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JLG 740AJ Service And Maintenance Manual

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Service and Maintenance Manual

Model

740AJ

Prior to S/N 0300185827

P/N - 3121160

October 24, 2017

AS/NZS

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Summary of Contents for JLG 740AJ

Page 1 Service and Maintenance Manual Model 740AJ Prior to S/N 0300185827 P/N - 3121160 October 24, 2017 AS/NZS...
Page 3: Bhydraulic System Safety
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL Relieve system pressure by cycling the applicable control sev- eral times with the engine stopped and ignition on, to direct This section contains the general safety precautions which any line pressure back into the reservoir. Pressure feed lines to must be observed during maintenance of the aerial platform.
Page 4 INTRODUCTION REVISON LOG Original Issue - November 4, 2002 Revised - September 8, 2003 - March 10, 2006 Revised - September 28, 2007 Revised Revised - June 3, 2008 Revised - January 8, 2013 - October 24, 2017 Revised 3121160...
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 3.10 Swing Bearing ..................3-47 Turntable Bearing Mounting Bolt Condition Check .
Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.27 Dual Fuel System ................. . . 3-141 Changing from Gasoline to LP Gas .
Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.34 GM Engine Fuel System Repair ..............3-190 Propane Fuel System Pressure Relief .
Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Powertrack Maintenance ................4-6 Flat Bar Removal .
Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.17 Upright Monitoring System............... . . 4-48 Re-Synchronizing Upright .
Page 12 To Connect the JLG Control System Analyzer ........
Page 13 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO CANbus Communications ................6-50 Machine Orientation When Doing Speed Tests .
Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Operator Maintenance and Lubrication Diagram ........... . 1-7 1-2.
Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-48. Motor Control Valve................3-91 3-49.
Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-105. EPR Assembly ..................3-192 3-106.
Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-21. Tapered Bushing Removal................5-16 5-22.
Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-78. Cylinder Rod Support................5-38 5-79.
Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-135. Plug Locations, Sizes, and Torques ..............5-89 5-136.
Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-9. Connector Assembly Figure 1 ............... 7-8 7-10.
Page 21 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Dimensional Data .
Page 22 LIST OF TABLES TABLE NO. TITLE PAGE NO. Actuator Response Is Sluggish ..............5-84 System Operating Hot .
Page 23: Specifications
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS OPERATING SPECIFICATIONS Capacities Table 1-1. Operating Specifications Table 1-3. Capacities Maximum Work Load (Capacity) Fuel Tank Approx. 39 gallons (147.6 liters) ANSI Unrestricted: 500 lb. (227 kg) Hydraulic Tank Approx. 40 gallons (151.4 liters) CE/AUS Unrestricted: 500 lb.
Page 24 SECTION 1 - SPECIFICATIONS Table 1-5. Deutz F4M2011F Specifications Table 1-7. Caterpillar 3044C/3.4 Type Liquid Cooled (Oil) Type Four Stroke Cycle Fuel Diesel Cylinders 4 in-line Oil Capacity Bore 3.70 in. (94 mm) Cooling System 5 Quarts (4.5 L) Stroke 4.72 in.
Page 25: Tires
SECTION 1 - SPECIFICATIONS Tires Swing System Table 1-9. Tire Specifications Table 1-12. Swing System Specifications Swing Motor Displacement Load 4 cu. in. (66 cm Size Type Pressure Rating Range Swing Brake Automatic spring applied hydraulically IN 385/65D 19.5 pneumatic 95 psi released disc brakes (6.5 bar)
Page 26: Auxiliary Power Pump
SECTION 1 - SPECIFICATIONS Auxiliary Power Pump TORQUE REQUIREMENTS Table 1-16. Auxiliary Power Pump Specifications Table 1-20. Torque Requirements (SN 0300069000 through 0300109066) Pump Output 2.1 GPM (9.5 lpm) @ 1400 psi. (69 bar) Description Torque Value (Dry) Interval Hours Pump Displacement 0.305 cu.
Page 27: Lubrication
F. (-7 degrees C.), JLG Industries recommends the use of ISO Viscosity Grade 32/46 Mobil DTE10. Specific Gravity 0.922 NOTE: Aside from JLG recommendations, it is not advisable to mix Pour Point °C(°F) -32°(-25°) oils of different brands or types, as they may not contain Flash Point °C(°F) 220°(428°) the same required additives or be of comparable viscosi- Rust Protection, ASTM D 665A &...
Page 28: Cylinder Specifications
SECTION 1 - SPECIFICATIONS CYLINDER SPECIFICATIONS PRESSURE SETTINGS Table 1-26. Cylinder Specifications Table 1-28. Pressure Settings DESCRIPTION BORE STROKE ROD DIA. Main Boom Lift Down Relief 1400 PSI. (97 Bar) in. (mm.) in. (mm.) in. (mm.) Swing Relief 1400 PSI. (97 Bar) Upright Level 8.00 42.00...
Page 29: Maintenance And Lubrication
SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance and Lubrication Diagram 1. Swing Bearing - Internal Ball Bearing MAINTENANCE AND LUBRICATION NOTE: The following numbers correspond to those in Figure 1-1., Operator Maintenance and Lubrication Diagram. Table 1-30. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350°...
Page 30 SECTION 1 - SPECIFICATIONS 2. Wheel Bearings 4. Hydraulic Return Filter Lube Point(s) - Repack Interval - Change after first 50 hrs. and every 6 months Capacity - A/R or 300 hrs. thereafter or as indicated by Condition Lube - MPG Indicator.
Page 31 8. Oil Change w/Filter - Ford Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation.
Page 32 SECTION 1 - SPECIFICATIONS Lube Point(s) - Replaceable Element 15. Electronic Pressure Regulator (LP only) Interval - Every Year or 1200 hours of operation. 12. Fuel Filter - Deutz Interval - 3 Months or 150 hours of operation. Comments - Drain oil build up. Refer to “Draining Oil Build Up From The Propane Regulator (Prior to SN 0300134626)”...
Page 33: Draining Oil Build Up From The Propane Regulator (Prior To Sn 0300134626)
SECTION 1 - SPECIFICATIONS 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 propane pressure regulator.
Page 34: Propane Fuel Filter Replacement
SECTION 1 - SPECIFICATIONS 1.10 PROPANE FUEL FILTER REPLACEMENT 1. Electric Lock Off Solenoid 8. Fuel Outlet 2. Mounting Plate 9. O-ring 3. Housing Seal 10. Filter 4. Filter Magnet 11. Fuel Inlet 5. Filter Housing 12. Retaining Bolt 6. Seal 13.
Page 35: Propane Fuel System Pressure Relief
SECTION 1 - SPECIFICATIONS 1.11 PROPANE FUEL SYSTEM PRESSURE RELIEF THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.
Page 36 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 1 of 5 (SAE Fasteners) 1-14 3121160...
Page 37 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 (SAE Fasteners) 3121160 1-15...
Page 38 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 (SAE Fasteners) 1-16 3121160...
Page 39 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 (Metric fasteners) 3121160 1-17...
Page 40 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 (Metric Fasteners) 1-18 3121160...
Page 41: General
Machine Inspection. JLG Industries, Inc. recognizes a Factory- Certified Service Technician as a person who has successfully pleted before placing the machine into service. completed 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 42: Service And Guidelines
Service and Maintenance Manual Maintenance Maintenance Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. Be sure all parts are clean before they are installed. New SERVICE AND GUIDELINES parts should remain in their containers until they are ready to be used.
Page 43: Bearings
SECTION 2 - GENERAL Bearings Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring, as well 1. When a bearing is removed, cover it to keep out dirt and as their receptacles, when disconnecting or removing them abrasives.
Page 44: Lubrication And Information
1. Refer to Section 1 for recommendations for viscosity ranges. 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below - 15 degrees F (-26 degrees C) is not recommended.
Page 45: Cylinder Drift Test
SECTION 2 - GENERAL CYLINDER DRIFT TEST 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 46: Pins And Composite Bearing Repair Guidelines
• Ground only to structure being welded. a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing. Do NOT Do the Following When Welding on JLG c. Bearings that have moved or spun in their housing. Equipment d.
Page 47 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 48 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 49 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 50 -10° F (-23° C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIF IED COLD WEATHER -20° F (-29° C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ET HER INJECTION OR KEROSENE -30°...
Page 51 SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 3121160 2-11...
Page 52 -10° F (-23° C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIF IED COLD WEATHER -20° F (-29° C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ET HER INJECTION OR KEROSENE -30°...
Page 53: Chassis & Turntable
The air pressure for pneumatic tires must be equal to the air center piece location, larger or smaller diameter, etc., without pressure that is stenciled on the side of the JLG product or rim written factory recommendations, may result in an unsafe decal for safe and proper operational characteristics.
Page 54: Emergency Towing
SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Fol- 3.2 EMERGENCY TOWING lowing the recommended sequence, tighten nuts per wheel torque chart. Table 3-1. Wheel Torque Chart RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES.
Page 55 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121160...
Page 56 SECTION 3 - CHASSIS & TURNTABLE 0258286 C Figure 3-2. Axle and Steering Installation - Sheet 1 of 2 3121160...
Page 57 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Weldment 13. Tie Rod Pin 25. Wear Shim 36. Stop Pad 2. Steer Cylinder Assembly 14. Bearing 26. Washer 37. Shim 3. Frame Weldment 15. Washer 27. Washer 38. Screw 4. Bolt 16.
Page 58: Chassis Component Location
SECTION 3 - CHASSIS & TURNTABLE 1. Drive Hub 4. Steer Cylinders 2. Drive Brake 5. Flow Divider Valve 2WD 3. Drive Motor 6. Flow Divider Valve 4WD Figure 3-4. Chassis Component Location 3121160...
Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Engine 4. Main Control Valve 7. Return Filter Assembly 9. Fuel Tank 2. Piston Pump 5. Auxiliary Power Pump 8. Hydraulic Oil Tank 10. Rotor y Coupling 3. Gear Pump 6. Swing Drive Figure 3-5.
Page 60: Wheel Drive Assembly (Prior To Sn 0300138447)
Place blocking strong enough to support the weight of the machine under the 1. Apply coat of JLG Threadlocker P/N 0100011 on studs. frame and remove the jack. Install the studs on the drive hub. Slide the drive brake NOTE: The foam-filled tire &...
Page 61: Wheel Drive Assembly (Sn 0300138447 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.4 WHEEL DRIVE ASSEMBLY (SN 0300138447 plug all openings to ensure no dirt enters the hydraulic system. THROUGH 0300185827) NOTE: The drive hub and drive motor assembly weighs approxi- mately 280 lbs. (128 kg). Removal 4.
Page 62: Drive Hub (Prior To Sn 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE HUB (PRIOR TO SN 0300185827) Cleaning and Inspection 1. Thoroughly clean all parts in an approved cleaning sol- Disassembly vent. 4. Position hub over suitable container and remove drain 2. Inspect bearing cups and cones for damage, pitting, cor- plugs (10) from unit.
Page 63 SECTION 3 - CHASSIS & TURNTABLE k. Turn cover over and push disconnect rod into cover cap. Rod will be held in place by friction from o-ring. 2. Carrier Assembly. a. Drive anti-roll pin (19) into planet shaft (17) using a suitable punch.
Page 64 SECTION 3 - CHASSIS & TURNTABLE Install retaining ring into input shaft groove to secure spacers o. Drive anti-roll pin flush into carrier hole, locking and spring to shaft. planet shaft into place. p. repeat steps (h) through (o) for remaining two clus- ter gears.
Page 65: Assembly
SECTION 3 - CHASSIS & TURNTABLE Assembly 1. Using a suitable press, press new bearing cups (3, 5), with large inside diameters facing out, into hub (7) counter bores. 5. Place bearing cone (6) over end of spindle and into bear- ing cup.
Page 66 SECTION 3 - CHASSIS & TURNTABLE 7. Install new retaining ring (9) completely into spindle 10. Install retaining ring (34) into input shaft retaining ring groove and against bearing shim. Ensure retaining ring groove. is entirely in groove. 11. Place input shaft assembly (35) into spindle bore with 8.
Page 67 SECTION 3 - CHASSIS & TURNTABLE 13. Locate the four counter reamed holes in the face of the 16. With shoulder side of ring gear (21) facing down, place hub, mark them for later identification. ring gear over (into mesh with) large gears. Ensure punch marks remain in correct location during ring gear installation.
Page 68 SECTION 3 - CHASSIS & TURNTABLE 19. After inserting at least one shoulder bolt in the proper 22. Place cover assembly over ring gear with oil level check location, rotate the carrier. Check freedom of rotation plug in cover located approximately 90 degrees from oil and timing.
Page 69 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 70: Drive Brake - Mico (Prior To Sn 0300138447)
SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE BRAKE - MICO (PRIOR TO SN NOTE: Cover plate (16) must be supported as indicated in Figure 3-9. 0300138447) 4. Install retaining ring (20) in cover plate (16). Disassembly 5. Press shaft (10) into bearing (18) until it bottoms on shoulder.
Page 71 SECTION 3 - CHASSIS & TURNTABLE 1. Capscrew 8. O-ring 15. Dowel Pin 2. Washer 9. Backup Ring 16. Cover Plate 3. Pressure Plate 10. Shaft 17. Oil Seal 4. Case Seal 11. Stator Disc 18. Bearing 5. O-ring 12. Rotor Disc 19.
