 3 - CHASSIS & TURNTABLE DETAIL A 1. Rotary Coupling 5. Bolt 2. Torque Lug 6. Nut 3. Locknut 7. Bracket 4. Flatwasher Figure 3-80. Rotary Coupling (Prior to SN 0300137913) - Sheet 1 of 2 3-142 3121234...
Page 195 SECTION 3 - CHASSIS & TURNTABLE 1. O-ring 6. Spring 11. Housing 16. Bearing 2. Plug 7. Valve Block Plunger 12. Retaining Ring 17. Cap Seal 3. Check Valve 8. Valve Block 13. Ring 18. O-ring 4. Screw 9. O-ring 14.
Page 196 SECTION 3 - CHASSIS & TURNTABLE 1660303 B Figure 3-82. Rotary Coupling Port Location (Prior to SN 0300137913) 3-144 3121234...
Page 197 SECTION 3 - CHASSIS & TURNTABLE 3.22 ROTARY COUPLING (SN 0300137913 6. Remove proximity switch. 7. Assemble lip seals (2) in direction shown in Figure 3-83., THROUGH 0300189341) Rotary Coupling Seal Installation (SN 0300137913 Use the following procedure to install the seal kit. through 0300189341).
Page 198 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 6. Thrust Ring 2. Seal 7. Snap Ring 3. Housing 8. Valve Block (Axle Oscillation) 4. O-ring 9. O-ring 5. Seal 10. Proximity Switch Figure 3-84. Rotary Coupling Cutaway (SN 0300137913 through 0300189341) 3-146 3121234...
Page 199 SECTION 3 - CHASSIS & TURNTABLE 1001106974 B Figure 3-85. Rotary Coupling Port Location (SN 0300137913 through 0300189341) 3121234 3-147...
Page 200 SECTION 3 - CHASSIS & TURNTABLE COMPLETE VALVE BLOCK ASSEMBLY 1001107531 A 1. Housing 7. Bracket 13. Cap Seal 18. Capscrew 23. Check Valve 28. Washer 2. Body 8. Locknut 14. Thrust Ring 19. O-ring 24. Plunger Valve 29. Locknut 3.
Page 201 SECTION 3 - CHASSIS & TURNTABLE EVERY 500 HOURS Table 3-9. Coupling Port Information Table (SN 0300137913 Every 500 hours of operation, service the generator brushes through 0300189341) and slip rings. Hostile environments may require more fre- Operating Proof quent service. Port Port Size Description...
Page 202 SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings Refer to Figure 3-87., Inspecting Generator Brushes, Replacing STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings. BREAKER. INSPECTING BRUSH POSITION The circuit breaker protects the generator windings from over- Inspect brush alignment with slip rings.
Page 203 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 204: Assembly
SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly 2. Remove brush holder assembly. 3. Disassemble generator parts shown in Figure 3-88. Refer to Figure 3-89. and Figure 3-90. to determine if trouble is in stator, rotor, control box, or combination of these compo- 4.
Page 205 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121234 3-153...
Page 206 SECTION 3 - CHASSIS & TURNTABLE Figure 3-89. Generator Troubleshooting Circuit Diagram - Sheet 1 of 2 3-154 3121234...
Page 207 SECTION 3 - CHASSIS & TURNTABLE Figure 3-90. Generator Troubleshooting Circuit Diagram - Sheet 2 of 2 3121234 3-155...
Page 208 SECTION 3 - CHASSIS & TURNTABLE 3-156 3121234...
Page 209 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-157...
Page 210 SECTION 3 - CHASSIS & TURNTABLE Figure 3-93. Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2 3-158 3121234...
Page 211 SECTION 3 - CHASSIS & TURNTABLE Figure 3-94. Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2 3121234 3-159...
Page 212 SECTION 3 - CHASSIS & TURNTABLE Lead Connection List for Generator NOTE: Apply small amount of dielectric grade, nonconductive electric grease to connectors where factory-applied grease NOTE: Table shows physical lead connections and should be used had been present. with circuit diagram (table replaces wiring diagram). Table 3-10.
Page 213 SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-11. Troubleshooting Trouble Remedy No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform. Check and secure electrical connections at platform, generator, and control box. Be sure all equipment is turned off when starting unit.
Page 214 SECTION 3 - CHASSIS & TURNTABLE 1001109065 D 1. Engine Assembly 8. ECM Module 15. Adaptor 22. Exhaust Tube Weldment 2. Alternator 9. Radiator Hose (Bottom) 16. Coupling 23. Exhaust Tube 3. Fan 10. Radiator 17. Flywheel 24. Piston Pump 4.
Page 215 SECTION 3 - CHASSIS & TURNTABLE RETURN VENT SUPPLY TANK REF. 1001109065 D 29. Tray 32. Flex Trim 35. Fuel Pump 30. Battery Hold-down 33. Pivot Pin 36. Exhaust Tube Weldment 31. Battery 34. Relay 37. Hitch Pin Figure 3-96. Caterpillar Tier IVi Engine Assembly - Sheet 2 of 2 3121234 3-163...
Page 216 SECTION 3 - CHASSIS & TURNTABLE 0274302 G 1001099829 E 1. Engine Assembly 8. Muffler 14. Glow Plug 20. Engine Mount Plate (Rear) 2. Fan 9. Engine Mount Plate (Front Left) 15. Injector Pump 21. Sensing Pump Assembly 3. Radiator 10.
Page 217 SECTION 3 - CHASSIS & TURNTABLE 0274302 G 1001099829 E 26. Tray 30. Hitch Pin 34. Fuel Pump 38. Thermostat 27. EMR2 Controller Module 31. Pivot Pin 35. Relay 39. Fuel In-line Filter 28. Battery 32. Relay 36. Fuel Filter 40.
Page 218 SECTION 3 - CHASSIS & TURNTABLE 1001114634 F 1. Engine Assembly 8. Intake Tube 14. Piston Pump Assembly 20. Engine Mount Plate 2. Radiator 9. Oil Drain Valve 15. Load Sensing Pump Assembly 21. Engine Mount (Front) 3. Fan 10. Muffler 16.
Page 219 SECTION 3 - CHASSIS & TURNTABLE RETURN ON FUEL TANK TO LP FUEL SHUT-OFF TO ENGINE 1001114634 F 26.Fuel Filter Figure 3-100. GM Engine 3.0L Tier III/IV Installation - Sheet 2 of 2 3121234 3-167...
Page 220 Power/Emergency Stop switch has been pulled on. The lamp and glow plugs will remain ener- gized for the period of time specified by the setting in the JLG Control System. Engine start shall be disabled during this period.
Page 221 SECTION 3 - CHASSIS & TURNTABLE Replacing Engine Oil 5. Open the oil drain valve. 6. Drain the oil. 1. Allow the engine to warm up. The engine oil should reach approximately 176° F (80° C). 7. Close the oil drain valve. 2.
Page 222 SECTION 3 - CHASSIS & TURNTABLE Replacing the Oil Filter 3. Catch any escaping oil. 4. Clean any dirt from filter carrier sealing surface. 5. Lightly coat new oil filter rubber gasket with clean oil. 1. Wipe the area around the filter to clean any dirt from the area.
Page 223 Replacing the Fuel Filter 3.25 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 224 SECTION 3 - CHASSIS & TURNTABLE Figure 3-103. EMR 2 Engine Side Equipment 3-172 3121234...
Page 225 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-173...
Page 226 SECTION 3 - CHASSIS & TURNTABLE 3-174 3121234...
Page 227 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-175...
Page 228 SECTION 3 - CHASSIS & TURNTABLE 3-176 3121234...
Page 229 SECTION 3 - CHASSIS & TURNTABLE Figure 3-108. EMR 2 Engine Plug Pin Identification 3121234 3-177...
Page 230 SECTION 3 - CHASSIS & TURNTABLE Figure 3-109. EMR 2 Vehicle Plug Pin Identification 3-178 3121234...
Page 231 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-179...
Page 232 SECTION 3 - CHASSIS & TURNTABLE 3-180 3121234...
Page 233 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-181...
Page 234 SECTION 3 - CHASSIS & TURNTABLE 3-182 3121234...
Page 235 SECTION 3 - CHASSIS & TURNTABLE 3121234 3-183...
Page 236 SECTION 3 - CHASSIS & TURNTABLE 3.26 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for hardening, cracking, chafing, separation, split boot covers proper fit Maintenance of the Drive Belt • Replace spark plugs at the proper intervals as prescribed in The serpentine drive belt utilizes a spring loaded tensioner the engine manufacturer’s manual which keeps the belt properly adjusted.
