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

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Service and Maintenance Manual
Model
800A
800AJ
Prior to S/N 0300183033
P/N - 3120740
December 18, 2015

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Summary of Contents for Oshkosh JLG 800A

  • Page 1 Service and Maintenance Manual Model 800A 800AJ Prior to S/N 0300183033 P/N - 3120740 December 18, 2015...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Ageneral

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISON LOG Original Issue - August, 1998 Revised - August 2, 2001 Revised - January 14, 2003 Revised - October 19, 2004 Revised - July 11, 2005 Revised - March 7, 2006 Revised - June 12, 2007 Revised - May 23, 2008 Revised - August 5, 2011 Revised...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ..............A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Lubrication Specifications ........... 2-4 Cylinder Drift Test .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Wear Tolerance ............3-47 Swing Bearing Replacement .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Quick-start Installations ........... . . 3-111 Mounting-Actuator .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Platform ..............4-1 Support Removal .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Turntable Sensor Faulted ........... 4-45 EEPROM checksums failure .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Cylinder Checking Procedure ........... . .5-5 Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinders .
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS General ..............7-1 Multimeter Basics .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-8 1-2.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-46. Swing Motor (S/N 0300068040 to S/N 0300183033)..........3-83 3-47.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-16. UMS Module Pin Identification ..............4-42 4-17.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-45. Cylinder Barrel Support ................5-25 5-46.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-102. Rod Assembly Installation ................5-48 5-103.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-159. Rod Assembly Installation ................5-73 5-160.
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-15. DT/DTP Contact Removal................7-11 7-16.
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Capacities .
  • Page 21 LIST OF TABLES TABLE NO. TITLE PAGE NO. System Operating Hot................5-92 Low Pump Output Flow .
  • Page 22 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally xviii – JLG Lift –...
  • Page 23 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 24: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS OPERATING SPECIFICATIONS Capacities Table 1-1. Operating Specifications Table 1-2. Capacities Travel Speed Fuel Tank Approx. 40 Gal. (151.4 L) 3.0 MPH (4.83 Km/hr.) Hydraulic Tank Approx. 40 Gal. (151.4 L) 3.0 MPH (4.83 Km/hr.) Hydraulic System (Including Tank) 77 Gal.
  • Page 25 SECTION 1 - SPECIFICATIONS Table 1-4. Deutz F4M2011F Specifications Table 1-6. Caterpillar 3044C Type Liquid Cooled (Oil) Type Four Stroke Cycle Fuel Diesel Cylinders 4 in-line Oil Capacity Bore 3.70 inch (94 mm) Cooling System 5 Quarts (4.5 L) Stroke 4.72 inch (120 mm) Crankcase 11 Quarts (10.5 L) w/Filter...

  • Page 26: Tires

    SECTION 1 - SPECIFICATIONS Drive System (S/N 0300083332 to S/N 0300183033, Table 1-8. GM 3.0L S/N B300000100) Fuel Gasoline or Gasoline/LP Gas Table 1-11. Drive System Specifications No. of Cylinders Drive Motor Displacement Gasoline 83 hp @ 3000 rpm 2.439 cu. in. max. 1.347 cu. in. min. 75 hp @ 3000 rpm (40 cc max.

  • Page 27: Hydraulic Load Sense Pump

    SECTION 1 - SPECIFICATIONS Hydraulic Load Sense Pump TORQUE REQUIREMENTS Table 1-15. Hydraulic Load Sense Pump Specifications Table 1-18. Torque Requirements Pump Displacement 2.1cu. in. (34.4 cm ) Max. Torque Value Pump Output 15.5 GPM (59 lpm) @ 1800 RPM Description Interval Hours (Dry)

  • Page 28: Lubrication

    SECTION 1 - SPECIFICATIONS LUBRICATION Table 1-21. Mobil DTE 13M Specs ISO Viscosity Grade Hydraulic Oil Specific Gravity 0.877 Table 1-19. Hydraulic Oil Pour Point, Max -40°F (-40°C) Flash Point, Min. 330°F (166°C) Hydraulic System S.A.E. Viscosity Viscosity Operating Grade Temperature Range at 40°...

  • Page 29: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS MAJOR COMPONENT WEIGHTS Table 1-24. Exxon Univis HVI 26 Specs Table 1-27. Major Component Weights - 800A Specific Gravity 32.1 Pour Point -76°F (-60°C) MAJOR COMPONENTS LBS. Flash Point 217°F (103°C) Platform & Control Console Viscosity Upper Boom (Inc.