Page 72: Bleeding
SECTION 3 - CHASSIS & TURNTABLE Bleeding Pressure should not exceed 6.9 bar (100 psi) during bleeding. 1. Install brake in system and connect pressure lines. 3. Apply sufficient pressure to release brake and check for proper operation in system. 2.
Page 73: Drive Brake (Sn 0300138447 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE BRAKE (SN 0300138447 THROUGH Assembly 0300185827) 1. Lightly lubricate rotary shaft seal (12) and assemble to housing (2) taking care not to damage seal lip. Disassembly 2. Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing (2) bearing recess adjacent to 1.
Page 74 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 75: Drive Motor (Prior To Sn 0300138447)
SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE MOTOR (PRIOR TO SN 0300138447) Rotary group complete 9 pistons, cylinder sub-assembly, valve plate (cw or ccw corresponding to the order) retaining plate and retaining ball. Spare Parts Kits Sealing kit, existing spare parts: shaft sealing ring, 6 different O-rings and a circlip (sealing mat.: perbunan) Swash Plate Same sealing kit like shown above only seal material changed...
Page 76: Replacing The Drive Shaft Seal
SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. 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 the snap ring 3-24 3121160...
Page 77: Disassembly And Assembly
SECTION 3 - CHASSIS & TURNTABLE 3. Be careful while you seal the drive shaft, use an adhesive Disassembly and Assembly tape to protect the splines. 1. Disassemble the pilot valve. 4. Assemble the sealing ring. The fitting tool will hold the 2.
Page 78 SECTION 3 - CHASSIS & TURNTABLE 5. Disassemble the taper roller bearing. 9. Turn in the stopper max flow to get swivel angle zero. 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11.
Page 79 SECTION 3 - CHASSIS & TURNTABLE 13. Disassemble the plug. 17. Remove the spring. 18. Remove both bearing shells. 14. Disassemble the control piston while moving the swash plate. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disassemble the piston rod.
Page 80 SECTION 3 - CHASSIS & TURNTABLE 21. Disassemble the sealing ring. 24. A usual commercial bearing puller is used to disassem- ble the external bearing ring of the taper roller bearing inside the port plate. Take care not to damage the sur- face of the port plate.
Page 81: Assembly Notes
SECTION 3 - CHASSIS & TURNTABLE Assembly Notes 4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees de-centered in ccw position. 1. Measurement of the taper roller bearing pretension. 5. Assembly of the port plate and the pump housing: Note the correct position of the drilling that connects high 2.
Page 82 SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rota- tion is appr. 3.1 cm3. Figure 3-12. Flow Control Pilot Valves 3-30 3121160...
Page 83: 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 84: Drive Motor (Sn 0300138447 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.9 DRIVE MOTOR (SN 0300138447 THROUGH Shaft Seal Replacement 0300185827) REMOVAL Description 1. Remove the snap ring (1) retaining the shaft seal and support washer. The drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston.
Page 85: Loop Flushing Valve
SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT THE COMPONENTS Inspect new o-rings and the sealing area for rust, wear, or con- REMOVAL tamination. Also check springs and poppet for wear. 1. Using a 11/16 in internal hex wrench remove plug (1) INSTALLATION and (2).
Page 86: Troubleshooting
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-3. 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 Fill the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.
Page 87: Disassembly
SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all o-rings and gaskets. It is recommended that all o-rings be replaced.
Page 88: Valve Plate & Rear Shaft Bearing
SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring Figure 3-19. End Cap 28. O-ring 29. Angle Stop 30. Servo Spring 13. Using an 8 mm internal hex wrench, remove the endcap screws (22).
Page 89: Shaft Seal
SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring (30) 20. Turn the housing over and remove the snap ring (32) from the housing. retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34).
Page 90 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-24. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer 23.
Page 91: Inspection
SECTION 3 - CHASSIS & TURNTABLE 28. Turn the block over. Using a press, apply pressure on the SLIPPERS block spring washer (50) to compress the block spring. Inspect the running surface of the slippers. Replace any piston Compress the spring enough to safely remove the spiral assemblies with scored or excessively rounded slipper edges.
Page 92 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Cylinder Block Measurements Measurement Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) Cylinder Block Surface Flatness 0.002 0.002 0.002 0.002 0.002 (0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079) BALL GUIDE AND SLIPPER RETAINER SWASHPLATE AND JOURNAL BEARINGS...
Page 93: Assembly
SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate the bearings while feeling for uneven movement. Bearings 1. Install new O-ring (1) and piston seal (2) to the servo pis- should spin smoothly and freely. Replace bearings that appear ton (3).
Page 94: Swash Plate And Journal Bearing
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 RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES block. ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT.
Page 95: Shaft And Front Bearing
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 96: Valve Plate And Rear Bearing
SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the endcap. Install 15. Install the endcap (25) onto the housing with the end- the bearing with letters facing out. Press until bearing cap screws (26). Check to ensure the endcap will prop- surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap sur- erly seat onto the housing without interference.
Page 97: Shaft Seal
SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation new shaft seal (27) with the cup side facing the motor. torques.
Page 98: Initial Start-Up Procedures
SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). Initial Start-up Procedures Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage incurred dur- 11/16 in ing shipping.
Page 99: Swing Bearing
NOTE: This check is designed to replace the existing bearing bolt insert the 0.0015” feeler gauge between the bolt torque checks on JLG Lifts in service. This check must be head and hardened washer at the arrow indicated performed after the first 50 hours of machine operation position.
Page 100 SECTION 3 - CHASSIS & TURNTABLE Figure 3-37. Swing Bearing Tolerance Boom Placement - (Sheet 1 of 2) 3-48 3121160...
Page 101 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-49...
Page 102: Wear Tolerance
SECTION 3 - CHASSIS & TURNTABLE Figure 3-40. Swing Bearing Tolerance Measuring Point. Figure 3-39. Swing Bolt Feeler Gauge Check. Swing Bearing Replacement Wear Tolerance 1. From the underside of the machine, at rear center, with REMOVAL the main boom fully elevated and fully retracted, and 1.
Page 103 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-51...
Page 104 8. Carefully place the turntable on a suitably supported trestle. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS- 9. Use a suitable tool to scribe a line on the outer race of CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE the swing bearing and the frame.
Page 105: Swing Bearing Torque Values
SECTION 3 - CHASSIS & TURNTABLE 3. Refer to the Torque Sequence diagram as shown in Fig- 8. Following the Torque Sequence diagram shown in Fig- ure 3-42., Swing Bearing Torque Sequence. Spray a light ure 3-42., Swing Bearing Torque Sequence., tighten the coat of Safety Solvent 13 on the new bearing bolts.
Page 106 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 5. Capscrew 2. Jam Nut 6. Washer 3. Shim 7. Swing Motor and Drive Assembly 4. Shoulder Screw Figure 3-43. Swing Drive Installation 3-54 3121160...
Page 107: Swing Hub Removal
8. Using the suitable lifting device, remove the swing drive hub from mounting plate without damaging the swing gear. 9. Place swing drive hub in the clean area. 3. Apply JLG Threadlocker P/N 0100019 and torque shoul- der screw to 420 ft. lbs. (569 Nm). 3121160 3-55...
Page 108: Swing Drive Lubrication
Fill Swing Drive Gearbox with 43 oz (1.27 L) 90w80gear oil with EP additives. Oil should cover the ring gear. Fill Plug 6. Apply JLG Threadlocker P/N 0100019 and torque set- screw 50 ft. lbs. (67.5 Nm) (w/JLG Threadlocker P/N 0100019).
Page 109: Swing Hub (Prior To Sn 0300074383)
SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING HUB (PRIOR TO SN 0300074383) 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 Assembly from the unit.
Page 110 SECTION 3 - CHASSIS & TURNTABLE 3. Place O-ring (5) into Hub counterbore. Use petroleum 5. Place Carrier Assembly (3) on a flat surface with the large jelly to hold o-ring in place. gears (3F) up and positioned as shown. Find the punch marked tooth on each large gear (3F) and locate at 12 o’clock (straight-up) from each planet pin.
Page 111 SECTION 3 - CHASSIS & TURNTABLE 7. While holding Ring Gear (4) and Cluster Gears (3F) in 10. Thrust Washer (11) is installed into the counterbore of the Carrier (3). mesh, place small side of Cluster Gears (3F) into mesh with the Internal Gear (2) and Input Gear (13).
Page 112: Hub Shaft Sub-Assembly
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 seal of some sort.
Page 113 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 114: Carrier Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE 10. A soft metal punch should be used to insure that this Carrier Sub-Assembly Retaining Ring (11) is completely seated in the groove of 1. Apply a coat of grease or petroleum jelly to Cluster Gear the Output Shaft (1A).
Page 115 SECTION 3 - CHASSIS & TURNTABLE 4. Place second set of sixteen Needle Rollers into Cluster 7. Line up Cluster Gear and thrust Washers with hole in Gear. Carrier and slide Planet Shaft through. Line up cham- fered side of hole in Planet Shaft with pin hole in Carrier. 5.
Page 116 SECTION 3 - CHASSIS & TURNTABLE 3-64 3121160...
Page 117: Swing Hub (Sn 0300074383 Through 0300134352)
SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING HUB (SN 0300074383 THROUGH Main Assembly Procedure 0300134352) 1. With the hub shaft sub-assembly resting on the shaft (1A) install internal gear (2). The spline of the internal Disassembly gear (2) bore will mesh the spline of the output shaft (1A).
Page 118 SECTION 3 - CHASSIS & TURNTABLE 4. Thrust spacer (9) is installed into the bore of the output 7. While holding ring gear (4) and cluster gears (3F) in mesh, place small side of cluster gears (3F) into mesh shaft (1A). This should be a slip fit and thrust spaces with the internal gear (2) and input gear (13).
Page 119 SECTION 3 - CHASSIS & TURNTABLE 9. Thrust washer (10) is installed onto the input gear (8) 12. The cover (6) is now installed on this assembly. Taking and should locate on the gear teeth shoulder. care to correctly align pipe plug hole (20) with those in the hub (1J), usually 90°...
Page 120: Hub Shaft Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE 15. Torque shoulder bolts (13) to 23-27 ft. lbs. and regular 3. Invert hub (1G) and press bearing cup (1E) into inter counterbore of hub (1G). grade 8 bolts (12) to 23-27 ft. lbs. 4.
Page 121 SECTION 3 - CHASSIS & TURNTABLE 6. The bearing cone (1F) is an interference fit and has to be 9. Retaining ring (1I) installed into groove provided in the pressed or tapped on. output shaft (1A). This retaining ring (1I) should never be reused in a repair or rebuild.
Page 122: Carrier Sub-Assembly
SECTION 3 - CHASSIS & TURNTABLE 11. Upon completion of step 10, rap the internal end of the 3. Place spacer washer into opposite side of cluster gear output shaft (1A) twice with a piece of soft metal rod. and against needle rollers. This will release the preload which was on the bearings.
Page 123 SECTION 3 - CHASSIS & TURNTABLE 5. Apply grease or petroleum jelly to the tang side of two 7. Line up cluster gear and thrust washer with hole in car- thrust washers. Place thrust washers against bosses in rier and slide planet shaft through. Line up chamfered carrier with washer tang fitting into slot in carrier out- side of hole in planet shaft with pin hole in carrier.
Page 124 SECTION 3 - CHASSIS & TURNTABLE 3-72 3121160...
Page 125: Swing Drive Brake (Prior To Sn 0300134352)
SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING DRIVE BRAKE (PRIOR TO SN Assembly 0300134352) 1. Lightly lubricate rotary shaft seal (12) and assemble to housing (2) taking care not to damage seal lip. Disassembly 2. Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing (2) bearing recess adjacent to 1.
Page 126 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 127: Swing Motor (Prior To Sn 0300134352)
SECTION 3 - CHASSIS & TURNTABLE 3.16 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 128: Swing Drive Motor (Prior To Sn 0300134352)
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 129 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 130 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 131 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 132 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 133 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 134: Assembly
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
Page 135 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 136 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 137 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 138 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 139 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 140 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 141: One Piece Stator Construction
SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.
Page 142: Swing Hub (Sn 0300134353 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING HUB (SN 0300134353 THROUGH Tightening and Torquing Bolts 0300185827) 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 143: Motor Control Valve Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32). NOTE: Refer to Figure 3-48. 5. Remove O-ring Plugs (23) from Motor Control Valve (32). 1.
Page 144: Motor And Brake Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 4. Remove the Springs (8L) from the piston. 5. Apply less than 50 psi (3.45 bar) air to the “brake port” to NOTE: Refer to Figure 3-49. remove Brake Piston (8A). 1.
Page 145: Main Drive Disassembly
SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly 5. Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Subassembly. NOTE: Refer to Figure 3-50. 6. Remove Ring Gear (4) from Housing (1G). 7. Remove O-ring (5) from between Ring Gear (4) and 1.
Page 146: Hub-Shaft Disassembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G). NOTE: Refer to Figure 3-51. NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by 1.
Page 147: Carrier Disassembly
SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E). NOTE: Refer to Figure 3-52. 3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).
Page 148: Hub-Shaft Assembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-52. NOTE: Refer to Figure 3-51. 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 149: Main Drive Assembly
SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing. NOTE: Refer to Figure 3-50. 9.
Page 150: Motor And Brake Assembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-49. NOTE: Refer to Figure 3-48. 1. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. 1. Lay assembly down with motor ports facing up. Remove splines) into bore of Brake Housing (6).