Page 237 SECTION 3 - CHASSIS & TURNTABLE 6. If the oil level is below the "ADD" mark, proceed to Step Coolant Fill Procedure - Dual Fuel Engine 7 and 8 and reinstall the dipstick into the dipstick tube. 7. Remove the oil filter cap from the valve rocker arm cover.
Page 238 3. With the radiator cap still removed, start the engine and run until the thermostat opens. The thermostat opens at 170° F (77° C), which can be checked using the JLG handheld analyzer. WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRESENT COMING FROM THE RADIATOR.
Page 239 SECTION 3 - CHASSIS & TURNTABLE 3.27 GM ENGINE DUAL FUEL SYSTEM Electric Lock Off The Dual Fuel system allows the operator to operate the vehi- The Electric Lock Off device is an integrated assembly. When cle on either gasoline or LPG by positioning a selector switch energized the solenoid opens the valve and allows the Pro- in the operator's platform.
Page 240 SECTION 3 - CHASSIS & TURNTABLE Low Pressure Regulator (LPR) Air Fuel Mixer The LPR is a combination vaporizer, pressure regulating The air valve mixer is an air-fuel metering device and is com- device. The LPR is a negative pressure, two stage regulator that pletely self-contained.
Page 241 SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control (ETC) Engine Control Module Engine speed and load control is maintained by an ETC device. To obtain maximum effect from the catalyst and accurate con- Speed and load control are determined by the ECM. Defaults trol of the air fuel ratio the emission certified engine is programmed into the ECM software and throttle position sen- equipped with an onboard computer or Engine Control Unit...
Page 242 SECTION 3 - CHASSIS & TURNTABLE Heated Exhaust Gas Oxygen Sensor Gasoline Fuel Pump There are two Heated Exhaust Gas Oxygen Sensors (HEGO). The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by an electric fuel pump. The fuel pump The first HEGO is mounted in the exhaust system downstream will receive a signal from the ECM to prime the fuel system for of the engine.
Page 243 SECTION 3 - CHASSIS & TURNTABLE Fuel Filter 3.28 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel System Pressure Relief After the fuel is drawn into the fuel pump, the fuel flows through the gasoline fuel filter. The fuel filter will trap small particles as the fuel passes through the filter to remove debris and prevents the fuel pressure and temperature manifold and THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5...
Page 244 SECTION 3 - CHASSIS & TURNTABLE Propane Fuel Filter Replacement 1. Electric Lock Off Solenoid 6. Seal 10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9.
Page 245 SECTION 3 - CHASSIS & TURNTABLE Electronic Pressure Regulator (EPR) Assembly 10. Disconnect the EPR electrical connector Replacement 11. Remove the (3) three nuts from the EPR isolators and the EPR mounting bracket 12. Remove the EPR from the bracket 13.
Page 246 SECTION 3 - CHASSIS & TURNTABLE 10. Start the vehicle and leak check the propane fuel system Temperature Manifold Absolute Pressure (TMAP) at each serviced fitting Refer to Propane Fuel System Sensor Leak Test. Figure 3-127. Pressure Regulator Section PRESSURE REGULATOR SECTION REMOVAL Figure 3-128.
Page 247 SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control Replacement 2. Install the two quad seals. Install one seal at a time to insure the seal does not roll. The seal must sit flat on the throttle body. See Figure 3-128. REMOVAL 1.
Page 248 3. Remove the hose from each of the fittings. INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1. Install the hose clamps to each hose and set the clamp back on each hose to make installation easier.
Page 249 SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL REMOVAL 1. Disconnect Negative battery cable. 1. Disconnect Negative battery cable. 2. Remove controller from mounting bracket. 2. Disconnect the O2 sensor electrical connector. 3.
Page 250 SECTION 3 - CHASSIS & TURNTABLE 3.29 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on Fuel System Description LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks.
Page 251 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION VALUE(S) Were you referred to this procedure by a DTC diagnostic chart? Go to Step 3 Go to Step 2 Perform the On Board Diagnostic (OBD) System Check. Go to the Go to Step 3 Are any DTCs present in the ECM?
Page 252 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. LPF Fuel System Diagnosis STEP ACTION VALUE(S) 1. Turn the ignition OFF. Go to Step 23 Go to Step 17 2. Close the manual shut-off valve on the LPG tank. CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Perform this step in a well ventilated area.
Page 253 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2.
Page 254 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp The following components can cause intermittent MIL and no DTC(s): (MIL) A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
Page 255 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Exhaust System Checks Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter.
Page 256 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Additional Checks Cuts Out, Misses DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spit- ting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Page 257 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a prob- lem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. Check for the proper ignition voltage output with J 26792 or the equivalent.
Page 258 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Fuel System Checks Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. Check for proper installation of the mixer module assembly.
Page 259 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Additional Check Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual. Check for dragging brakes. Rough, Unstable, or Incorrect Idle, Stalling DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
Page 260 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Symptom Diagnosis Checks Action Fuel System Checks Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. Check the fuel pressure while the condition exists.
Page 261 SECTION 3 - CHASSIS & TURNTABLE Table 3-14. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code Crank Never Synced at Start Fuel Pump Low Voltage Fuel Pump High Voltage MAP Low Voltage MAP High Pressure IAT Higher Than Expected 1 IAT Low Voltage IAT High Voltage ECT Higher Than Expected 1...
Page 262 SECTION 3 - CHASSIS & TURNTABLE Table 3-14. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code System Voltage Low System Voltage High Flash Checksum Invalid RAM Failure COP Failure External 5V Reference Low 1079 External 5V Reference High 1079 Power Relay Open 1485...
Page 263 B, C B, C B, C B, C A. Counterweight Casting B. Apply JLG Threadlocker P/N 0100019 to Bolt Threads and to Threads in Counterweight. C. Torque to 285 ft. lbs. (386 Nm). Typical Four Places. Figure 3-131. Counterweight 3121234 3-211...
Page 264 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-212 3121234...
Page 265 SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM 3. Remove hardware securing the platform control valve to the mounting bracket. Remove platform control valve. Platform Valve Removal (Prior to SN 0300141319) 1. Remove hardware securing cover to the platform sup- port.
Page 266 SECTION 4 - BOOM & PLATFORM Platform Valve Installation (Prior to SN 3. Install cover onto the platform support and secure with mounting hardware. 0300141319) 1. Install platform control valve onto the mounting bracket and secure using hardware. 4. Remove tag and reconnect the hydraulic lines to the 2.
Page 267 SECTION 4 - BOOM & PLATFORM Platform Valve Removal (SN 0300141319 through 4. Remove hardware securing cover to the platform sup- port. Remove cover. 0300189341) 1. Tag and disconnect the hydraulic lines from the plat- form control valve. Use suitable container to retain any residual hydraulic fluid.
Page 268 SECTION 4 - BOOM & PLATFORM 6. Remove hardware securing the platform control valve to Platform Valve Installation (SN 0300141319 the mounting bracket. Remove platform control valve. through 0300189341) 1. Install platform control valve onto the mounting bracket and secure using hardware. 2.
Page 269 SECTION 4 - BOOM & PLATFORM 3. Install cover onto the platform support and secure with 5. Install high pressure filter onto filter mounting bracket mounting hardware. and secure with mounting hardware. 6. Remove tag and reconnect the hydraulic lines to the platform control valve.
Page 270 SECTION 4 - BOOM & PLATFORM Support Removal 3. Using a suitable device, support the platform support. NOTE: The platform support weighs approximately 135 lbs. CENTRE BOLT (61 kg). BOLTS 4. Remove the bolts and locknuts securing the support to ROTATOR the rotator.
Page 271 2. Install the rotator center bolt. 6. Connect the electrical cables to the platform control console. 3. Apply JLG Threadlocker P/N 0100011 to the eight bolts and locknuts securing the support to the rotator and install the bolts and locknuts.
Page 272 C, D Torque to 40 ft. lbs. (55 Nm) JLG Threadlocker P/N 0100011 Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 75 ft. lbs. (102 Nm) Figure 4-2.
Page 273 SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR AND SLAVE CYLINDER 6. Tag and disconnect hydraulic lines to the slave cylinder. Use a suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports. Remove the slave Removal cylinder.
Page 274 SECTION 4 - BOOM & PLATFORM 4.3 MAIN BOOM POWERTRACK 8. With powertrack supported and using all applicable safety precautions, remove bolts #3, #4 and #5 securing rail to the base boom section. Remove powertrack from Removal boom section. 1. Disconnect wiring harness connectors located in tower Installation upright.