Page 151 SECTION 3 - CHASSIS & TURNTABLE 1001101060 A 1A. Output Shaft 1G. Housing 2. Internal Gear 5A. O-Ring 12. Bolt 1B. Lip Seal 1H. Thrust Washer 3. Carrier Assembly 6. Brake Housing 13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4.
Page 152 SECTION 3 - CHASSIS & TURNTABLE 1001101060 A 6. Brake Housing 8L. Spring 35. Tube 108. Rotor Set 117. Backup Washer 101. Bolt 109. Wear Plate 118. Housing 8A. Piston 21. Thrust Washer 8D. 0-Ring 22. Lock washer 102. End Cover 110.
Page 153: Swing Motor (Sn 0300134353 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING MOTOR (SN 0300134353 THROUGH 0300185827) Disassembly and Inspection 1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
Page 154: Swing Drive Motor (Sn 0300134353 Through 0300185827)
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 14. Thrust Washer 20. Dirt & Water Seal 3. Seal Ring-Commutator 8B. Stator or Stator Vane 4.
Page 155 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 156 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 157 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 158 SECTION 3 - CHASSIS & TURNTABLE NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and 0.020 in. (0.51 mm) diametrically, replace coupling shaft. discard seal 20. A blind hole bearing or seal puller is required. NOTE: A slight “polish”...
Page 159 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 160: Assembly
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
Page 161 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 162 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 163 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 164 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 165 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 166 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 bolt end cover bolt hole relationship to housing port bosses.
Page 167 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts bolts after the other bolts are in place.
Page 168: One Piece Stator Construction
SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.
Page 169: Rotary Coupling (Prior To Sn 0300138447)
SECTION 3 - CHASSIS & TURNTABLE 3.19 ROTARY COUPLING (PRIOR TO SN 0300138447) 5. Assemble lip seals (2) in direction shown in Figure 3-56., Rotary Coupling Seal Installation (Prior to SN Use the following procedure to install the seal kit. 0300138447).
Page 170 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 5. Cap Seal 2. Seal 6. Ring 3. Housing 7. Retaining Ring 4. O-ring Figure 3-57. Rotary Coupling Cutaway (Prior to SN 0300138447) 3-118 3121160...
Page 171 SECTION 3 - CHASSIS & TURNTABLE 1660223 C Figure 3-58. Rotary Coupling Port Location (9 Port) (Prior to SN 0300138447) 3121160 3-119...
Page 172 SECTION 3 - CHASSIS & TURNTABLE 1. Loctite #242 6. Rotary Coupling 10. Torque Lug 14. Bearing 2. Bolt 7. Spool 11. Ring 15. Cap Seal 3. Bolt 8. Retaining Ring 12. Seal 16. O-ring 4. Bolt 9. Plug 13. O-ring 17.
Page 173: Rotary Coupling (Sn 0300138447 Through 0300185827)
SECTION 3 - CHASSIS & TURNTABLE 3.20 ROTARY COUPLING (SN 0300138447 6. Remove proximity switch. 7. Assemble lip seals (2) in direction shown in Figure 3-56., THROUGH 0300185827) Rotary Coupling Seal Installation (Prior to SN Use the following procedure to install the seal kit. 0300138447).
Page 174 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 3-61. Rotary Coupling Cutaway (SN 0300138447 through 0300185827) 3-122 3121160...
Page 175 SECTION 3 - CHASSIS & TURNTABLE Figure 3-62. Rotary Coupling Port Location (9 Port) (SN 0300138447 through 0300185827) 3121160 3-123...
Page 176 SECTION 3 - CHASSIS & TURNTABLE 1. JLG Threadlocker 6. Rotary Coupling 11. Ring 16. O-ring 21. Bolt 2. Bolt 7. Spool 12. Seal 17. Valve 22. Nut 3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 23. Washer 4.
Page 177 SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Coupling Port Information Table (9 port) (Prior to Table 3-10. Coupling Port Information Table (9 port) (SN SN 0300138447) 0300138447 through 0300185827) Operating Proof Operating Proof Port Port Port Size Description Pressure Pressure Port Size Description...
Page 178: Tilt Alarm Switch
SECTION 3 - CHASSIS & TURNTABLE 3.21 TILT ALARM SWITCH 3.22 SPARK ARRESTER CLEANING INSTRUCTIONS 1. Remove the cleanout plug in the bottom of spark arrester (muffler). PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY 2. Without causing deformation (or any type of damage to SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.
Page 179 SECTION 3 - CHASSIS & TURNTABLE 1. DC Motor 7. Spider 13. Washer 19. Retaining Ring 25. Spring 31. Screw 2. Coupling Half 8. Pin 14. Screw 20. Gear 26. Ball 32. Dowel Bushing 3. Washer 9. Idler Shaft 15. Gasket Kit 21.
Page 180: Auxiliary Pump
SECTION 3 - CHASSIS & TURNTABLE 1. Auxiliary Pump 2. Hydraulic Tank Figure 3-66. Auxiliary Pump Location 3-128 3121160...
Page 181: Deutz Engine
SECTION 3 - CHASSIS & TURNTABLE 3.23 DEUTZ ENGINE 1. Radiator Mounting 4. Air Cleaner 6. Piston Pump 8. Deutz ENgine 2. Fan 5. Gear Pump 7. Pump Adapter Plate 9. Oil Cooler 3. Exhaust Tube Figure 3-67. Deutz Engine Assembly (SN 0300077500 through 0300185827) - Sheet 1 of 2 3121160 3-129...
Page 182 SECTION 3 - CHASSIS & TURNTABLE SUPPLY VENT FUEL PUMP SUPPLIED WITH ENGINE RETURN 10. Engine Tray 13. Hitch Pin 16. Rubber Panel 11. Battery 14. EGR Relay 17. Fuel Filter 12. Fuel Tank 15. Battery Hold-Down Figure 3-68. Deutz Engine Assembly (SN 0300077500 through 0300185827) - Sheet 2 of 2 3-130 3121160...
Page 183: Ford Engine
SECTION 3 - CHASSIS & TURNTABLE 3.24 FORD ENGINE 1. Ford LRG-425 Engine 5. Fan 9. Air Cleaner 13. Muffler 2. Radiator Mount 6. Pump Coupling 10. EPM Module 14. Radiator 3. Battery 7. Piston Pump 11. Gear Pump 15. Fuel Pump 4.
Page 184 SECTION 3 - CHASSIS & TURNTABLE 1. Ford Engine 5. Engine Mount 9. Air Cleaner 12. Pressure Regulator and Filter 2. Radiator Mount 6. Coupling Pump 10. Muffler 13. Engine Mount (Rear) 3. Radiator 7. Piston Pump 11. Engine Mount (Front) 14.
Page 185 SECTION 3 - CHASSIS & TURNTABLE 15. Engine Tray 18. Fuel Tank 21. Rubber Panel 23. Fuel Filter 16. Battery 19. Fuel Pump Mount 22. Battery Hold-Down 24. Fuel Pump 17. Hitch Pin 20. ECM Mount Figure 3-71. Ford Engine Assembly (SN 0300077500 through 0300185827) - Sheet 2 of 2 3121160 3-133...
Page 186: Gm Engine
SECTION 3 - CHASSIS & TURNTABLE 3.25 GM ENGINE 1. GM Engine 5. Piston Pump 9. Radiator 12. Battery Hold-Down 2. Engine Tray 6. Gear Pump 10. Rubber Panel 13. Engine Mount (Front) 3. Battery 7. Radiator Mount 11. Fan 14.
Page 187 SECTION 3 - CHASSIS & TURNTABLE 15. Oil Filter 18. LP Hose 16. Fuel Tank 19. Intake Tube 17. Fuel Filter Figure 3-73. GM Engine Assembly (Prior to SN 0300140592) - Sheet 2 of 2 3121160 3-135...
Page 188 SECTION 3 - CHASSIS & TURNTABLE 1. GM Engine 6. Fan 11. Muffler 15. Engine Mount (Front) 2. Engine Tray 7. Piston Pump 12. Relay 16. Engine Mount (Rear) 3. Battery 8. Gear Pump 13. Control Module (ECU) 17. Intake Tube 4.
Page 189 SECTION 3 - CHASSIS & TURNTABLE 19. Fuel Filter Bracket 22. Fuel Tank 20. Tube (Fuel Line) 23. Fuel Filter 21. LP Hose Figure 3-75. GM Engine Assembly (SN 0300140592 through 0300185827) - Sheet 2 of 2 3121160 3-137...
Page 190: Generator
SECTION 3 - CHASSIS & TURNTABLE 3.26 GENERATOR Overload Protection Every 250 hours STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Every 250 hours of operation, check the drive belt for proper BREAKER. tension. The circuit breaker protects the generator windings from over- load.
Page 191 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 192 SECTION 3 - CHASSIS & TURNTABLE 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. Reset circuit breaker CB1.
Page 193: Dual Fuel System
• Inspect intake air system and air filter for restrictions. 4. If a diagnostic trouble code (DTC) is stored, contact a JLG • Inspect battery condition and starter current draw. distributor to make an effective repair.
Page 194: Engine Module And Sensors
SECTION 3 - CHASSIS & TURNTABLE Engine Module and Sensors ENGINE COOLANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor is a g thermistor (a resistor which changes value based on temperature) CRANKSHAFT POSITION (CKP) SENSOR mounted in the engine coolant stream. Low coolant tempera- The crankshaft position (CKP) sensor provides a signal used by ture produces a high resistance of 100,000 ohms at -40°C the Engine Module to calculate the ignition sequence.
Page 195 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. ECM Diagnostic Trouble Codes Diagnostic Trouble Description Code All Systems OK Throttle Position (TP) Sensor Low Voltage Manifold Absolute Pressure (MAP) Low Voltage Overspeed Throttle Position (TP) Sensor High Voltage Manifold Absolute Pressure (MAP) High Voltage Fuel Pump Low Voltage Heated Oxygen Sensor (HO2S) Low Voltage Engine Coolant Temperature (ECT) Sensor High Voltage...
Page 196 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code Closed Loop Multiplier High (LPG) This fault sets if the Closed Loop multiplier exceeds the limits of normal operation and cannot correctly modify the fuel flow within its limits.
Page 197 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code IAT High Voltage This fault will set if the signal voltage is more than 4.95 volts anytime the engine is running. The EPM will use the default value for the IAT sensor in the event of this fault.
Page 198 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code Injector Driver #1 Open (2.5L) This fault will set if the EPM detects low feedback voltage on the internal injector while the injector drive circuit is in the off-state and battery voltage is greater than 9 volts.
Page 199 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code FPP1 Low Voltage This fault will set if voltage is less than 0.2 volts at any operating condition while the key is on. If the voltage is less than 0.2, then FPP1 is considered to be out of specifications.
Page 200 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code TPS1 Lower Than TPS2 This fault will set if TPS1 is 20% (or more) lower than TPS2. At this point the throttle is considered to be out of specification, or there is a problem with the TPS signal circuit.
Page 201 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. EPM Diagnostic Trouble Codes Diagnostic Trouble Description Cause for Setting DTC Code Flash Checksum Invalid Several different things can happen within the microprocessor that will cause this fault. The EPM will reset itself in the event this fault is set, and the MIL will be on until the code is cleared. This fault should be erased after diagnosis by removing battery power.
Page 202 SECTION 3 - CHASSIS & TURNTABLE ELECTRICALLY ERASABLE PROGRAMMABLE READ INTAKE AIR TEMPERATURE (IAT) SENSOR ONLY MEMORY (EEPROM) The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air enter- The electrically erasable programmable read only memory ing the engine.
Page 203 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-151...
Page 204: Ecm/Epm Identification
SECTION 3 - CHASSIS & TURNTABLE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The Engine Module supplies either 5 or 12 volts to power vari- ous sensors or switches. The power is supplied through resis- The manifold absolute pressure (MAP) sensor responds to tances in the Engine Module which are so low in value that a changes in intake manifold pressure (vacuum).
Page 205 SECTION 3 - CHASSIS & TURNTABLE ENGINE MODULE SERVICE PRECAUTIONS The Engine Module calculates fuel delivery based on throttle valve angle (operator demand). A broken or loose TP sensor The Engine Module is designed to withstand normal current may cause intermittent bursts of fuel from an injector and draws associated with engine operation.
Page 206 SECTION 3 - CHASSIS & TURNTABLE Figure 3-78. ECM/EPM Identification 3-154 3121160...
Page 207: Fuel System
SECTION 3 - CHASSIS & TURNTABLE ELECTROSTATIC DISCHARGE DAMAGE A fuel injector which is stuck partly open will cause a loss of fuel pressure after the engine is shut down, causing long crank Electronic components used in the Engine Module are often times.
Page 208 SECTION 3 - CHASSIS & TURNTABLE HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-79. Typical Fuel System FUEL METERING SYSTEM PURPOSE The Engine Module monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is deliv- The basic function of the air/fuel metering system is to control ered under one of several conditions called "modes."...
Page 209 SECTION 3 - CHASSIS & TURNTABLE FUEL PRESSURE REGULATOR FUEL RAIL The fuel pressure regulator is a relief valve mounted in the fuel The fuel rail is mounted to the top of the engine and distrib- filter. It provides a constant fuel pressure of 441 kPa (64 psi). utes fuel to the individual injectors.