Page 275 SECTION 4 - BOOM & PLATFORM 3121234 4-11...
Page 276 SECTION 4 - BOOM & PLATFORM HOSES AND CABLES SHOULD NOT BE HOSES AND CABLES SHOULD BE AGAINST PULLED TIGHT AGAINST THE INSIDE THE OUTSIDE RADIUS OF THE POWER RADIUS OF THE POWER TRACK TRACK 0271990 E Figure 4-6. Powertrack Installation Main Boom - Sheet 2 of 2 4-12 3121234...
Page 277 SECTION 4 - BOOM & PLATFORM 4.4 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 278 SECTION 4 - BOOM & PLATFORM 5. Slide the poly roller off of the round bar. 7. Slide the flat bar out. 8. Remove the snap ring from one side of the bracket. 6. Hold the round bar to remove the other screw. 9.
Page 279 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 280 SECTION 4 - BOOM & PLATFORM 4. Hold the flat bar and remove the screws. 6. Remove the screws from the bar. Remove the snap ring and pin. 5. Remove the snap rings and pins. 7. Slide the link out. 4-16 3121234...
Page 281 SECTION 4 - BOOM & PLATFORM Snap Rings and Screws A snap ring that is not seated is shown below. WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO DISCARD AND REPLACE ALL OLD SCREWS. Make sure screws are tight and installed properly. A seated and closed snap ring is shown below.
Page 282 1. Using suitable lifting equipment, adequately support 1. JLG recommends the use of the JLG Hostile Environment boom assembly weight along entire length. Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom.
Page 283 SECTION 4 - BOOM & PLATFORM 6. Remove hardware securing timing link to boom assem- Disassembly bly. Remove pin from boom assembly. NOTE: The following procedure assumes the boom is removed from the machine. 1. Extend the boom approximately 2 ft. (0.6 m). This will enable access to the bolts that secure the cable mount block to the boom fly section.
Page 284 SECTION 4 - BOOM & PLATFORM 4. Clamp both threaded ends of wire rope to prevent rota- 7. Remove the four bolts, shims, and attachment blocks tion. Remove jam nuts and nuts which secure the wire that secure the telescope cylinder barrel to the boom rope adjustments to the bottom front of the base boom mid section.
Page 285 SECTION 4 - BOOM & PLATFORM This page left blank intentionally. 3121234 4-21...
Page 286 SECTION 4 - BOOM & PLATFORM Figure 4-7. Boom Assembly Cutaway - Sheet 1 of 2 4-22 3121234...
Page 287 SECTION 4 - BOOM & PLATFORM 1. Base Boom 9. Retract Cable 2. Mid Boom 10. Extend Cable Adjustment 3. Fly Boom 11. Retract Cable Adjustment 4. Telescope Cylinder 12. Proximity Switch 5. Extend Sheave 13. Wear Pad 6. Retract Sheave 14.
Page 288 SECTION 4 - BOOM & PLATFORM 0275554 I 1001155753 H 1. Pivot Pin 6. Upright 2. Timing Link 7. Lift Cylinder Pivot Pin 3. Tower Weldment 8. Tower Pin 4. Tension Link 9. Level Link Pin 5. Boom Pivot Pin Figure 4-9.
Page 289 SECTION 4 - BOOM & PLATFORM DETAIL A DETAIL B DETAIL C SEE DETAIL B SEE DETAIL A SEE DETAIL C 0275554 I 1001155753 H 1. Pivot Pin 5. Level Cylinder 2. Tension Link Pivot Pin 6. Level Cylinder Pivot Pin 3.
Page 290 SECTION 4 - BOOM & PLATFORM 9. Carefully remove the telescope cylinder and sheave 13. Remove hardware which secures the wear pads to the assembly. Place telescope cylinder on a suitable trestle. front of mid boom section; remove wear pads from the top, sides and bottom of the mid boom section.
Page 291 SECTION 4 - BOOM & PLATFORM Inspection 8. Inspect inner diameter of boom pivot bushing for scor- ing, distortion, wear, or other damage. Replace bearing as necessary. NOTE: When inspecting pins and bearings Refer to the guidelines established in Section 2 - General. 9.
Page 292 SECTION 4 - BOOM & PLATFORM NOTE: To avoid damaging the proximity switch, install and adjust the switch AFTER assembling the switch block and compression spring, and after torquing the wire ropes. To adjust the proximity switch, thread the switch all the way in and back out 1/8 to 1/2 a turn.
Page 293 SECTION 4 - BOOM & PLATFORM 4. Install retract wire ropes into rear end of fly section, 9. Properly position the retraction wire rope sheaves route wire ropes through holes in side of fly boom sec- assemblies at the rear end of the mid boom section; tion and pull into slot.
Page 294 SECTION 4 - BOOM & PLATFORM NOTE: The telescope cylinder weighs approximately 496 lbs. 21. Apply JLG Threadlocker P/N 0100011 to the bolts and (225 kg). fasten the telescope cylinder rod to the boom base sec- tion with the bolts, shims, mounting blocks.
Page 295 SECTION 4 - BOOM & PLATFORM Installation 5. Using suitable lifting device, align main lift cylinder rod end with mounting holes on boom assembly. 1. Using a suitable lifting device, position boom assembly 6. Extend the main lift cylinder by using the auxiliary on upright so that the pivot holes in both boom and power switch.
Page 296 SECTION 4 - BOOM & PLATFORM Telescope Cylinder/Boom Cable Removal 7. Remove the four bolts, shims, and attachment blocks that secure the telescope cylinder barrel to the boom 1. Make sure the machine is on a firm, level surface. mid section. 2.
Page 297 SECTION 4 - BOOM & PLATFORM 9. Push the boom fly sections back in to gain access to the 12. Twist the ends of the retraction cables to remove the boom retraction cable. ends of the cables from the slots in the side of the boom fly section.
Page 298 5. Pull the boom sections out to approximately where they 10. Apply JLG Threadlocker P/N 0100011 to the bolts and were extended to for telescope cylinder removal. fasten the telescope cylinder barrel to the boom mid section with the bolts, shims, mounting blocks.
Page 299 SECTION 4 - BOOM & PLATFORM 12. Using a 3/8 drive extension approximately 4 ft. (1.2 m) 4.7 MAIN LIFT CYLINDER long, install the bolts and washers securing the cable mount block to the boom fly section. Tape the bolts to Removal the socket at the end of the extension to prevent it from coming out of the socket before it engages the mount-...
Page 300 SECTION 4 - BOOM & PLATFORM 5. Remove the hardware securing the rod end pivot pin Installation and remove the pivot pin. 1. Using an adequate lifting device, position the lift cylin- der in the machine in the same manner that it was removed.
Page 301 SECTION 4 - BOOM & PLATFORM 5. Connect the hydraulic lines to the cylinder as tagged 6. Inspect sheaves with a groove wearout gauge for exces- during removal. sive wear. 6. Remove the supporting device and function check the boom to make sure the lift cylinder operates properly and there are no leaks.
Page 302 SECTION 4 - BOOM & PLATFORM 4.9 BOOM ROPE TORQUING PROCEDURES 4. Torque retract adjusting nuts (platform end) to 15 ft. lbs. (20 Nm) alternating between the two wire ropes and 1. Position boom in fully down and fully retracted position. keeping approximately the same amount of thread beyond the adjusting nut.
Page 303 SECTION 4 - BOOM & PLATFORM 4.10 ELEVATION & CAPACITY SWITCHES 3121234 4-39...
Page 304 SECTION 4 - BOOM & PLATFORM BOOM CAPACITY ANGLE SWITCH (ANSI Only) BOOM ELEVATION SWITCH BOOM CAPACITY LENGTH SWITCH (ANSI Only) BOOM TRANSPORT LENGTH SWITCH 0271360 K Figure 4-18. Elevation, Dual Capacity and Transport Switch Information (Prior to SN 0300103969) - Sheet 2 of 2 4-40 3121234...
Page 305 SECTION 4 - BOOM & PLATFORM 3121234 4-41...
Page 306 SECTION 4 - BOOM & PLATFORM ROUTE LIMIT SWITCH CABLE THROUGH CLAMPS DETAIL A BOOM TRANSPORT LENGTH SWITCH BOOM ELEVATION SWITCH DETAIL B 1001091187 E Figure 4-20. Elevation, Dual Capacity and Transport Switch Information (SN 0300103969 through 0300189341) - Sheet 2 of 2 4-42 3121234...