Page 210 SECTION 3 - CHASSIS & TURNTABLE The electronic governor also acts as an idle air control (IAC) CAMSHAFT POSITION (CMP) SENSOR valve. Changes in engine load are detected by the Engine The CMP sensor uses a variable reactor sensor to detect cam- Module by comparing manifold absolute pressure (MAP) with shaft position.
Page 211 SECTION 3 - CHASSIS & TURNTABLE ELECTRONIC IGNITION ENGINE MODULE (ECM OR EPM) The electronic ignition system controls fuel combustion by The Engine Module is responsible for maintaining proper providing a spark to ignite the compressed air/fuel w mix- spark and fuel injection timing for all operating conditions. To ture at the correct time.
Page 212: Ford Lpg System
SECTION 3 - CHASSIS & TURNTABLE 3.29 FORD LPG SYSTEM Megajector The megajector is an electronic pressure regulator. This elec- NOTE: +20° F (-6.6° C) is the low temperature limit for LP gas, for tronic regulator outputs a specific pressure needed at the both starting and operation.
Page 213: Lpg System Components
SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid Figure 3-80. LPG System Components 3121160 3-161...
Page 214: Lockoff Solenoid
The following diagnostic codes are specific to the megajector. c. Lockoff Solenoid - Check the lock off to make sure They will be displayed on the analyzer if the JLG Control Sys- it is opening properly. If it is not opening com- tem senses a fault dealing with the megajector.
Page 215: Electric Governor Installation And Adjustments - Ford Lrg425 Engine
Repair as necessary and retest. tion made in the least amount of time. b. Megajector - Megajector has an internal failure. Contact JLG Industries for further assistance. Quick-start Installations DTC 364 - Megajector Internal Circuitry Fault Detection. If you are experienced in installing and adjusting Electric Gov- a.
Page 216: Linkage
SECTION 3 - CHASSIS & TURNTABLE Linkage 1/4 in. -28 threaded rod and low friction rod-end bearings are recommended for linkage materials. Keep the linkage as short and as straight as possible. The linkage must not rub against the engine, brackets, hoses, etc.
Page 217: Wiring
SECTION 3 - CHASSIS & TURNTABLE Wiring Check-Out and Initial Start-Up Procedures Before proceeding, familiarize yourself with the locations of See wiring diagram for details of hook-up. the various adjustment pots. Use #16 wire minimum. Adjustments: Keep all wiring to the Governor as short as is practical. High engine Mid engine Go directly from the controller ground terminal (B of the 8 pin...
Page 218 SECTION 3 - CHASSIS & TURNTABLE MID ENGINE: FACTORY: This adjustment is made by turning the 1/8 in. brass screw This adjustment is made by turning the plastic screw clock- clockwise (CW ) to increase speed, and counterclockwise wise (CW) to increase governor sensitivity, counterclockwise (CCW) to decrease speed.
Page 219 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-167...
Page 220: Troubleshooting
SECTION 3 - CHASSIS & TURNTABLE 8. The overspeed adjustment is factory set. If necessary, it • Governor won’t work. may be readjusted to shut off ignition power at a differ- No reaction from Governor. Actuator output arm never ent engine speed by means of the overspeed adjust- moved, engine off or engine running.
Page 221 SECTION 3 - CHASSIS & TURNTABLE (2.) Incorrect Linkage - Re-check linkage. The freedom of If steps 1a. through 1e. can be accomplished as described, the movement and lack of play are important. Governor is probably OK. It recognizes underspeed, over- speed, onspeed and is not binding internally.
Page 222: Automatic Choke Adjustment Procedure
(For all JLG 1.IL and 2.3L Ford carbureted engines) The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control Sys- 1. At 70°F the choke plate should be open 1/3” (not touch- tem are connected by means of separate cable harnesses to ing the choke bore).
Page 223: Emr 2 Engine Side Equipment
SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE & FAULT OIL PRESSURE REPORTING.
Page 224 SECTION 3 - CHASSIS & TURNTABLE 3-172 3121160...
Page 225 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-173...
Page 226 SECTION 3 - CHASSIS & TURNTABLE 3-174 3121160...
Page 227 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-175...
Page 228: Emr 2 Engine Plug Pin Identification
SECTION 3 - CHASSIS & TURNTABLE Figure 3-87. EMR 2 Engine Plug Pin Identification 3-176 3121160...
Page 229: Emr 2 Vehicle Plug Pin Identification
SECTION 3 - CHASSIS & TURNTABLE Figure 3-88. EMR 2 Vehicle Plug Pin Identification 3121160 3-177...
Page 230 SECTION 3 - CHASSIS & TURNTABLE 3-178 3121160...
Page 231 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-179...
Page 232 SECTION 3 - CHASSIS & TURNTABLE 3-180 3121160...
Page 233 SECTION 3 - CHASSIS & TURNTABLE 3121160 3-181...
Page 234 SECTION 3 - CHASSIS & TURNTABLE 3-182 3121160...
Page 235: Gm Engine General Maintenance
SECTION 3 - CHASSIS & TURNTABLE 3.32 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 236: Changing The Engine Oil
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 237 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 238: Gm Engine Dual Fuel System
SECTION 3 - CHASSIS & TURNTABLE 3.33 GM ENGINE DUAL FUEL SYSTEM Electric Lock Off The Electric Lock Off device is an integrated assembly. When NOTE: +20° F (-6.6° C) is the low temperature limit for LP gas, for energized the solenoid opens the valve and allows the Pro- both starting and operation.
Page 239: Low Pressure Regulator (Lpr)
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 240: Electronic Throttle Control (Etc)
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 241: Heated Exhaust Gas Oxygen Sensor
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 242: Fuel Filter
SECTION 3 - CHASSIS & TURNTABLE Fuel Filter 3.34 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 243: Propane Fuel Filter Replacement
SECTION 3 - CHASSIS & TURNTABLE Propane Fuel Filter Replacement 1. Electric Lock Off Solenoid 7. Electrical Connector 2. Mounting Plate 8. Fuel Outlet 3. Housing Seal 9. O-ring 4. Filter Magnet 10. Filter 5. Filter Housing 11. Fuel Inlet 6.
Page 244: Electronic Pressure Regulator (Epr) Assembly Replacement
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 245: Temperature Manifold Absolute Pressure (Tmap) Sensor
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 3-106. Pressure Regulator Section PRESSURE REGULATOR SECTION REMOVAL Figure 3-107.
Page 246: Electronic Throttle Control Replacement
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 See Figure 3-107. throttle body. REMOVAL 1.
Page 247: Mixer Replacement
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 248: Engine Control Module Replacement
SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Replacement 3.35 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS REMOVAL Fuel System Description 1. Disconnect Negative battery cable. 2. Remove controller from mounting bracket. 3. Push connector lock back to unlock connector. 4.
Page 249: Diagnostic Aids
SECTION 3 - CHASSIS & TURNTABLE Diagnostic Aids Pressure Gauges • IMPCO ITK-2 Test kit This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to • Water Column Gauge / Manometer (GM 7333-6 or equiva- Hard Start for preliminary checks.
Page 250 SECTION 3 - CHASSIS & TURNTABLE Table 3-14. 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 251 SECTION 3 - CHASSIS & TURNTABLE Table 3-14. 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 252 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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 253 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp The following components can cause intermittent MIL and no DTC(s): (MIL) ² 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 254 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Exhaust System Checks ² 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. ²...
Page 255 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Additional Checks ² 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 256 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. 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. ²...
Page 257 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. ² Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. ²...
Page 258 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Additional Check ² Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual. ² Check for dragging brakes. Rough, Unstable, or Incorrect Idle, Stalling DEFINITION: The engine runs unevenly at idle.
Page 259 SECTION 3 - CHASSIS & TURNTABLE Table 3-15. Symptom Diagnosis Checks Action Fuel System Checks ² 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.
Page 260 SECTION 3 - CHASSIS & TURNTABLE Table 3-16. 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 261 SECTION 3 - CHASSIS & TURNTABLE Table 3-16. 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 262: Air Compressor
SECTION 3 - CHASSIS & TURNTABLE 3.36 AIR COMPRESSOR Air Filter Unit The air filter is dry type replaceable element and is mounted Description directly on top of the inlet valve assembly. The element is eas- ily replaced for service changeout - Refer to Maintenance Sec- The compressor consists of a heavy duty rotary screw air com- tion.
Page 263 SECTION 3 - CHASSIS & TURNTABLE 1. Compressor Assembly 2. Air Filter Element 3. Coalescer Spin-On Element 4. Oil Filter Element Figure 3-110. Air Compressor 3121160 3-211...
Page 264: Minimum Pressure Valve/Check Valve Assembly
SECTION 3 - CHASSIS & TURNTABLE Minimum Pressure Valve/Check Valve Assembly Compressor Cooling System The package contains a cooler assembly powered by a 12 volt This combined valve located in the filter support housing has D.C. electric fan. Oil from the compressor sump passes two functions.
Page 265: Normal Startup Procedure
SECTION 3 - CHASSIS & TURNTABLE 15. Allow all air to vent to atmosphere, then check compres- General Maintenance sor oil level - top up if necessary. Check and correct any leaks, tighten any loose fittings, check drive belt tension. A good maintenance program is the key to long compressor life.
Page 266: Lubrication Guide
SECTION 3 - CHASSIS & TURNTABLE Lubrication Guide tion to the primary oil characteristics, good water sepa- ration is required. These lubricants should be applied where conditions IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOMMENDED TYPE above 32°F (0°C) prevail. AND THAT IT IS INSPECTED AND REPLACED TOGETHER WITH THE OIL AND AIR FILTERS, IN ACCORDANCE WITH THIS MANUAL.
Page 267: Coalescer (Air/Oil Separator) Replacement
SECTION 3 - CHASSIS & TURNTABLE Coalescer (Air/Oil Separator) Replacement Belts - Tightening and Replacement This is a spin-on, throw away type unit. Before attempting to Correct tensioning and alignment is important for belt life, change ensure all pressure is relieved from the system. Change bearing life and power transmission.
Page 268: Cooler Core Cleaning (Exterior)
SECTION 3 - CHASSIS & TURNTABLE Cooler Core Cleaning (Exterior) Pressure Adjustments Remove leaves, papers, etc. from outside face. Use com- Before adjusting the pressure control system it is necessary to pressed air and carefully blow through the core from the determine the rated full load pressure setting.
Page 269: Intake Control
SECTION 3 - CHASSIS & TURNTABLE Intake Control Safety Shutdown Systems Protection for over-pressure and/or over-temperature is pro- The intake control consists of two main sub-assemblies: vided. If either condition should occur the diverter valve should activate to divert hydraulic fluid back to tank and the 1.
Page 270 SECTION 3 - CHASSIS & TURNTABLE Table 3-18. Air Compressor Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION 1. Compressor shuts down with air demand a. Compressor temperature; switch opening. a. Low oil level-top up. Restricted cooling air intake- clean- reposition machine. Fan not operating-check ground-check fan switch.
Page 271 SECTION 3 - CHASSIS & TURNTABLE Table 3-18. Air Compressor Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION 5. Oil carryover a. Oil level overfull a. Drain to correct level b. Plugged oil scavenge line b. Remove and clean c. Discharge pressure too low c.
Page 272: Counterweight
Figure 3- 111., Counterweight. A. Actual Weight Stamping B. Apply JLG Threadlocker P/N 0100011 to Bolt Threads and to Threads in Counterweight. C. Torque to 285 ft. lbs. (386 Nm). Typical Four Places. Figure 3-111. Counterweight...
Page 273: Boom & Platform
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM 4. Remove the bolts and locknuts securing the support to the rotator. Platform/Support Removal CENTER BOLT ROTATOR BOLTS LOCKNUT 5. Using a suitable brass drift and hammer, remove the center bolt and locknut.
Page 274: Support Installation
6. Connect the electrical harness to the platform control console. 3. Apply JLG Threadlocker P/N 0100011 to the eight bolts securing the support to the rotator and install the bolts. 4. Torque the nut on the rotator center bolt and the retain- ing bolts.
Page 275 NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. 0258766 E Torque to 85 ft. lbs. (116 Nm) JLG Threadlocker P/N 0100011 Torque to 480 ft. lbs. (651 Nm) Check torque every 150 hours of operation Torque to 40 ft. lbs. (55 Nm) Figure 4-2.
Page 276: Rotator And Slave Cylinder
SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR AND SLAVE CYLINDER Installation 1. Telescope the fly section out approximately 20 in. Removal (50.8 cm) to gain access to the slave leveling cylinder. 1. Tag and disconnect hydraulic lines to rotator and slave 2.
Page 277: Main Boom Powertrack
SECTION 4 - BOOM & PLATFORM 4.3 MAIN BOOM POWERTRACK Installation Removal 1. Using suitable lifting device, adequately support the powertrack weight along entire length. 1. Disconnect wiring harness connectors located in tower 2. With powertrack supported and using all applicable upright.
Page 278: Powertrack Maintenance
SECTION 4 - BOOM & PLATFORM 4.4 POWERTRACK MAINTENANCE Round Bar/Poly Bar Removal 1. Use a small 1/4 in. ratchet with a T-25 Torx bit. Remove Flat Bar Removal the 10-24 x 0.812 screw. (If the bar spins then grip the bar and poly tightly with a vise-grip).
Page 279: Removing And Installing Links
SECTION 4 - BOOM & PLATFORM 3. While gripping the bar tightly, remove the other Removing and Installing Links 10-24 x 0.812 screw. 1. To remove the links, the rivets holding the links together must be removed. The following will show one way this can be done.
Page 280 SECTION 4 - BOOM & PLATFORM 3. After grinding, it is sometimes necessary to use a center 4. To install new links, extend the upper moving end over punch to punch out the rivet from the link. the lower part of the track so the new connection point is in the curved part of the track.
Page 281 SECTION 4 - BOOM & PLATFORM 5. Install the pin into the center hole, then slide the washer NOTE: When installing snap rings make sure they are seated in over the pin. Install the snap ring into the groove in the the pin groove and closed properly.
Page 282: Installing A New Flat Bar
SECTION 4 - BOOM & PLATFORM 6. Install more pins, washers, and snap rings into all the Installing a New Flat Bar links where a rivet was removed. 1. While holding the flat bar, install new 8-32 x 0.500 self threading torx screws into both holes on each side of track.
Page 283: Installing A New Round Bar/Poly Roller
SECTION 4 - BOOM & PLATFORM Installing a New Round Bar/Poly Roller NOTE: Maximum tightening torque for the 10-24 screw is 45-50 in. lbs. (5-5.6 Nm.). 1. While tightly holding the round bar, install the new 10-24 x 0.812 self threading torx screw. Next lift up the Replacing a Fixed End Bracket other end and slide a new poly roller on.
Page 284: Replacing A Moving End Bracket
SECTION 4 - BOOM & PLATFORM Replacing a Moving End Bracket Replacing a One Piece Bracket 1. Remove bracket by removing all pins, washers, and snap 1. Remove all pins, washers, and snap rings and slide the rings. Replace with a new bracket and reinstall the pins, bracket off of the links.
Page 285: Boom Cleanliness Guidelines
1. JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom.
Page 286: Main Boom Assembly
SECTION 4 - BOOM & PLATFORM 4.6 MAIN BOOM ASSEMBLY c. Remove the bolt and keeper pin securing the mas- ter cylinder barrel end pin to the base boom sec- tion. Next, install a 3/8-16 UNC threaded lifting eye Removal into the threaded hole of the pin and pull pin out.
Page 287: Disassembly
SECTION 4 - BOOM & PLATFORM 6. Remove hardware securing the boom pivot pin to the Disassembly upright. Using a suitable brass drift and hammer, remove the pivot pin from upright. 1. Remove hardware securing telescope cylinder to after end of the base boom section. 2.
Page 288: Inspection
SECTION 4 - BOOM & PLATFORM Inspection Assembly NOTE: When inspecting pins and bearings Refer to Section 2, Pins NOTE: When installing fly section wear pads, install same number and Composite Bearing Repair Guidelines. and thickness of shims as were removed during disassem- bly.
Page 289: Installation
SECTION 4 - BOOM & PLATFORM Installation b. Install the master cylinder rod end pin. Install the bolt and keeper pin securing the master cylinder 1. Using all applicable safety precautions, carefully lift rod end pin to the upright. boom assembly to align the pivot holes in the boom with those of the upright.
Page 290: Upright
SECTION 4 - BOOM & PLATFORM 4.7 UPRIGHT Upright Level Cylinder Removal 1. With upright removed, override tower telescope limit Removal switch and extend the tower boom to gain access to the upright level cylinder barrel end attach pin. 2. Tag and disconnect hydraulic lines to the upright lift cyl- HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- inder.
Page 291: Tower Boom Assembly
SECTION 4 - BOOM & PLATFORM 4.8 TOWER BOOM ASSEMBLY Inspection NOTE: Refer to Section 2, Pins and Composite Bearing Repair Removal Guidelines. 1. Inspect tower boom pivot pin for wear scoring, tapering, and ovality, or other damage. Replace pins as necessary. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.
Page 292: Installation
SECTION 4 - BOOM & PLATFORM Installation Tower Out of Sync Tower is out of sync backwards, upright leaning toward the 1. Using a suitable lifting device, position the tower boom platform. such as to align upright leveling cylinder with attach holes in tower boom.
Page 293 SECTION 4 - BOOM & PLATFORM 3. The counterbalance valve in the piston end of the Tower is out of sync forwards, upright leaning toward the upright level cylinder. There could be a leak path from steer axle. the valve port to the pilot port. Replace the counterbalance valve.
Page 294 SECTION 4 - BOOM & PLATFORM 2. The counterbalance valve in the piston end of the 3. The counterbalance valve in the rod end of the lower lift upright level cylinder. There could be a leak path from cylinder. There could be a leak path from the pilot port the pilot port to the valve port.
Page 295: Articulating Jib Boom
SECTION 4 - BOOM & PLATFORM 4.9 ARTICULATING JIB BOOM Inspection NOTE: When inspecting pins and bearings Refer to Section 2 - Pins Removal and Composite Bearing Repair Guidelines. 1. For platform/support removal see platform/support removal diagram. 1. Inspect articulating fly boom pivot pin for wear, scoring, tapering and ovality, or other damage.
Page 296: Assembly
SECTION 4 - BOOM & PLATFORM Assembly 4.10 LIMIT SWITCHES ADJUSTMENT 1. Align lift cylinder with attach holes in articulating jib Main Boom Horizontal Limit Switch boom. Using a soft head mallet, install cylinder pin #7 into articulating jib boom and secure with mounting 1.
Page 297 SECTION 4 - BOOM & PLATFORM VIEW B VIEW A SUGGESTED SWITCH ORIENTATION SWITCH ORIENTATION INITIAL ARM SUGGESTED POSITION INITIAL ARM SETTING MOUNTING MOUNTING POSITION SURFACE REF. SURFACE REF. SETTING SWITCH TO ACTIVATE WHEN MAIN BOOM IS RAISED TO 5° TO 10° ABOVE HORIZONTAL.
Page 298 SECTION 4 - BOOM & PLATFORM LIMIT SWITCH CABLE ROUTING SECTION D-D LIMIT SWITCH CABLE ROUTING SECTION C-C 0271989 D Figure 4-10. Boom Valve and Limit Switches Location - Sheet 2 of 2 4-26 3121160...
Page 299: Platform
SECTION 4 - BOOM & PLATFORM 4.11 PLATFORM 4.12 WEAR PADS Platform Sections Replacement Tower Boom The platform is made up of five sections: floor, right side, left 1. Shim up wear pads until 1/32 in. (0.79 mm) clearance to side, back (console box mounting) and gate.
Page 300: Main Boom
SECTION 4 - BOOM & PLATFORM Main Boom 4.13 ROTATOR - HELAC (PRIOR TO SN 0300130881) 1. Shim up wear pads to within 1/32 in. (0.79 mm) Disassembly clearance between wear pad and adjacent surface. 1. Place actuator on a clean workbench. 2.
Page 301: Inspection
SECTION 4 - BOOM & PLATFORM 4. Using a torch, apply heat to the setscrews on the bottom 7. Remove the shaft (2) from piston sleeve (3) and the actu- of actuator. ator housing (1). Figure 4-14. Heating Setscrews 5. Remove the two (2) setscrews (4) from bottom of the actuator (1).
Page 302: Assembly
SECTION 4 - BOOM & PLATFORM Assembly NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. 1. Install piston seal (7) and rod seal (6) on the piston sleeve (3). NOTE: Apply a coat of grease to the thrust ring before sliding onto the shaft.
Page 303 SECTION 4 - BOOM & PLATFORM Figure 4-20. Rotator Assembly (HELAC) 3121160 4-31...
Page 304: Rotator Assembly (Sn 0300130881 Through 0300185827)
SECTION 4 - BOOM & PLATFORM 4.14 ROTATOR ASSEMBLY (SN 0300130881 The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from THROUGH 0300185827) the housing by the upper and lower thrust washers. The end cap is adjusted for axial clearance and locked in position by set Theory of Operation screws or pins.
Page 305 SECTION 4 - BOOM & PLATFORM The seal tool is merely a customized standard flat head screw- driver. To make this tool you will need to heat the flat end with a torch. Secure the heated end of the screwdriver in a vice and physically bend the heated end to a slight radius.
Page 306 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 307: Disassembly
SECTION 4 - BOOM & PLATFORM Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). 1. Remove the capscrews (113) over end cap lock pins (109). If the pin will not come out with the ”Easy Out”, use 5/16 in.
Page 308 SECTION 4 - BOOM & PLATFORM 6. Remove the end cap (4) and set aside for later inspec- 8. Every actuator has timing marks for proper engage- tion. ment. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator.
Page 309 SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the 13. 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 310 SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202). cut them using a sharp razor blade being careful not to damage the seal groove. 20.
Page 311: Inspection
SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123” or 3.12 mm). 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting. Carefully inspect all criti- cal areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.
Page 312 SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto (4). shaft (2) and end cap (4). Use the seal tool in a circular motion.
Page 313 SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using a 7. Insert the piston (3) into the housing (1) as shown, until circular motion. Install the outer T-seal (202) by stretch- the outer piston seal (202) is touching inside the hous- ing it around the groove in a circular motion.
Page 314 SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) you 11. Looking from the view shown, use the existing timing can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the tap the piston (3) in until the gear teeth mesh together.
Page 315 SECTION 4 - BOOM & PLATFORM 14. Coat the threads on the end of the shaft with anti-seize 17. Tighten the end cap (4). In most cases the original holes grease to prevent galling. for the lock pins will line up. 18.
Page 316: Installing Counterbalance Valve
SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. Loctite Refer to Figure 4-23., Rotator Counterbalance Valve. #242 should be applied to the shank of the three bolts at the time of installation.
Page 317: Testing The Actuator
SECTION 4 - BOOM & PLATFORM Testing the Actuator If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the pressure at which the shaft begins to rotate — should be approximately 400 psi (28 bar).
Page 318: Troubleshooting
SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.
Page 319: Drive Card Setup Procedures
Turn P3 counter clockwise 2. Install test harness JLG P/N 4922012. until the adjustment pot starts clicking. Place a current 3. Set the minimum and maximum currents. The input meter in series with the “A”...
Page 320: Foot Switch Adjustment
SECTION 4 - BOOM & PLATFORM 4.16 FOOT SWITCH ADJUSTMENT Adjust so that functions will operate when pedal is at center of travel. If switch operates within last 1/4 in. (6.35 mm) of travel, top or bottom, it should be adjusted. 4.17 UPRIGHT MONITORING SYSTEM The UMS provides a visual and audible warning to the operator when the limits of the upright assembly alignment have been...
Page 321 SECTION 4 - BOOM & PLATFORM 3121160 4-49...
Page 322: Calibration - Pre Ade Machines
SECTION 4 - BOOM & PLATFORM Calibration - Pre ADE Machines a. In access level 1, scroll through the menu items until "CALIBRATIONS" is displayed on the second line of the analyzer screen as shown below. CALIBRATION OF THE UPRIGHT MONITORING SYSTEM REQUIRES THE MACHINE TO BE ON A FIRM AND LEVEL SURFACE WITH SUFFICIENT OVERHEAD CLEARANCE TO FULLY ELEVATE THE TOWER BOOM.
Page 323 SECTION 4 - BOOM & PLATFORM c. Press "ENTER" , and the following screen will THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION. be displayed asking if you wish to calibrate the upright monitoring system. e. Verify the machine is level and press "ENTER" The screen will display the following, asking you to fully elevate the main boom.
Page 324 SECTION 4 - BOOM & PLATFORM NOTE: By pressing the left or right arrows in this screen, you may If the calibration is executing properly, you shall see view the output of each sensor. the following display: g. Pull and hold the red re-leveling knob on the hydraulic tank while lifting the tower boom.
Page 325 SECTION 4 - BOOM & PLATFORM release the function switch and press "ENTER" j. If the calibration has not been completed success- fully, the display will automatically change to: . The analyzer will display the following mes- sage: Repeat step i until the calibration time requirement has been satisfied.
Page 326: Calibration - Ade Equipped Machines
Calibration - ADE Equipped Machines b. After pressing 'ENTER" one of the following 1. Connect the JLG Hand-held analyzer to the original ana- screens will be displayed: lyzer connection in the ground box. DO NOT CONNECT TO THE ANALYZER CONNECTION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE.
Page 327 SECTION 4 - BOOM & PLATFORM e. Press "ENTER" and the next screen will display IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THE GROUND CON- the following, asking if the machine is on a level sur- TROL MODULE AT THIS TIME. HOWEVER, WHEN THE TILT SENSOR IN THE face: GROUND CONTROL MODULE IS RECALIBRATED, THE UPRIGHT MONITORING SYSTEM TILT SENSOR MUST BE RECALIBRATED AS WELL.
Page 328 SECTION 4 - BOOM & PLATFORM g. After the main boom has been fully elevated, press quate sensor activity, the screen will display: "ENTER" . The analyzer will display the follow- ing: Should you get the above message, verify that the sensor is installed correctly and verify the sensor connection to the sensor harness is secure.
Page 329 SECTION 4 - BOOM & PLATFORM i. When viewing above display, press The analyzer will display the following message: "ENTER" . The screen will display the following: If the calibration has been completed successfully, the screen will automatically change to: j.
Page 330: Calibration Faults
SECTION 4 - BOOM & PLATFORM If the calibration has not been completed success- Calibration Faults fully, the display will automatically change to: CAL Failed-Chassis Not Level In the event the turntable tilt switch input is logic low indicating that the machine is not level the UMS calibration screens shall display this fault.