Page 307 SECTION 4 - BOOM & PLATFORM 4.11 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR INTERACTION Two tilt sensors, mounted on each side of the platform support, Description are used to measure the incline of the platform with respect to gravity and control the automatic platform angle control func- Electronic platform leveling replaces the conventional hydraulic tion.
Page 308 SECTION 4 - BOOM & PLATFORM SWITCH #1 HARNESS FROM PLATFORM CONTROL BOX SWITCH #2 TYPICAL SENSOR INSTALLATION, COVER SHOWN IN PHANTOM FOR CALRITY 0273695 D SWITCH #1 SWITCH #2 PIN# DESCRIPTION SWITCH HARNESS PIN# DESCRIPTION SWITCH HARNESS PIN #1 POWER PIN #1 POWER...
Page 309 SECTION 4 - BOOM & PLATFORM PLATFORM VALVES In order to provide a better system response, the controls also compute the rate of angular change of the platform position and The platform specific valves are located in a manifold at the plat- set the leveling valve positions to achieve a matching velocity.
Page 310 The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been The JLG Control System takes a snapshot of the two sensor val- lost). ues and records the difference once on each power up. The Con- c.
Page 311 Replacing the Level Sensors Earlier generations of this machine had three different genera- tions of level sensors that were used on this machine. JLG P/N 4360503, P/N 4360528, and P/N 4360544. P/N 4360528 and 4360544 supersede P/N 4360503. If one of the 4360503 sensors fail, BOTH sensors must be replaced with two P/N 4360544 sen- sors.
Page 312 4. Enter “33271” to get into Access Level 1 mode. 5. Go to the “Personalities” menu and adjust the following personalities. Refer to the Personality Ranges/Defaults table in Section 6 - JLG Control System for proper setting values. Basket Level Up Min...
Page 313 SECTION 4 - BOOM & PLATFORM STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN 21. The preceding steps will provide acceptable crackpoint VALVE CRACKPOINTS settings for the majority of machines. However, if the operator can feel small jolts in the platform from the NOTE: Since the valve position which allows minimum oil flow valve opening during a leveling operation, the crack- (crackpoint) is dependent on the oil pressure, verify the...
Page 314 SECTION 4 - BOOM & PLATFORM 4.12 ROTARY ACTUATOR The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the upper and lower thrust washers. The end cap Theory of Operation is adjusted for axial clearance and locked in position by set screws or pins.
Page 315 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 302. Wear Guide 2. Shaft 202. T-Seal 304. Thrust Washer 3. Piston Sleeve 204. O-ring 304.1. Wiper Seal 4. End Cap 205. Cup Seal 400. Counterbalance Valve 109. Lock Pin 207.
Page 316 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 317 SECTION 4 - BOOM & PLATFORM Tools Required for Assembly/Disassembly Making a Seal Tool The seal tool is merely a customized standard flat head screw- Upon assembly and disassembly of the actuator there are basic driver. tools required. The tools and their intended functions are as fol- lows: TO AVOID INJURY BE CAREFUL WHILE HANDLING THE HOT SCREWDRIVER.
Page 318 SECTION 4 - BOOM & PLATFORM Disassembly 4. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 5/1 6 in. drill bit to a depth of 1/2 in. (12.7 mm) to drill out the entire pin.
Page 319 SECTION 4 - BOOM & PLATFORM 7. Remove the end cap (4) and set aside for later 9. Every actuator has timing marks for proper engage- inspection. ment. 8. Remove the stop tube (400) if equipped with one. The stop tube is an available option to limit the rotation of the actuator.
Page 320 SECTION 4 - BOOM & PLATFORM 11. Remove the shaft (2). It may be necessary to strike the 14. At the point when the piston gear teeth come out of threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis- ton and housing with a marker as shown.
Page 321 SECTION 4 - BOOM & PLATFORM 17. To remove the main pressure seals (205), it is easiest to 20. Remove the piston O.D. seal (202) from the piston. cut them using a sharp razor blade being careful not to damage the seal groove. 21.
Page 322 SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123 in. or 3.12 mm). SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED. 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting.
Page 323 SECTION 4 - BOOM & PLATFORM 2. Coat the thrust washers (304) with a generous amount 4. Using a seal tool install the main pressure seal (205) onto of Lithium grease. Install the thrust washer (304) onto shaft (2) and end cap (4). Use the seal tool in a circular shaft (2) and end cap (4).
Page 324 SECTION 4 - BOOM & PLATFORM 6. Install the o-ring (204) and backup ring (207) into the Beginning with the inner seal (200) insert one end of inner seal groove on the end cap (4). backup ring in the lower groove and feed the rest in using a circular motion.
Page 325 SECTION 4 - BOOM & PLATFORM 9. Looking from the angle shown, rotate the piston (3) until 11. Install the shaft (2) into the piston (3). Be careful not to the marks put on the piston and the housing (1) during damage the seals.
Page 326 SECTION 4 - BOOM & PLATFORM 13. Install two bolts in the threaded holes in the flange. 15. Coat the threads on the end of the shaft with anti-seize Using a bar, rotate the shaft in a clockwise direction until grease to prevent galling.
Page 327 SECTION 4 - BOOM & PLATFORM 17. Tighten the end cap (4). In most cases the original holes 19. Insert the set screws (113) over the lock pins. Tighten for the lock pins will line up. them to 25 in. lbs. (2.8 Nm). 18.
Page 328 Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. JLG Threadlocker P/N 0100011 should be applied to the Refer to Figure 4-24., Rotator Counterbalance Valve.
Page 329 SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on a 5. After the actuator is assembled but before it is put into hydraulic test bench. The breakaway pressure — the pressure at service, the thrust washer area must be packed with which the shaft begins to rotate —...
Page 330 SECTION 4 - BOOM & PLATFORM Installation and Bleeding 2. With an operator in the platform, open both bleed nip- ples 1/4 turn. Hydraulically rotate the platform to the After installation of the actuator on the equipment, it is import- end of rotation (either clockwise or counterclockwise), ant that all safety devices such as tie rods or safety cables are and maintain hydraulic pressure.
Page 331 SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Solution Problem Cause 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 332 6. Select Access Level from Main Menu. Calibrating the Load Sensor 7. Enter 33271. NOTE: Refer to Section 6 - JLG Control System. 8. Select Machine Set-Up>Load Cell>1 Warn Only. 9. Select Machine Diagnostics>System Load Cell on the 1. Place the boom in the following position.
Page 333 SECTION 4 - BOOM & PLATFORM Figure 4-25. Load Sensing Device 3121234 4-69...
Page 334 SECTION 4 - BOOM & PLATFORM 4.14 SKYGUARD IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE & “BOTH” IS SELECTED. In Platform Mode: Operation NOTE: Machine will treat Soft Touch/SkyGuard override switch as Skyguard is used to provide enhanced control panel protection. if it is a Soft Touch and SkyGuard switch.
Page 335 SECTION 4 - BOOM & PLATFORM Diagnostic & Troubleshooting 2. If machine operation is not available: Help menu or diagnostics menu is to be used to collect If you are experiencing a problem that is not described here, see the fault information. your authorized dealer for service.
Page 336 SECTION 4 - BOOM & PLATFORM NOTES: 4-72 3121234...
Page 337 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULICS INFORMATION & 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 338 SECTION 5 - BASIC HYDRAULICS INFORMATION & 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 339 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.2 HYDRAULIC CYLINDERS 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews Axle Lockout Cylinder from cylinder barrel.
Page 340 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 10** 10** 10** 21*** * Torque to 30-35 ft. lbs. (41-47 Nm) ** Torque to 12-15 ft. lbs. (16-20 Nm) *** Torque to 9 ft. lbs. (12 Nm) ****Torque to 55 ft. lbs. (75 Nm) 1683078 N 1.
Page 341 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
Page 342 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 343 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 8. Insert the tapered bushing into piston cable cylinder head gland groove. Install a new wear 9. Assemble the tapered bushing loosely into the piston ring into the applicable cylinder head gland groove.
Page 344 Figure 5-14. Rod Assembly Installation 15. Position the cylinder barrel in a suitable holding fixture. 18. Apply JLG Threadlocker P/N 0100011 to the socket head capscrews and secure the cylinder head gland using the capscrews. Torque capscrews to 55 ft. lbs. (75 Nm).
Page 345 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Boom Lift Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel.