Page 331: Function Check
SECTION 4 - BOOM & PLATFORM Function Check 4. Scroll through the top level menu until SERVICE MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will ON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANALYZER CONNEC- be displayed: TION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE.
Page 332: Service Mode/Tower Boom Retrieval
SECTION 4 - BOOM & PLATFORM 6. The controller will now display the following: 8. From the ground controls, raise the tower boom several feet. Verify that the tower boom will not lower. 9. To end the system test, press the Emergency Stop Switch (EMS) at the ground controls.
Page 333 SECTION 4 - BOOM & PLATFORM 4. Scroll through the top level menu until SERVICE MODE 5. Scroll left to right through the above menu items until "TOWER LIFT DOWN?" sub menu appears on the bottom appears. Press "ENTER" to select this menu item. After pressing "ENTER"...
Page 334 SECTION 4 - BOOM & PLATFORM 7. Enter the service code "81075" and press the "ENTER" 8. When the "ENTER" key is pressed, the UMS will be key. The controller display will now display the disabled and the display will read: following, 9.
Page 335 SECTION 4 - BOOM & PLATFORM THIS SENSOR ON NON ADE MACHINES ONLY Figure 4-27. UMS Sensor Location 3121160 4-63...
Page 336 SECTION 4 - BOOM & PLATFORM NON-ADE MACHINES MACHINES Figure 4-28. UMS Module Location 4-64 3121160...
Page 337 SECTION 4 - BOOM & PLATFORM IGN POWER (7-33V) +5V ANALOG EXCITATION GROUND ANALOG INPUT 0 DIGITAL INPUT 0 ANALOG GROUND DIGITAL INPUT 1 +5V ANALOG EXCITATION DIGITAL INPUT 2 ANALOG INPUT 1 DIGITAL INPUT 3 ANALOG GROUND DIGITAL OUTPUT 0 (PWM, IF) ANALOG INPUT 2 DIGITAL OUTPUT 1 (PWM, IF) ANALOG INPUT 3 (NOT POPULATED)
Page 338: Ums Troubleshooting And Fault Messages Non-Ade Machines
SECTION 4 - BOOM & PLATFORM 4.18 UMS TROUBLESHOOTING AND FAULT MESSAGES Forward Stability Concern Message NON-ADE MACHINES 2/5 UMS SENSOR FORWARD LIMIT REACHED. When the upright angle relative to the turntable is less than –4.0° Tower Lift Down Permanently closed for longer than 1.5 seconds, the ground boom malfunction indi- 2/2 FUNCTION LOCKED OUT - TOWER LIFT DOWN PERMANENTLY cator lamp, the platform distress lamp, and platform alarm shall...
Page 339: Ums Sensor Not Calibrated Message
SECTION 4 - BOOM & PLATFORM UMS Sensor Not Calibrated Message Platform Indicator Output Short to Ground or Open Circuit 8/1 UMS SENSOR NOT CALIBRATED. 8/1 PLATFORM INDICATOR OUTPUT SHORT TO GROUND OR If the control system detects a sensor out of range condition or a OPEN CIRCUIT.
Page 340: Turntable Sensor Faulted
2/5 AUTO DETECTION INPUT LOW Solution: If the UMS detects a valid ground module software version but • Contact JLG if message is reoccurring. digital input 2 is not tied high the UMS module shall report a fault. 4.19 UMS TROUBLESHOOTING AND FAULT...
Page 341: Out Of Usable Range Message
SECTION 4 - BOOM & PLATFORM Out of Usable Range Message Incompatible Software Detected Message 8/1 UMS SENSOR OUT OF USABLE RANGE 9/9 INCOMPATIBLE SOFTWARE DETECTED When both the Chassis tilt sensor and the UMS sensor read If the control system detects that the ground module software is greater than 10...
Page 342: Use And Care Of Fall Arrest System
SECTION 4 - BOOM & PLATFORM 4.20 USE AND CARE OF FALL ARREST SYSTEM Inspecting Cable Tension and Slip Indicator Cable tension is adjusted using the Line Tenser. The Line The external fall arrest system is designed to provide a lanyard Tenser is the disc at the end of the cable (shown below).
Page 343: Annual Inspection And Certification
SECTION 4 - BOOM & PLATFORM Shown below is the slip indicator with a gap, signifying that The following items should be checked per your maintenance the fall arrest system should be replaced immediately. schedule. Cable: Corrosion Broken Strands Swage Pull Out Dust or Debris Fittings: Loose Fittings...
Page 344: Platform Load Sensing System
The Platform Load Sensing System (LSS) consists of 1 load cell alarm will sound at the standard JLG duty cycle of and 2 linkages mounted to the platform rotator and replaces the 5 sec on / 2 sec off and all platform controls (except emergency platform support on machines that get this optional installation.
Page 345: Basic Hydraulic Information And Schematics
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION AND SCHEMATICS 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 346: Dip Method
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 347: Valves - Theory Of Operation
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS VALVES - THEORY OF OPERATION HOLDING VALVE CHECKS 1. Start the machine and warm the hydraulic system to Solenoid Control Valve - Rexroth operating temperature. Control valves used are four-way three-position solenoid valves of the sliding spool design.
Page 348: Cylinders - Theory Of Operation
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5. Check the Tower lift up holding valve function as fol- CYLINDERS - THEORY OF OPERATION lows: Systems Incorporating Double Acting Cylinders a. Fully retract and fully lower the main boom and tower boom assemblies.
Page 349: Cylinder Checking Procedure
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS CYLINDER CHECKING PROCEDURE Cylinders With Single Counterbalance Valve Main Lift Cylinder. NOTE: Cylinder check must be performed anytime a system com- ponent is replaced or when improper system operation is suspected. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. Cylinders Without Counterbalance Valves - Master 1.
Page 350: Cylinders With Dual Counterbalance Valves
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Cylinders With Dual Counterbalance Valves 3. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial Articulating Jib Boom Lift, Slave Level, Tower Lift, Upright level discharge, there should be no further leakage from the and Main Telescope.
Page 351: Cylinder Repair
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS CYLINDER REPAIR 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 Upright Level Cylinder from cylinder barrel.
Page 352 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 50-55 ft. lbs. (68-75 Nm) **Torque to 60 ft. lbs. (81 Nm) ***Torque to 300 ft. lbs. (407 Nm) 1684497 C 1683546 H 1. Rod 6. Rod Seal 11. Backup Ring 15.
Page 353 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 355 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 9. Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the ring into the applicable cylinder head gland groove.
Page 356 RING WASHER Figure 5-15. Rod Assembly Installation BACKUP RING 18. Apply JLG Threadlocker (P/N 0100011) to the socket head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 300 ft. lbs. (406 Nm).
Page 357: Jib Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Jib 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. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
Page 358 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 5 ft. lbs. (7 Nm) **Torque to 20 ft. lbs. (27 Nm) ***Torque to 50-55 ft. lbs. (68-75 Nm) 1683609 K 1. Rod 6. Hydrolock Seal 11. O-ring 16. Piston 21.
Page 359 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 5 ft. lbs. (7 Nm) **Torque to 20 ft. lbs. (27 Nm) ***Torque to 50-55 ft. lbs. (68-75 Nm) 1683609 K 1. Rod 6. Hydrolock Seal 11. O-ring 16. Piston 20.
Page 360 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 361 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 362 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 9. Place a new o-ring and backup rings in the inner piston cable cylinder head gland groove. Install a new wear diameter groove.
Page 363 CA SCREW applicable outside diameter grooves of the cylinder pis- ton. Figure 5-31. Rod Assembly Installation HYDROLOCK GUIDELOCK 22. Apply JLG Threadlocker (P/N 0100011) to the socket SEAL RING BACKUP O-RING head bolts and secure the cylinder head gland using the RING washer ring and bolts.
Page 364: Main Boom Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 365 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 12-24 ft. lbs. (16 Nm) **Torque to 60 ft. lbs. (81 Nm) ***Torque to 300 ft. lbs. (407 Nm) 1683547 L 1. Rod 6. Rod Seal 11. Seal 16. Piston 21.
Page 366 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 367 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 368 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 10. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. PISTON TAPERED BUSHING CAPSCREW Figure 5-40. Wiper Seal Installation 3.
Page 369 Figure 5-45. Rod Assembly Installation Figure 5-44. Piston Seal Kit Installation 20. Apply JLG Threadlocker (P/N 0100011) to the socket 17. Position the cylinder barrel in a suitable holding fixture. head bolts and secure the cylinder head gland using the washer ring and bolts.
Page 370: Tower Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Tower 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. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
Page 371 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 30 ft. lbs. (41 Nm) **Torque to 50-55 ft. lbs. (68-75 Nm) ***Torque to 300 ft. lbs. (407 Nm) 1683537 I 1. Rod 6. O-ring 10. Lock Ring 14. O-ring 18.
Page 372 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 373 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 374 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 9. Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the ring into the applicable cylinder head gland groove.
Page 375 Figure 5-60. Rod Assembly Installation HYDROLOCK GUIDELOCK O-RING SEAL 18. Apply JLG Threadlocker (P/N 0100011) to the socket BACKUP RING RING head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 300 ft. lbs.
Page 376: Master Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Master Cylinder 4. 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. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
Page 377 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 5 ft. lbs. (7 Nm) **Torque to 20 ft. lbs. (27 Nm) 1683682 G 1. Rod 5. Wiper Seal 9. Backup Ring 13. O-Ring 17. Tapered Bushing 2. Barrel 6. Rod Seal 10.
Page 378 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 379 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 380 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the rings into the applicable cylinder head gland groove.
Page 381 (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to CA SCREW install the solid seal). Figure 5-75. Rod Assembly Installation 19. Apply JLG Threadlocker (P/N 0100011) to the socket HYDROLOCK O-RING GUIDELOCK SEAL...
Page 382: Slave Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Slave 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. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
Page 383 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 9 ft. lbs. (12 Nm) **Torque to 35 ft. lbs. (47 Nm) ***Torque to 50-55 ft. lbs. (68-75 Nm) 1684228 E 1. Rod 6. Seal 11. Tube Spacer 16. Piston 21.
Page 384 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 385 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 386 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 10. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston. PISTON TAPERED BUSHING CAPSCREW Figure 5-84. Wiper Seal Installation 3.
Page 387 O.D. of the piston is recommended to CA SCREW install the solid seal). Figure 5-90. Rod Assembly Installation HYDROLOCK GUIDELOCK 19. Apply JLG Threadlocker (P/N 0100011) to the socket SEAL O-RING RING BACKUP head bolts and secure the cylinder head gland using the RING washer ring and bolts.
Page 388: Steer Cylinder (Prior To Sn 0300142664)
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Steer Cylinder (Prior to SN 0300142664) 4. Using a hook spanner, loosen the spanner nut retainer, and remove spanner nut from cylinder barrel. DISASSEMBLY CYLINDER BARREL DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SPANNER NUT SURFACE IN A DIRT FREE WORK AREA.
Page 389 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 390 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS CLEANING AND INSPECTION 7. Using suitable protection, clamp the cylinder rod in a 1. Clean all parts thoroughly in an approved cleaning sol- vise or similar holding fixture as close to the piston as vent.
Page 391 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 392 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install a new wear SEAL O-RING ring into the applicable cylinder head gland groove. Figure 5-100.
Page 393: Steer Cylinder (Sn 0300142664 Through 0300185827)
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Steer Cylinder (SN 0300142664 through 4. Using a hook spanner, loosen the spanner nut retainer, and remove spanner nut from cylinder barrel. 0300185827) DISASSEMBLY CYLINDER BARREL SPANNER NUT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 394 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS * 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 395 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS CLEANING AND INSPECTION 7. Using suitable protection, clamp the cylinder rod in a 1. Clean all parts thoroughly in an approved cleaning sol- vise or similar holding fixture as close to the piston as vent.
Page 396 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 397 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install a new wear SPLIT SEAL SEAL ring into the applicable cylinder head gland groove. Figure 5-110.
Page 398: Main Telescope Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Main 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. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
Page 399 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS *Torque to 9 ft. lbs. (12 Nm) **Torque to 35 ft. lbs. (47 Nm) ***Torque to 85 ft. lbs. (115 Nm) 1683672 I 1. Rod 6. Plate 11. O-Ring 16. Backup Ring 21.
Page 400 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 401 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 402 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Thread piston onto rod until it abuts the spacer end and cable cylinder head gland groove. Install new wear rings install the tapered bushing.
Page 403 Figure 5-124. Rod Assembly Installation 17. Position the cylinder barrel in a suitable holding fixture. 20. Apply JLG Threadlocker (P/N 0100011) to the socket head bolts and secure the cylinder head gland using the washer ring and bolts. Torque bolts to 35 ft. lbs.
Page 404: Cylinder Removal And Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5.7 CYLINDER REMOVAL AND INSTALLATION 4. Using a suitable sling and lifting device, secure the plat- form end of the boom. Main Boom Telescope Cylinder Removal 5. Place blocking under the main lift cylinder to prevent it from falling when the attaching hardware is removed.
Page 405: Main Boom Telescope Cylinder Installation
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- blocks and torque the bolts to 35 ft. lbs. (48 Nm). Use JLG CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS- Threadlocker P/N 0100011 on bolts.
Page 406: Main Lift Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 6. Remove the lifting device from the main telescope cylin- Main Lift Cylinder Removal der and retract the main telescope cylinder. NOTE: The Main Boom weighs approximately 2226 lbs. (1010 kg). 7. Extend the main lift cylinder using the auxiliary control from the ground controls to align with rod end hole in 1.
Page 407: Main Lift Cylinder Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 7. Remove hardware securing cover plate on the bottom Main Lift Cylinder Installation of the upright. Remove cover plate. 1. Lift the main boom to allow enough space to lower the 8. Use a suitable brass drift and hammer to remove main main lift cylinder to align with pin mounting holes of the lift cylinder barrel end pin from Upright.
Page 408: Upright Level Cylinder Removal
Secure the pin in place and torque the bolt to 285 ft. lbs. (388 Nm). Use JLG Threadlocker HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- P/N 0100011 on bolts.
Page 409 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 7. Tag, disconnect and cap the hydraulic lines of the Upright level Cylinder barrel. MAIN BOOM TELESCOPE CYLINDER 8. Attach a suitable lifting device to support the Upright Level Cylinder. 9. Remove mounting hardware from the upright level cyl- inder rod end and remove the pin.
Page 410: Upright Level Cylinder Installation
Use JLG Threadlocker P/N 0100011 on bolts. end. 2. Secure the leveling cylinder rod end pin to tower boom and torque the bolts to 35 ft. lbs. (48 Nm). Use JLG Threadlocker P/N 0100011 on bolts. 6. Install Main Lift Cylinder.
Page 411: Tower Boom Lift Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Tower Boom Lift Cylinder Removal 5. Using all applicable safety precautions, operate auxiliary power, activate tower lift down and fully retract lift cylin- 1. Place machine on a flat and level surface. Place the main der.
Page 412: Tower Boom Lift Cylinder Installation
JLG Threadlocker P/N 0100011 on bolts. Install the cylinder barrel pin and torque the bolt to 285 ft. lbs. (388 Nm). Use JLG Threadlocker P/N 0100011 on bolts. 5. Remove main boom support and lifting device support- ing the upright.
Page 413: Slave Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Slave Cylinder Removal Slave Cylinder Installation 1. Place the machine on a flat surface and lower the main 1. Remove caps from the hydraulic hoses and attach hoses boom and tower boom to the lowest position. to the proper cylinder ports.
Page 414: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
Cold temperatures have a significant impact on pressure read- ings. JLG Industries Inc. recommends operating the machine SAUER/DANFOSS PUMP until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc.
Page 415: Adjustments Made At The Main Valve Block
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2. High pressure relief Adjustments Made At The Main Valve Block Install a high pressure gauge at the "MP" port of the 1. Main lift down main valve block. Activate main telescope in. The gauge should read 2600 psi (179 bar).
Page 416 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 4641453 B Figure 5-126. Main Control Valve Pressure Adjustments 5-72 3121160...
Page 417 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 4641453 B 1. Front Steer Right Solenoid 6. Load Sensing Cartridge 10. Tower Lift Check 14. Platform Level Down Relief 2. Front Steer Relief 7. Main Lift Up Solenoid 11. Main Tele In Solenoid 15.
Page 418 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 4641453 B 1. Front Steer Left Solenoid 6. Load Sensing Cartridge 10. Tower Lift Up 14. Platform Level Check 2. Load Sensing Cartridge 7. Main Lift Down Solenoid 11. Platform Rotate Flow Regulator 15.
Page 419 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 4641453 B NOTE: When removing control valves from the manifold, it is important to observe the tag on the Ft. Lbs. face of the valve, as the new valve must be installed with the tag facing the same way as 19-21 25.8-28.5 the tag on the valve that was removed.
Page 420 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 4641453 B NOTE: When removing control valves from the manifold, it is important to observe the tag on the Ft. Lbs. face of the valve, as the new valve must be installed with the tag facing the same way as 19-21 25.8-28.5 the tag on the valve that was removed.
Page 421: Wheel Steer (If Equipped)
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5. Platform Level Up 4 Wheel Steer (If Equipped) Install a high pressure gauge at port “M3”, located on the 1. At the platform console using the steer select switch right side of the block at the bottom. There is pressure activate “4 wheel steer”.
Page 422: Hydraulic Oil Change-Out Procedure
(red knob). Disconnect the 1/4" hose (port #1) where it connects to the side of the hyd. return filter (plug the This procedure is written to change out JLG std. hydraulic oil port) and place into a container that will hold approx. 10 (Mobile 424) to cold weather fluid for machines operating in gallons (38 L).
Page 423 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5.11 HYDRAULIC COMPONENT START-UP NOTE: It is highly recommended to use the highest possible case drain port, this ensures that the housing contains as much PROCEDURES AND RECOMMENDATIONS oil as possible and offers the greatest amount of lubrica- tion to the internal components.
Page 424: Rexroth Variable Displacement Pump (Prior To Sn 0300121643)
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS NOTE: The Drive Pump and Displacement Pump must be filled with oil before starting the engine. As the tank is being filled, remove the specified plug from the Variable Dis- INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABILITY TO placement Pump.
Page 425 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Figure 5-131. Variable Displacement Pump (Rexroth) 3121160 5-81...
Page 426: Sauer Piston Pump
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5.13 SAUER PISTON PUMP Table 5-1. 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 O-ring boss port...
Page 427: Initial Start-Up Procedures
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Initial Start-up Procedures 5. Install a gauge at port M2 to monitor system pressure during start up. Follow this procedure when starting-up a new pump or when 6. While watching the pressure gauge installed at M2, jog the pump has been removed.
Page 428 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Table 5-3. Actuator Response Is Sluggish Item Description Action Check external system relief valve setting. Low external relief valve setting will slow down system. Adjust external relief valve setting per manufacturer’s rec- ommendations.
Page 429 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Table 5-5. Low Pump Output Flow Item Description Action Check fluid level in reservoir. Insufficient hydraulic fluid will limit output flow and cause Fill the reservoir to proper level. internal damage to pump. Hydraulic fluid viscosity above acceptable limits.
Page 430 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Table 5-7. System Pressure Not Reaching Pressure Compensator Setting Item Description Action Check Pressure Compensator control setting. System pressure will not rise above Pressure Compensator Adjust Pressure Compensator to appropriate setting. Refer setting.
Page 431: Shaft Seal Replacement
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Shaft Seal Replacement Control Assembly K010 C118 K020 C138 C117 C116 C136 C117 C135 C114 C134 C115 C133 C113 C102 (2pl.) Figure 5-133. 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 432 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS DISASSEMBLY REASSEMBLY 1. Remove the four screws (C300) holding the control 1. Install the Pressure Compensator spool, spherical end housing onto the end cap. first, into the Pressure Compensator bore. The Pressure Compensator spool is the shorter of the two.
Page 433: Plug And Fitting Sizes And Torques
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 434: Eaton Piston Pump
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5.14 EATON PISTON PUMP Endcover Inspection • Check the bearing (press fit) in endcover. If needles remain Servo Controlled Piston Pump in cage, move freely, and setting is at the dimension shown in Figure 5-136., removal not required.
Page 435 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 436 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 437: Charge Pump Adapter Assembly
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Charge Pump Adapter Assembly DISASSEMBLY 1. Remove plug, shims, spring, and poppet from adapter assembly as shown in Figure 5-140. Inspection • Inspect the charge pump relief valve seat inside the charge Gerotor Ring pump adapter.
Page 438: Manual Servo Control Basic Assembly
3. Remove o-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 439: Manual Servo Control Assembly Options
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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- 1.
Page 440 SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 441: Rotating Kit Assembly
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 442: Fault- Logic Trouble Shooting
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Fault- logic Trouble Shooting 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 443 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Figure 5-146. Fault - Logic Troubleshooting 3121160 5-99...
Page 444 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Figure 5-147. Fault - Logic Troubleshooting 5-100 3121160...
Page 445 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS Figure 5-148. Fault - Logic Troubleshooting 3121160 5-101...
Page 446 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS DIAGRAM ACTION STEP COMMENTS 10. Check System Pressure: a. See Figure 5-145. 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 447: Start-Up Procedure
SECTION 5 - BASIC HYDRAULIC INFORMATION AND 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 When initially starting a new or a rebuilt transmission system. operate system slowly with no load on motors until sys- it is extremely important that the start-up procedure be fol- tem responds fully.
Page 448: Hydraulic Schematics
SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 5.15 HYDRAULIC SCHEMATICS SHEET 1 Figure 5-149. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 1 of 6 5-104 3121160...
Page 449 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS 2792535 B SHEET 1 Figure 5-150. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 2 of 6 3121160 5-105...
Page 450 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 2 Figure 5-151. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 3 of 6 5-106 3121160...
Page 451 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 2 2792535 B Figure 5-152. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 4 of 6 3121160 5-107...
Page 452 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 3 Figure 5-153. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 5 of 6 5-108 3121160...
Page 453 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 3 2792535 B Figure 5-154. Hydraulic Schematic (Prior to SN 0300137975) - Sheet 6 of 6 3121160 5-109...
Page 454 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 1 Figure 5-155. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 1 of 6 5-110 3121160...
Page 455 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 1 1001108855 A Figure 5-156. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 2 of 6 3121160 5-111...
Page 456 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 2 Figure 5-157. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 3 of 6 5-112 3121160...
Page 457 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 2 1001108855 A Figure 5-158. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 4 of 6 3121160 5-113...
Page 458 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 3 Figure 5-159. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 5 of 6 5-114 3121160...
Page 459 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS SHEET 3 1001108855 A Figure 5-160. Hydraulic Schematic (SN 0300137975 through 0300185827) - Sheet 6 of 6 3121160 5-115...
Page 460 SECTION 5 - BASIC HYDRAULIC INFORMATION AND SCHEMATICS NOTES: 5-116 3121160...
Page 461: Jlg Control System
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH The JLG Control System controller has a built in LED to indicate AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- any faults. The system stores recent faults which may be TRIES, INC.
Page 462: To Connect The Jlg Control System Analyzer
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 463: Changing The Access Level Of The Hand Held Analyzer
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 464: Adjusting Configuration Using The Hand Held Analyzer
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 465: Level Vehicle Description
SECTION 6 - JLG CONTROL SYSTEM Level Vehicle Description Place machine in stowed position with the boom between the rear wheels. A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE To level machine chose: FOLLOWING PROCEDURE IS PERFORMED.
Page 466 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING LENGTH ACCEL ACCELERATE LIMIT ACTIVE LEVEL ANALOG DIGITAL CONVERTER COUNT MINUTES AMBIENT MINIMUM ANGLE MAXIMUM AUXILIARY MAIN BOOM CONTROL SYSTEM NORMALLY OPEN or NO...
Page 467 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram 3121160...
Page 468 SECTION 6 - JLG CONTROL SYSTEM 3121160...
Page 469 SECTION 6 - JLG CONTROL SYSTEM 3121160...
Page 470 SECTION 6 - JLG CONTROL SYSTEM 6-10 3121160...
Page 471 SECTION 6 - JLG CONTROL SYSTEM 3121160 6-11...
Page 472 SECTION 6 - JLG CONTROL SYSTEM 6-12 3121160...
Page 473 SECTION 6 - JLG CONTROL SYSTEM 3121160 6-13...
Page 474 SECTION 6 - JLG CONTROL SYSTEM 6-14 3121160...
Page 475 SECTION 6 - JLG CONTROL SYSTEM 3121160 6-15...
Page 476 SECTION 6 - JLG CONTROL SYSTEM DIAGNOSTICS: SYSTEM MENU : SYTEM TEST NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions. Figure 6-11. Analyzer Flow Chart Version 6.X Software - Sheet 1 of 8...
Page 477 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: DIAGNOSTICS: ENGINE CAN STATISTICS NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and soft- ware versions. Figure 6-12. Analyzer Flow Chart Version 6.X Software - Sheet 2 of 8...
Page 478 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: LOAD NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configura- tion and software versions. Figure 6-13. Analyzer Flow Chart Version 6.X Software - Sheet 3 of 8...
Page 479 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : DIAGNOSTICS PERSONALITIES: MAIN TELESCOPE MENU : MACHINE SETUP NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions.
Page 480 SECTION 6 - JLG CONTROL SYSTEM NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions. Figure 6-15. Analyzer Flow Chart Version 6.X Software - Sheet 5 of 8...
Page 481 SECTION 6 - JLG CONTROL SYSTEM NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions. Figure 6-16. Analyzer Flow Chart Version 6.X Software - Sheet 6 of 8...
Page 482 SECTION 6 - JLG CONTROL SYSTEM NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions. Figure 6-17. Analyzer Flow Chart Version 6.X Software - Sheet 7 of 8...
Page 483 SECTION 6 - JLG CONTROL SYSTEM NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration and software versions. Figure 6-18. Analyzer Flow Chart Version 6.X Software - Sheet 8 of 8...
Page 484 SECTION 6 - JLG CONTROL SYSTEM GROUND CONTROL MODULE Figure 6-19. Ground Control Module Location (Prior to SN 0300139070) GROUND CONTROL MODULE Figure 6-20. Ground Control Module Location (SN 0300139070 through 0300185827) 6-24 3121160...
Page 485 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONTROL MODULE Figure 6-21. Platform Control Module Location (Prior to SN 0300138447) FAULT CODE LIGHT 1704997 PLATFORM CONTROL MODULE Figure 6-22. Platform Control Module Location (SN 0300138447 through 0300185827) 3121160 6-25...
Page 486 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-23. Analyzer Connecting Points 6-26 3121160...