Page 346 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 24** 20*** * Torque to 30 ft. lbs. (41 Nm) ** Torque to 5 ft. lbs. (7 Nm) ***Torque to 300 ft. lbs. (407 Nm) 1684199 G 1. Rod 6. Head 11. Wiper Seal 16.
Page 347 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
Page 348 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 349 Push the head along the rod to the rod end, as applicable. 5. Carefully slide the piston spacer onto the rod. NOTE: Apply JLG Threadlocker P/N 0100011 on threads of set- PISTON screw before installation.
Page 350 Figure 5-29. Rod Assembly Installation RING SEAL 20. Apply JLG Threadlocker P/N 0100011 to the socket head bolts and secure the cylinder head gland using the cap- screws. Torque capscrews to 300 ft. lbs. (407 Nm). 21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves.
Page 351 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Platform Level Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. BARREL DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 352 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS * Torque to 9 ft. lbs. (12 Nm) ** Torque to 50-55 ft. lbs. (68-75 Nm) ***Torque to 55 ft. lbs. (75 Nm) 1684189 E 1. Capscrew 6. Barrel 11. Guidelock Ring 16.
Page 353 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 354 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 355 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. cable cylinder head gland groove. Install a new wear rings into the applicable cylinder head gland groove.
Page 356 GUIDELOCK RING RING O-RING 19. Apply JLG Threadlocker P/N 0100011 to the socket head bolts and secure the cylinder head gland using the washer ring and capscrews. Torque capscrews to 55 ft. lbs. (75 Nm). 20. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- installation of any holding valve or valves.
Page 357 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Steer Cylinder (Prior to SN 0300142666) 4. Using a hook Spanner, loosen the spanner nut and remove spanner nut from cylinder barrel. DISASSEMBLY CYLINDER BARREL SPANNER NUT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 358 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 1683740 C 1. Rod 6. Retainer Ring 11. Head 2. Barrel 7. Backup Ring 12. Piston 3. O-Ring 8. O-Ring 13. Locknut 4. Spanner Nut 9. Seal 14. Bushing 5. Wiper Seal 10.
Page 359 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 360 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 361 80/100 psi to push rod guide firmly 7. Install locknut onto the piston rod. against the round retaining ring. (Apply 1 drop of JLG 8. Remove the cylinder rod from the holding fixture. Threadlocker P/N 0100011, 2 places, at 180° apart. Hand tighten nut, then tighten 1/4 turn with spanner wrench).
Page 362 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Steer Cylinder (SN 0300142666 through 4. Using a hook Spanner, loosen the spanner nut and remove spanner nut from cylinder barrel. 0300189340) DISASSEMBLY CYLINDER BARREL SPANNER NUT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 363 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 10** * Torque to 76-84 ft. lbs. (30-33 Nm) ** Torque to 275-330 ft. lbs. (373 - 407 Nm) 1001097243 C 1. Rod 6. O-Ring 10. Piston 2. Barrel 7. Head 11. Seal 3.
Page 364 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 365 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 366 80/100 psi to push rod guide firmly 6. Carefully thread the piston on the cylinder rod and hand against the round retaining ring. (Apply 1 drop of JLG tight, ensuring that the o-ring and backup rings are not Threadlocker P/N 0100011, 2 places, at 180°...
Page 367 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS STEER CYLINDER SEAL REPAIR INSTRUCTIONS 8. If the cylinder utilizes a teflon piston seal, special care must be taken when installing the new seal. Teflon seals 1. The cylinder should be disassembled in a clean environ- are not as elastic as rubber or urethane seals.
Page 368 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Telescope Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. CYLINDER BARREL DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 369 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 21** * Torque to 9 ft. lbs. (12 Nm) **Torque to 80 ft. lbs. (108.5 Nm) 1684519 D 1. Capscrew 6. Wear Ring 11. O-ring 16. Plug 21. Capscrew 2. Tapered Bushing 7.
Page 370 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- vent.
Page 371 NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See the respective JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 372 Push the head along the rod to the rod end, as applicable. 5. Carefully slide the piston spacer on the rod. PISTON NOTE: Apply JLG Threadlocker P/N 0100011 on threads of set- screw before installation. CAPSCREW 6. Install setscrew onto the spacer.
Page 373 Figure 5-78. Rod Assembly Installation Figure 5-77. Piston Seal Kit Installation 20. Apply JLG Threadlocker P/N 0100011 to the socket head 17. Position the cylinder barrel in a suitable holding fixture. capscrews and secure the cylinder head gland using the washer ring and capscrews.
Page 374 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 1001151209 A 0274644 K 1. Main Control Valve 3. Auxiliary Pump 5. Dual Select Valve 7. High Pressure Filter 2. Flow Divider (4WD) 4. Platform Valve 6. Hydraulic Filter 8. Flow Divider (2WD) Figure 5-79.
Page 375 Cold temperatures have a significant impact on pressure read- bolts mounting it to the pump. The stand by adjustment ings. JLG Industries Inc. recommends operating the machine is at the top. To adjust this, a 4 mm and 6 mm allen until the hydraulic system has warmed to normal operating wrench will be needed.
Page 376 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS HIGH PRESSURE RELIEF b. Next, using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclock- 1. Install a high pressure gauge at the “M1” port of the wise to decrease. This adjustment will be reset at the main valve block.
Page 377 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS STEER PLATFORM LEVEL DOWN 1. Install a high pressure gauge at port M4. Activate steer 1. Install a high pressure gauge at gauge port “M2”, Acti- left or right. The gauge should read 2500 psi (172.3 bar). vate level down to the end of stroke, you should read 1800 psi (124 Bar).
Page 378 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 4641432 D 1. Check Valve 9. Load Sense - Steer 2. Pilot Valve - Lift 10. Load Sense - Swing 3. Check Valve (100 psi - 6.9 Bar) 11. Check Valve (60 psi - 4.1 Bar) 4.
Page 379 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 4641251 B 1001118473 B 1. Level Down Relief 6. Platform Level Solenoid 2. Level Up Relief 7. Flow Regulator 3. Flow Regulator 8. Flow Regulator 4. Rotator Solenoid 9. Filter 5. Pressure Solenoid 10.
Page 380 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 7, C 9, B 4, A 4641432 D Table 5-1. Cartridge Torque Values Table 5-2. Coil Torque Values Ft-Lbs. Ft-Lbs. 18-20 24-27 33-37 45-50 19-21 26-28 50-55 68-75 19-21 26-28 50-55 68-75 24-26 33-35 70-80...
Page 381 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 4641251 B 1001118473 B Table 5-3. Cartridge Torque Values Table 5-4. Coil Torque Values Ft-Lbs. Ft-Lbs. Figure 5-83. Platform Valve Cartridge Torque Values 3121234 5-45...
Page 382 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.4 START UP PROCEDURES 3. Remove the 3/4 in. hose from port “P1”, using a #12 male union add approx. 30 in. of 3/4 in. hose to it. Remove the return filter cap at the top of the tank, lift out the ele- Start Up After Overhaul or Replacement of ment making sure the canister stays in the tank.
Page 383 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.5 PISTON PUMP (PRIOR TO SN 0300180778) Table 5-5. Symbols Used Symbol Meaning Symbol Meaning Non-reusable part, use a new Inspect for wear or damage part Option - either part may exist Note correct orientation Internal hex head Torque specification...
Page 384 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Initial Start-up Procedures Fluid and Filter Maintenance To ensure optimum life of products, perform regular mainte- Follow this procedure when starting-up a new pump or when the pump has been removed. nance of the fluid and filter. Contaminated fluid is the main cause of unit failure.
Page 385 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Troubleshooting Table 5-8. Excessive Noise and/ or Vibration Item Description Action Check fluid level in reservoir. Insufficient hydraulic fluid will cause cavitation. Fill the reservoir to proper level. Check for air in system. Air in system will cause noisy, erratic control.
Page 386 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-10. System Operating Hot Item Description Action Check fluid level in reservoir. Insufficient volume of hydraulic fluid will not meet cooling Fill reservoir to proper level. Verify proper size of reservoir. demands of system.
Page 387 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-12. Pressure or Flow Instability Item Description Action Check for air in system. Air in system will cause erratic operation. Activate Pressure Compensator, allowing system to bleed air. Check inlet line for leaks and eliminate source of air ingression.
Page 388 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-14. High Inlet Vacuum Item Description Action HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE INTERNAL PUMP COMPONENTS. Check fluid temperature. Low temperature increases viscosity. High fluid viscosity Allow system to warm up before operation. causes high inlet vacuum.
Page 389 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Set Up the Function Pump e. Then using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclock- wise to decrease. The pressure should read between (The pump that is mounted on the back of the drive pump). 400-440 psi (27.58-30.34 bar).
Page 390 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Shaft Seal Replacement Control Assembly K010 C118 K020 C138 C117 C116 C136 C117 C135 C114 C134 C115 C133 C113 C102 (2pl.) Figure 5-87. Shaft Seal and Retaining Ring 7-11 N•m [6-8 lbf•ft] A lip type shaft seal is used in the pump and can be replaced without major disassembly of the unit.
Page 391 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS DISASSEMBLY REASSEMBLY 1. Remove the four screws (C300) holding the control hou- 1. Install the Pressure Compensator spool, spherical end sing onto the end cap. first, into the Pressure Compensator bore. The Pressure Compensator spool is the shorter of the two.
Page 392 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Plug and Fitting Sizes and Torques composite. Your configuration may differ but the appropriate wrench size and torque can be found here. If any plugs or fittings are removed from the unit during ser- vice, install and torque as indicated here.
Page 393 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.6 PISTON PUMP (SN 0300180778 THROUGH Endcover Inspection 0300189341) • Check the bearing (press fit) in endcover. If needles remain in cage, move freely, and setting is at the dimension shown in Figure 5-90., removal not required. Servo Controlled Piston Pump •...
Page 394 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Swashplate Inspection Bushing Inspection • Inspect bushing for contamination embedment within • The finish on the piston shoe surfaces of the swash plate coating of bushing surface coming in contact with swash- should show no signs of scoring.
Page 395 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 6. To assemble cradle sub-assembly, install bushing onto 18. Install key and inner ring gerotor onto shaft or coupler cradle retaining with button head capscrews. Torque assembly. Lubricate inner ring gerotor. button head capscrew 14 to 16 in. lbs. (1.6 to 1.8 Nm). NOTE: Refer to “Charge Pump Adapter Assembly”...
Page 396 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Charge Pump Adapter Assembly DISASSEMBLY 1. Remove plug, shims, spring, and poppet from adapter assembly as shown in Figure 5-94. Inspection • Inspect the charge pump relief valve seat inside the charge Gerotor Ring Pocket pump adapter.
Page 397 3. Remove E-ring from pin retaining feedback link and control housing and bell crank. valve spool. Remove pin, feedback link, valve spool, and 5. JLG Threadlocker P/N 0100011 or equivalent to set bell crank from control housing. screw and install, retaining input shaft. Adjust set screw 4.
Page 398 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Manual Servo Control Assembly Options ASSEMBLY - DESTROKE VALVE ASSEMBLY OPTION 1. Install new o-rings and backup washers onto destroke DISASSEMBLY - DESTROKE VALVE ASSEMBLY valve. OPTION 2. Install destroke valve into manifold by hand until top o-ring is met by manifold.
Page 399 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS DISASSEMBLY - NEUTRAL LOCKOUT SWITCH DISASSEMBLY - NEUTRAL DETENT OPTION ASSEMBLY OPTION 1. Loosen seal nut and remove ball plunger from control housing. 1. Loosen set screw in adapter and remove neutral lockout switch from adapter.
Page 400 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Rotating Kit Assembly The following parts are required to disassemble the cylinder barrel: DISASSEMBLY 2 ea. 3/8 in. I.D. x 1-1/8 in. O.D. flat washers Disassembly of rotating assembly is required for inspection 1 ea.
Page 401 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Fault-logic Troubleshooting RECOMMENDED GAUGE LOCATIONS Gauges Recommended Match the transmission symptoms with the problem state- Inlet vacuum gauge: 30 PSI to 14.8 PSI (2 bar to 1 bar) ments and follow the action steps shown in the box diagrams. This will give expedient aid in correcting minor problems elim- System pressure gauge: 10,000 PSI (700 bar) inating unnecessary machine down time.
Page 402 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-100. Fault - logic Troubleshooting 5-66 3121234...
Page 403 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-101. Fault - logic Troubleshooting 3121234 5-67...
Page 404 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-102. Fault - logic Troubleshooting 5-68 3121234...
Page 405 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS DIAGRAM ACTION STEP COMMENTS 10. Check System Pressure: a. See Figure 5-99. for location of pressure gauge 1. Inspect External Control Linkage for: installation a. Misadjusted or disconnected b. Consult owner/operators manual for maximum sys- b.
Page 406 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Start-up Procedure 6. After the system starts to show signs of fill, slowly move pump swashplate to a slight cam angle. Continue to operate system slowly with no load on motors until sys- When initially starting a new or a rebuilt transmission system.
Page 407 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS This page left blank intentionally. 3121234 5-71...
Page 408 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.7 HYDRAULIC SCHEMATICS SHEET 1 Figure 5-103. Hydraulic Schematic - Sheet 1of 8 5-72 3121234...
Page 409 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 2792678 D SHEET 1 Figure 5-104. Hydraulic Schematic - Sheet 2 of 8 3121234 5-73...
Page 410 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 2 Figure 5-105. Hydraulic Schematic - Sheet 3 of 8 5-74 3121234...
Page 411 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 2 2792678 D Figure 5-106. Hydraulic Schematic - Sheet 4 of 8 3121234 5-75...
Page 412 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 3 Figure 5-107. Hydraulic Schematic - Sheet 5 of 8 5-76 3121234...
Page 413 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 3 2792678 D Figure 5-108. Hydraulic Schematic - Sheet 6 of 8 3121234 5-77...
Page 414 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 4 Figure 5-109. Hydraulic Schematic - Sheet 7 of 8 5-78 3121234...
Page 415 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 4 2792678 D Figure 5-110. Hydraulic Schematic - Sheet 8 of 8 3121234 5-79...
Page 416 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS NOTES: 5-80 3121234...
Page 417 ON ANY ANALYZER MENUS THAT REQUIRE MACHINE MODEL SELECTION, USE sticks, with steering being controlled by a rocker switch built THE 800S SELECTION TO SET UP FOR THE 680S MACHINE. THE SOFTWARE into the top the drive joystick. To activate Drive, Lift, and Swing DOES NOT INCLUDE A 680S SELECTION.
Page 418 SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer The analyzer will display the current top level menu item, for 1. Connect one end of the cable, supplied with the ana- example: lyzer, to the correct four pin connector on the motor control unit;...
Page 419 SECTION 6 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer Press ENTER to select the ACCESS LEVEL item; then When the analyzer is first connected, its access level ensures press UP & DOWN arrows and LEFT &...
Page 420 SECTION 6 - JLG CONTROL SYSTEM Adjusting Configuration Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press UP & When a personality item is selected, press UP & DOWN DOWN to adjust its value, for example:...
Page 421 SECTION 6 - JLG CONTROL SYSTEM Level Vehicle Description Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ACCEL ACCELERATE A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE ACTIVE FOLLOWING PROCEDURE IS PERFORMED. ANALOG DIGITAL CONVERTER COUNT AMB.
Page 422 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND SHORT CIRCUIT GREEN SELECTOR GROUND MODULE SERIAL NUMBER HOURS SPEED HARDWARE STOW STOWED HWFS HARDWARE FAILSAFE STOWD STOWED IN or CURRENT...
Page 423 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram 3121234...
Page 424 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT AUSTRALIA JAPAN ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1)
Page 425 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
Page 426 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / Welder MOTION CUTOUT: Motion cutout in platform mode only.
Page 427 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configuration Digit Number Description Default Number TEMPERATURE: CELSIUS: Celsius unit selection. FAHRENHEIT: Fahrenheit unit selection. LEVELING MODE: ALL FUNCTIONS: Platform level with all functions. LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
Page 428 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
Page 429 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
Page 430 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. AIR INTAKE: Glow plugs installed in the air intake on the manifold.
Page 431 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number TILT: 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep.
Page 432 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number ST TOUCH / SKYGUARD: NONE: No soft touch or skyguard system installed. SOFT TOUCH - Soft touch only installed.
Page 433 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number LOAD SYSTEM: NO: No load sensor installed. * Only visible under certain WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
Page 434 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number DISPLAY UNITS: IMPERIAL: DEG F, PSI, LBS. * Certain market selections METRIC: DEG C, KPA, KGS will alter default setting.
Page 435 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information (Software Version P5.X) Default Configuration Digit Number Description Number CRIBBING OPTION: NO: Cribbing Option is disabled. YES: Cribbing Option is enabled. FUEL TANK SIZE: 31 Gallon Tank 52 Gallon Tank ALARM / HORN: SEPERATE: Separate alarm and horn.