Page 487 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
Page 488 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 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;...
Page 489 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 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 490 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number TEMPERATURE: CELSIUS: Celsius unit selection. FAHRENHEIT: Fahrenheit unit selection. LEVELING MODE: ALL FUNCTIONS: Platform level with all functions.
Page 491 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
Page 492 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/Digit Number Description Default 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 selection.
Page 493 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/Digit Number Description Default Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
Page 494 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/Digit Number Description Default Number H & T LIGHTS: NO: No head and tail lights installed. YES: Head and tail lights installed.
Page 495 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/Digit Number Description Default Number GROUND ALARM: NO: No ground alarm installed. * Certain market selections will DRIVE: Travel alarm sounds when the drive function is active (Option).
Page 496 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
Page 497 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/Digit Number Description Default 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 selection.
Page 498 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/Digit Number Description Default Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
Page 499 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/Digit Number Description Default Number H & T LIGHTS: NO: No head and tail lights installed. YES: Head and tail lights installed.
Page 500 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/Digit Number Description Default Number GROUND ALARM: NO: No ground alarm installed. * Certain market selections will DRIVE: Travel alarm sounds when the drive function is active (Option).
Page 501 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: For version 6.X software, some screens may not be available depending upon machine configuration and software ver- sions. NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal- ity settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
Page 502 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information 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 503 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information 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. IN-CYLINDER: Glow plugs installed in each cylinder.
Page 504 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information 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 505 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number STOUCH / SKYGUARD: NONE: No soft touch or skyguard system installed. SOFT TOUCH - Soft touch only installed. SKYGUARD - Skyguard only installed.
Page 506 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information 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 507 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information 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. LEVELING MODE: ALL FUNCTIONS: Platform level with all functions.
Page 508 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number FUEL TANK SIZE: 31 Gallon Tank 52 Gallon Tank ALARM / HORN: SEPERATE: Separate alarm and horn. COMBINED: Combination alarm / horn.
Page 509 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Configuration Programming Settings Table 6-6. Machine Configuration Programming Settings 740 AJ 740 AJ Load Sensor Model Number Market Engine Function Cutout Flywheel Teeth Glow Plugs Ground Alarm Starter Lockout Fuel Cutout...
Page 510: Canbus Communications
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Machine Configuration Programming Settings 6.2 CANBUS COMMUNICATIONS CANbus: CAN (Control Area Network) is a two wire differential 740 AJ serial link between the Platform Module and Ground Module providing bi-directional communications. Temp Cutout Two-wire: One wire (red) is driven high (5v) and the other low (black) (0v) to send a signal;...
Page 511: Machine Orientation When Doing Speed Tests
Tower lift down, record time. 2. Drive test results reflect (15 X 19.5 OR 18 X 19.5). Tires on 740AJ is, air or foam filled. Lift: Tower lift fully elevated, tower telescope fully extended, 3. All speed tests are run from the platform. These speeds main telescope fully retracted.
Page 512 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Machine Configuration Parameters Configuration Parameter Parameter Value Description Range Definition Data Default Digit (Displayed on (Displayed on Analyzer Increment Value 2nd Line) Analyzer 1 Line) Model Number: 1=400 Displays/adjusts machine 2=450 model...
Page 513 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Machine Configuration Parameters Configuration Parameter Parameter Value Description Range Definition Data Default Digit (Displayed on (Displayed on Analyzer Increment Value 2nd Line) Analyzer 1 Line) Tower Lift: 0=NO Displays/adjusts tower lift No Tower Lift installed...
Page 514 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Machine Configuration Parameters Configuration Parameter Parameter Value Description Range Definition Data Default Digit (Displayed on (Displayed on Analyzer Increment Value 2nd Line) Analyzer 1 Line) length SENSOR 0=NO Displays presence/function No Length Sensor Installed...
Page 515: Machine Personality Settings
SECTION 6 - JLG CONTROL SYSTEM 6.4 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-9. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DEFAULTS (Sauer Danfoss) (Eaton) DRIVE ACCELeration 0.0 to 5.0s...
Page 516 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DEFAULTS (Sauer Danfoss) (Eaton) SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed...
Page 517 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DEFAULTS (Sauer Danfoss) (Eaton) JIB LIFT Lift ACCELeration 0.0 to 5.0s Lift DECELeration 0.0 to 3.0s MINimum UP speed 1 to 65% MAXimum UP speed 1 to 100%...
Page 518 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Help Fault Codes, Displayed Faults, and Descriptions - Prior to SN 0300066931 Communicated (Displayed on Fault Flash Code Description Priority Analyzer) Fault None No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
Page 519 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Help Fault Codes, Displayed Faults, and Descriptions - Prior to SN 0300066931 Communicated (Displayed on Fault Flash Code Description Priority Analyzer) Fault Flash code 2/5 indicates that a function is prevented due to a cutout.
Page 520 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Help Fault Codes, Displayed Faults, and Descriptions - Prior to SN 0300066931 Communicated (Displayed on Fault Flash Code Description Priority Analyzer) Fault Flash code 5/5 indicates problems with vehicle engine RPM or the encoder.
Page 521 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information HELP COMMENT EVERYTHING OK GROUND MODE OK RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0010 FSW OPEN...
Page 522 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information DRIVE PREVENTED - TILTED & ABOVE ELEVATION 2517 DRIVE PREVENTED - BOOM SELECTED 2518 DRIVE PREVENTED - TILTED & EXTENDED OR HIGH ANGLE...
Page 523 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information BRAKE - SHORT TO GROUND 3361 START SOLENOID - SHORT TO GROUND 3362 START SOLENOID - OPEN CIRCUIT...
Page 524 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information JIB LIFT DOWN VALVE - SHORT TO BATTERY 33105 TOWER LIFT UP VALVE - SHORT TO GROUND 33106...
Page 525 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information TELESCOPE IN VALVE - OPEN CIRCUIT 33189 TELESCOPE IN VALVE - SHORT TO GROUND 33190 HORN - OPEN CIRCUIT...
Page 526 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND 3414 JIB LIFT UP VALVE - OPEN CIRCUIT 3415 JIB LIFT UP VALVE - SHORT TO BATTERY...
Page 527 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information TILT SENSOR CHASSIS TILT SENSOR NOT CALIBRATED CHASSIS TILT SENSOR DISAGREEMENT UMS SENSOR NOT CALIBRATED UMS SENSOR FAULT...
Page 528 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Code Clear Sky Default Analyzer Text Flash Code Sequence Operational Fault Information RIGHT TRACK FORWARD VALVE - OPEN CIRCUIT 8652 RIGHT TRACK FORWARD VALVE - SHORT TO BATTERY 8653 RIGHT TRACK FORWARD VALVE - SHORT TO GROUND...
Page 529: Analyzer Diagnostics Menu Structure
SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure arrow keys move between items in the same level. The In the following structure descriptions, an intended item is /DOWN arrow keys alter a value if allowed selected by pressing ENTER ;...
Page 530 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. ADJUSTMENTS - Personality Descriptions SWING ACCEL … Displays/adjusts swing acceleration DECEL … Displays/adjusts swing deceleration MIN LEFT … Displays/adjusts minimum swing left speed MAX LEFT … Displays/adjusts maximum swing left speed CREEP LEFT …...
Page 531 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. ADJUSTMENTS - Personality Descriptions ACCEL … Displays/adjusts jib acceleration DECEL … Displays/adjusts jib deceleration MIN UP … Displays/adjusts minimum jib up speed MAX UP … Displays/adjusts maximum jib up speed MIN DOWN …...
Page 532 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. 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 533 SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC. CUTOUT … Displays function cutout switch status CREEP…...
Page 534 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-74 3121160...
Page 535: Basic Electrical Information & Schematics
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 536: Resistance Measurement
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. • Circuit power must be turned OFF before testing conti- Figure 7-2. Resistance Measurement nuity.
Page 537: Current Measurement
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 538: Installation Of Dielectric Grease
3. Leave a thin layer of dielectric grease on the face of the prevents the connector from latching, pierce one of the connector. unused wire seals. After assembly, install a seal plug (JLG #4460905) in that location to prevent moisture ingress. 4. Assemble the connector system immediately to prevent moisture ingress or dust contamination.
Page 539: Amp Mate-N-Lock
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs Exclusions A limited number of connectors do not benefit from dielectric AMP Mate-N-Lock grease, or may be permanently damaged by application.
Page 540 (replacement of female contacts required). The JLG Load dielectric grease. The EMR4 engine control module from Sensing System and Rotary Angle Sensors are examples of com- Deutz employs this connector system (for example).
Page 541: Amp Connector
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MIL-C-5015 SPEC CONNECTOR’S AMP CONNECTOR Crown Connector Inc’s recommendation is to not use dielectric grease for this series connector. For similar Applying Silicone Dielectric Compound to AMP model series connectors, the manufacturer should be Connectors contacted for confirmation before applying dielectric grease.
Page 542: Assembly
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Assembly 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go. (See Figure 7-11.) Check to be sure the wedge lock is in the open, or as-shipped, 2.
Page 543 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.
Page 544: Disassembly
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-14. Connector Disassembly Disassembly Service - Voltage Reading 1. 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 545 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-15. Connector Installation 3121160 7-11...
Page 546: Deutsch Connectors
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 25mm behind the contact shaped wire to pull wedge straight out.
Page 547: Hd30/Hdp20 Series Assembly
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 25mm behind the contact crimp 1. With rear insert toward you, snap appropriate size barrel.
Page 548 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Components Installation (Prior to SN 0300135982) - Sheet 1 of 2 7-14 3121160...
Page 549 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-23. Electrical Components Installation (Prior to SN 0300135982) - Sheet 2 of 2 3121160 7-15...
Page 550 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SOFT TOUCH SYSTEM LIMIT SWITCH PLATFORM PLATFORM CONTROL WORK LIGHTS GENERATOR SWITCH FOOTSWITCH PRIOR TO S/N 0300112885 S/N 0300112885 TO PRESENT MAIN BOOM ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH ANALYZER HEADLIGHTS GROUND CONTROL...
Page 551 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-25. Electrical Components Installation Without UGM (SN 0300135982 through 0300185827) - Sheet 2 of 2 3121160 7-17...
Page 552 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Electrical Components Installation With UGM - Sheet 1 of 2 7-18 3121160...
Page 553 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27. Electrical Components Installation With UGM - Sheet 2 of 2 3121160 7-19...
Page 554: Electrical Schematics
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS SHEET 1 Figure 7-28. Electrical Schematic - Deutz & Ford Engines without UGM - Sheet 1 of 2 7-20 3121160...
Page 555 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870199 F SHEET 1 1870163 D Figure 7-29. Electrical Schematic - Deutz & Ford Engines without UGM - Sheet 2 of 2 3121160 7-21...
Page 556 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-30. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 1 of 6 7-22 3121160...
Page 557 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1870199 F Figure 7-31. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 2 of 6 3121160 7-23...
Page 558 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-32. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 3 of 6 7-24 3121160...
Page 559 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1870199 F Figure 7-33. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 4 of 6 3121160 7-25...
Page 560 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-34. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 5 of 6 7-26 3121160...
Page 561 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1870199 F Figure 7-35. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to SN 0300099884) - Sheet 6 of 6 3121160 7-27...
Page 562 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-36. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 1 of 6 7-28 3121160...
Page 563 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1870220 E Figure 7-37. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 2 of 6 3121160 7-29...
Page 564 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-38. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 3 of 6 7-30 3121160...
Page 565 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1870220 E Figure 7-39. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 4 of 6 3121160 7-31...
Page 566 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-40. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 5 of 6 7-32 3121160...
Page 567 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1870220 E Figure 7-41. Electrical Schematic - Deutz EMR2 & GM Engines (SN 0300099884 through 0300185827) - Sheet 6 of 6 3121160 7-33...
Page 568 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-42. Deutz and GM Engines with UGM - Sheet 1 of 10 7-34 3121160...
Page 569 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1001115344 E Figure 7-43. Deutz and GM Engines with UGM - Sheet 2 of 10 3121160 7-35...
Page 570 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-44. Deutz and GM Engines with UGM - Sheet 3 of 10 7-36 3121160...
Page 571 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1001115344 E Figure 7-45. Deutz and GM Engines with UGM - Sheet 4 of 10 3121160 7-37...
Page 572 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-46. Deutz and GM Engines with UGM - Sheet 5 of 10 SHEET 4 7-38 3121160...
Page 573 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1001115344 E Figure 7-47. Deutz and GM Engines with UGM - Sheet 6 of 10 3121160 7-39...
Page 574 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 Figure 7-48. Deutz and GM Engines with UGM - Sheet 7 of 10 7-40 3121160...
Page 575 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 1001115344 E Figure 7-49. Deutz and GM Engines with UGM - Sheet 8 of 10 3121160 7-41...
Page 576 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 Figure 7-50. Deutz and GM Engines with UGM - Sheet 9 of 10 7-42 3121160...
Page 577 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 1001115344 E Figure 7-51. Deutz and GM Engines with UGM - Sheet 10 of 10 3121160 7-43...
Page 578 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 Figure 7-52. GM Engine Schematic (Engine Schematic Only) - Sheet 1 of 2 7-44 3121160...
Page 579 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 1 1001131992 A Figure 7-53. GM Engine Schematic (Engine Schematic Only) - Sheet 2 of 2 3121160 7-45...
Page 580 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-46 3121160...
Page 582 +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)