Page 436 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Settings Table 6-4. Machine Configuration Programming Settings 680S 680S Model Number Load System Market Engine Flywheel Teeth Glow Plugs Load Sensor Starter Lockout Function Cut- Fuel Cutout Ground Alarm...
Page 437 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Settings 680S Cribbing Option Fuel Tank Size Alarm / Horn Alert Beacon Temp Cutout Plat Lvl Ovr Cut Water In Fuel Sensor Dual Capacity BOLD TEXT indicates the default setting. Plain text indicates another available selec- tion.RED ITALIC TEXT...
Page 438 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 6-5. Machine Personality Settings and Function Speeds FUNCTION PERSONALITY...
Page 439 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Personality Settings and Function Speeds FUNCTION PERSONALITY RANGE SAUER DANFOSS EATON MAIN TELESCOPE ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum IN speed 0 to 65% MAXimum IN speed 0 to 100%...
Page 440 SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN DOING SPEED Test Notes TESTS 1. Stop watch should be started with the function, not with the controller or switch. Lift: Telescope Retracted. Lift Up, and Record Time. Lift Down and Record Time.
Page 441 SECTION 6 - JLG CONTROL SYSTEM 6.4 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc). CANbus: CAN (Control Area Network) is a two wire differential Platform Level: The GROUND MODULE stores the default val- serial link between the Platform Module, Ground Module, ues and handles interlocks.
Page 442 SECTION 6 - JLG CONTROL SYSTEM 6-26 3121234...
Page 443 SECTION 6 - JLG CONTROL SYSTEM 3121234 6-27...
Page 444 SECTION 6 - JLG CONTROL SYSTEM 6-28 3121234...
Page 445 SECTION 6 - JLG CONTROL SYSTEM 3121234 6-29...
Page 446 SECTION 6 - JLG CONTROL SYSTEM 6-30 3121234...
Page 447 SECTION 6 - JLG CONTROL SYSTEM 3121234 6-31...
Page 448 SECTION 6 - JLG CONTROL SYSTEM 6-32 3121234...
Page 449 SECTION 6 - JLG CONTROL SYSTEM 3121234 6-33...
Page 450 SECTION 6 - JLG CONTROL SYSTEM MENU : HELP : (001 ) HELP : PRESS ENTER EVERYTHING OK LOG :( xxx) x:xxxxxxxxxxx DIAGNOSTICS : MENU : DIAGNOSTICS : DIAGNOSTICS : BOOM FUNCTIONS DIAGNOSTICS DRIVE/STEER ENGINE JOYSTICK LIFT : JOYSTICK DRIVE :...
Page 451 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : ENGINE SYSTEM BOOM FUNCTIONS LOAD START SEQUENCE CHASSIS TILT GROUND MODULE : NOT ACTIVE BATTERY : XX.XV ANGLE : XX.X UMS TO TURNTABLE...
Page 452 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA DATALOG : GROUND MODULE SWITCH : CLOSED RX /SEC : X...
Page 453 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : DIAGNOSTICS MENU : SYSTEM TEST : SYSTEM TEST ACTIVATE ? MENU : ACCESS LEVEL ACCESS LEVEL CODE XXXXXX MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES...
Page 454 SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE RIGHT TRACK MAIN LIFT : SWING : TOWER LIFT : MAIN TELESCOPE : TOWER TELESCOPE : ACCEL X .XS...
Page 455 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : PERSONALITIES MENU : MODEL NUMBER : MARKET : ENGINE : FLYWHEEL TEETH : MACHINE SETUP 400S ANSI USA PERKINS ECM 133 TEETH ENGINE : FLYWHEEL TEETH : MODEL NUMBER : MARKET :...
Page 456 SECTION 6 - JLG CONTROL SYSTEM FROM TILT : 4 WHEEL STEER : JIB : STOUCH/SKYGUARD : ENGINE 5 DEGREES NONE SHUTDOWN: ENABLED TILT : JIB : 4 WHEEL STEER : STOUCH/SKYGUARD : 4 DEGREES SOFT TOUCH TILT : STOUCH/SKYGUARD :...
Page 457 SECTION 6 - JLG CONTROL SYSTEM DRIVE CONTROL : DRIVE PUMP : BOOM CONTROL : FUNCTION SPEED FROM ENHANCED SAUER DANFOSS NORMAL KNOB: YES LEVELING MODE: ALL FUNCTIONS DRIVE CONTROL : DRIVE PUMP : BOOM CONTROL : FUNCTION SPEED NORMAL...
Page 458 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : MACHINE SETUP MENU : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS TILT SENSOR UMS SENSOR FORD ENGINE LOAD SENSOR FORD ENGINE : TILT SENSOR: UMS SENSOR : LOAD SENSOR :...
Page 459 SECTION 6 - JLG CONTROL SYSTEM FAULT CODE LIGHT PLATFORM CONTROL MODULE GROUND CONTROL MODULE Figure 6-20. Fault Code Light and Module Location 3121234 6-43...
Page 460 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-21. Analyzer Connecting Points 6-44 3121234...
Page 461 SECTION 6 - JLG CONTROL SYSTEM 1001103667 Y Figure 6-22. Ground Control Module - Sheet 1 of 3 3121234 6-45...
Page 462 SECTION 6 - JLG CONTROL SYSTEM 1001103667 Y Figure 6-23. Ground Control Module - Sheet 2 of 3 6-46 3121234...
Page 463 SECTION 6 - JLG CONTROL SYSTEM 1001103667 Y Figure 6-24. Ground Control Module - Sheet 3 of 3 3121234 6-47...
Page 464 SECTION 6 - JLG CONTROL SYSTEM 1001141138 D Figure 6-25. Platform Control Module - Sheet 1 of 2 6-48 3121234...
Page 465 SECTION 6 - JLG CONTROL SYSTEM 1001141138 D Figure 6-26. Platform Control Module - Sheet 2 of 2 3121234 6-49...
Page 466 SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure The LEFT /RIGHT arrow keys move between In the following structure descriptions, an intended item is items in the same level. The UP / DOWN selected by pressing ENTER ; pressing ESC arrow keys alter a value if allowed.
Page 467 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Adjustments - Personality Descriptions MAX OUT Displays/adjusts maximum telescope out speed BASKET LEVEL ACCEL Displays/adjusts basket level acceleration DECEL Displays/adjusts basket level deceleration MIN UP Displays/adjusts minimum basket level up speed MAX UP...
Page 468 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES …...
Page 469 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions ANGLE … Displays angle switch status LOAD … Displays load sensor value NOTE: Not displayed if load = 0. DATALOG ON … Displays total controller on (EMS) time ENGINE …...
Page 470 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check EVERYTHING OK No response required for this DTC. GROUND MODE OK No response required for this DTC. 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Response described in Drive Modes section.
Page 471 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 2220 L/S JOY. CENTER TAP BAD Resistive joysticks. - There is a +/- 1V range. around these values due to resistor tolerances.
Page 472 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 2516 DRIVE PREVENTED - ABOVE ELEVATION The UGM shall prohibit Drive and Steer. 2517 DRIVE PREVENTED - TILTED & ABOVE ELEVATION The UGM shall prohibit Drive and Steer.
Page 473 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 3359 MAIN DUMP VALVE - OPEN CIRCUIT Check Harness for damage. 3360 MAIN DUMP VALVE - SHORT TO BATTERY Check Harness for damage.
Page 474 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 33110 TOWER LIFT DOWN VALVE - OPEN CIRCUIT Check Harness for damage. 33111 TOWER LIFT DOWN VALVE - SHORT TO BATTERY Check Harness for damage.
Page 475 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 33295 SWING LEFT VALVE - OPEN CIRCUIT Check Harness for damage. 33306 SWING LEFT VALVE - SHORT TO BATTERY Check Harness for damage.
Page 476 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check PLATFORM LEVEL UP VALVE - SHORT TO GROUND Check Harness for damage. PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN Check Harness for damage.
Page 477 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 4313 THROTTLE ACTUATOR FAILURE 4314 WRONG ENGINE SELECTED - ECM DETECTED 4322 LOSS OF ENGINE SPEED SENSOR Diesel engine only. 4323 SPEED SENSOR READING INVALID SPEED Diesel engine only.
Page 478 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check <<< PLATFORM LOAD SENSE >>> LSS HAS NOT BEEN CALIBRATED UGM to set Platform Load State = Overloaded RUNNING AT CREEP - PLATFORM OVERLOADED DRIVE &...
Page 479 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Diagnostic Trouble Code Chart (DTC) Flash Code Fault Message Check 9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED Display ??? or NO MODEL at Analyzer MACHINE SETUP menu MACHINE SETUP- >MODEL NUMBER...
Page 480 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-64 3121234...
Page 481 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERAL Polarity Getting a negative Voltage or current reading when expecting This section contains basic electrical information and sche- a positive reading frequently means the leads are reversed. matics to be used for locating and correcting most of the oper- Check what reading is expected, the location of the signal and ating problems which may develop.
Page 482 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing. Figure 7-2. Resistance Measurement • Circuit power must be turned OFF before testing conti- nuity.
Page 483 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 484 3. Leave a thin layer of dielectric grease on the face of the unused wire seals. After assembly, install a seal plug (JLG connector. #4460905) in that location to prevent moisture ingress.
Page 485 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Exclusions Figure 7-6. Use of Seal Plugs A limited number of connectors do not benefit from dielectric AMP Mate-N-Lok grease, or may be permanently damaged by application.
Page 486 EMR4 engine control module from Deutz employs this con- the dielectric grease (replacement of female contacts nector system (for example). required). The JLG Load Sensing System and Rotary Angle Sen- sors are examples of components with the M12 connector sys- tem.
Page 487 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MIL-C-5015 SPEC CONNECTOR’S MOLEX CMC SERIES CONNECTORS Crown Connector Inc’s recommendation is to not use dielec- The CMC connector family is a sealed, high-density connec- tric grease for this series connector. For similar model series tion system using matte-seal technology for CP 0.635 and 1.50 connectors, the manufacturer should be contacted for confir- mm terminals.
Page 488 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as-shipped, Applying Silicone Dielectric Compound to AMP position (See Figure 7-9.). Proceed as follows: Connectors Silicone Dielectric Compound must be used on the AMP con- nections for the following reasons: •...
Page 489 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. 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 7-13.).
Page 490 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-14. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16 in.) wide screwdriver blade between the mating seal and one of the red wedge lock DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. tabs.
Page 491 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-15. Connector Installation 3121234 7-11...
Page 492 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-17. DT/DTP Contact Removal Figure 7-16. DT/DTP Contact Installation 1. Remove wedgelock using needle nose pliers or a hook 1. Grasp crimped contact about 25 mm behind the contact shaped wire to pull wedge straight out.
Page 493 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-18. HD/HDP Contact Installation Figure 7-20. HD/HDP Contact Removal 1. Grasp contact about 25 mm behind the contact crimp 1. With rear insert toward you, snap appropriate size barrel.
Page 494 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 ELECTRICAL COMPONENT PLATFORM PLATFORM WORK CONSOLE LIGHTS GENERATOR SWITCH SOFT TOUCH SYSTEM LIMIT SWITCH TILT SENSOR TILT SENSOR NOTE: MODULE SHOWN INVERTED FOR CLARITY BOOM ANALYZER VALVES FOOT SWITCH MAIN LIFT HORN ALARM CYLINDER...
Page 495 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS RECEPTACLE AT PLATFORM AUX. POWER (OPTIONAL) SOLENOID (FORD ENGINE) PUMP BEACON SPEED LP LOCK VALVE PICKUP (FORD ENGINE) (DEUTZ ENGINE) GENERATOR RELAY ON ENGINE TRAY GENERATOR BOX ALTERNATOR BOOM (FORD ENGINE) CAPACITY LENGTH SWITCH BOOM DUAL...
Page 496 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM FLOODLIGHTS FOOTSWITCH 7500W GENERATOR GENERATOR PLATFORM SWITCH PLATFORM WORK LIGHTS ABOVE HORIZONTAL LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH BOOM CAPACITY LENGTH LIMIT SWITCHES BOOM TRANSPORT LENGTH LIMIT SWITCHES TILT SENSOR PLATFORM CONTROL BOOM...
Page 497 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2500W GENERATOR RELAY 2500W GENERATOR CONTROL BOX 2500W 7500W 7500W GENERATOR GENERATOR GENERATOR 7500W CONTROL BOX RELAYS SKYPOWER GENERATOR THROTTLE LP CONVERTOR CONTROL (FORD) (FORD) FUEL ALTERNATOR PUMP (FORD) (CAT) FUEL ENGINE SHUT CONTROL (DEUTZ)
Page 498 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM FLOODLIGHTS FOOTSWITCH 7500W GENERATOR GENERATOR PLATFORM SWITCH PLATFORM WORK LIGHTS ABOVE HORIZONTAL LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH BOOM CAPACITY LENGTH LIMIT SWITCHES BOOM TRANSPORT LENGTH LIMIT SWITCHES TILT SENSOR PLATFORM CONTROL BOOM...
Page 499 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2500W GENERATOR RELAY 2500W GENERATOR CONTROL BOX 2500W 7500W 7500W GENERATOR GENERATOR GENERATOR 7500W CONTROL BOX RELAYS SKYPOWER GENERATOR EGR VALVE ENGINE SWITCH CONTROL (DEUTZ) (DEUTZ) FUEL RELAY PUMP (DEUTZ) (CAT) ENGINE HARNESS (DEUTZ) DGC DCM...
Page 500 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.7 ELECTRICAL SCHEMATICS SHEET 1 Figure 7-28. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 1 of 6 7-20 3121234...
Page 501 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1870221 D Figure 7-29. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 2 of 6 3121234 7-21...
Page 502 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-30. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 3 of 6 7-22 3121234...
Page 503 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1870221 D Figure 7-31. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 4 of 6 3121234 7-23...
Page 504 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-32. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 5 of 6 7-24 3121234...
Page 505 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1870221 D Figure 7-33. Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 6 of 6 3121234 7-25...
Page 506 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-34. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 1 of 10 7-26 3121234...
Page 507 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1001110325 C Figure 7-35. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 2 of 10 3121234 7-27...
Page 508 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-36. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 3 of 10 7-28 3121234...
Page 509 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1001110325 C Figure 7-37. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 4 of 10 3121234 7-29...
Page 510 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-38. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 5 of 10 7-30 3121234...
Page 511 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1001110325 C Figure 7-39. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 6 of 10 3121234 7-31...
Page 512 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 Figure 7-40. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 7 of 10 7-32 3121234...
Page 513 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 1001110325 C Figure 7-41. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 8 of 10 3121234 7-33...
Page 514 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 Figure 7-42. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 9 of 10 7-34 3121234...
Page 515 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 1001110325 C Figure 7-43. Electrical Schematics Caterpillar, Deutz EMR2 and GM (SN 0300139080 through 0300161729) - Sheet 10 of 10 3121234 7-35...
Page 516 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-44. Electrical Schematic (0300161730 to 0300189341) - Sheet 1 of 10 7-36 3121234...
Page 517 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1001141141 C Figure 7-45. Electrical Schematic (0300161730 to 0300189341) - Sheet 2 of 10 3121234 7-37...
Page 518 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-46. Electrical Schematic (0300161730 to 0300189341) - Sheet 3 of 10 7-38 3121234...
Page 519 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1001141141 C Figure 7-47. Electrical Schematic (0300161730 to 0300189341) - Sheet 4 of 10 3121234 7-39...
Page 520 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-48. Electrical Schematic (0300161730 to 0300189341) - Sheet 5 of 10 7-40 3121234...
Page 521 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1001141141 C Figure 7-49. Electrical Schematic (0300161730 to 0300189341) - Sheet 6 of 10 3121234 7-41...
Page 522 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 Figure 7-50. Electrical Schematic (0300161730 to 0300189341) - Sheet 7 of 10 7-42 3121234...
Page 523 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 1001141141 C Figure 7-51. Electrical Schematic (0300161730 to 0300189341) - Sheet 8 of 10 3121234 7-43...
Page 524 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 Figure 7-52. Electrical Schematic (0300161730 to 0300189341) - Sheet 9 of 10 7-44 3121234...
Page 525 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 1001141141 C Figure 7-53. Electrical Schematic (0300161730 to 0300189341) - Sheet 10 of 10 3121234 7-45...
Page 526 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-54. Electrical Schematic GM - Sheet 1 of 2 7-46 3121234...
Page 527 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1001131992 A Figure 7-55. Electrical Schematic GM - Sheet 2 of 2 3121234 7-47...
Page 528 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-48 3121234...
Page 530 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)