  • Page 30: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS Critical Stability Weights Table 1-28. Major Component Weights - 800AJ MAJOR COMPONENTS LBS. Platform & Control Console DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTER Upper Boom (Inc.
  • Page 31 SECTION 1 - SPECIFICATIONS 2, 3 2, 3 9, 10, 11, 12, 13 14, 15, 16, 17, 18 Figure 1-1. Maintenance and Lubrication Diagram – JLG Lift – 3120740...

  • Page 32: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS MAINTENANCE AND LUBRICATION 2. Wheel Bearings NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-31. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pres- sure type.
  • Page 33 SECTION 1 - SPECIFICATIONS 4. Swing Drive Hub 7. Hydraulic Tank Lube Point(s) - Fill Cap Lube Point(s) - Level/Fill Plug Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L) Capacity - 43 oz. (1.3 L) System Lube - 90w80 Gear oil Lube - HO Interval - Check level every 3 months or 150 hrs of operation;...
  • Page 34 SECTION 1 - SPECIFICATIONS 9. Oil Change w/Filter - Ford Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 10.
  • Page 35 SECTION 1 - SPECIFICATIONS 13. Oil Change w/Filter - GM 16. Fuel Filter - Isuzu Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 17. Fuel Filter - Caterpillar Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 18.

  • Page 36: Draining Oil Build Up From The Propane Regulator (Prior To S/N 0300134626)

    SECTION 1 - SPECIFICATIONS 21. Fuel Filter (Propane) - GM Engine 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Filter Replacement 6.

  • Page 37: Propane Fuel Filter Replacement

    SECTION 1 - SPECIFICATIONS 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 38: Propane Fuel System Pressure Relief

    SECTION 1 - SPECIFICATIONS 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 39 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 1 of 5 (SAE Fasteners) 1-16 – JLG Lift – 3120740...
  • Page 40 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 2 of 5 (SAE Fasteners) 3120740 – JLG Lift – 1-17...
  • Page 41 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 3 of 5 (SAE Fasteners) 1-18 – JLG Lift – 3120740...
  • Page 42 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 4 of 5 (Metric fasteners) 3120740 – JLG Lift – 1-19...
  • Page 43 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 5 of 5 (METRIC Fasteners) 1-20 – JLG Lift – 3120740...
  • Page 44 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 45: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND Annual Machine Inspection MAINTENANCE The Annual Machine Inspection must be performed by a Fac- tory-Certified Service Technician on an annual basis, no later General than thirteen (13) months from the date of the prior Annual Machine Inspection.

  • Page 46: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual At each Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic...

  • Page 47: Bearings

    SECTION 2 - GENERAL Bearings Lubrication Service applicable components with the amount, type, and 1. When a bearing is removed, cover it to keep out dirt and grade of lubricant recommended in this manual, at the speci- abrasives. Clean bearings in nonflammable cleaning sol- fied intervals.

  • Page 48: Hydraulic Oil

    SECTION 2 - GENERAL Hydraulic Oil CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using 1. Refer to Section 1 for recommendations for viscosity the following methods. ranges. Platform Drift 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

  • Page 49: Welding On Jlg Equipment

    SECTION 2 - GENERAL b. Cracked or damaged liner backing. Do NOT Do the Following When Welding on JLG Equipment c. Bearings that have moved or spun in their housing. d. Debris embedded in liner surface. • Ground on frame and weld on any other area than the chassis.
  • Page 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers...
  • Page 51 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 52 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions...
  • Page 53 SECTION 2 - GENERAL A M B IE N T A IR T E M P E R A T U R E 120°F (49° C) N O O P E R A T IO N A B O V E T H IS 110°F (43°...
  • Page 54 SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 2-10 – JLG Lift – 3120740...
  • Page 55 SECTION 2 - GENERAL A M B IE N T A IR T E M P E R A T U R E 120 F(49 C) N O O P E R A T IO N A B O V E T H IS A M B IE N T T E M P E R A T U R E 110 F(43 C) 100 F(38 C)
  • Page 56 SECTION 2 - GENERAL 4150548 E Figure 2-4. Engine Operating Temperature Specifications - GM 2-12 – JLG Lift – 3120740...
  • Page 57 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 58: Section 3. Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS Wheel Replacement Tire Inflation The rims installed on each product model have been designed for stability requirements which consist of track width, tire The air pressure for pneumatic tires must be equal to the pressure, and load capacity.

  • Page 59: Oscillating Axle Bleeding Procedure And Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Wheel Torque Chart 3. Using a Phillips screwdriver, remove screw from connec- tion on the brake valve and remove connector as shown. TORQUE SEQUENCE Brake Valve (Prior to S/N 0300083332) 1st Stage 2nd Stage 3rd Stage 70 ft.

  • Page 60: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test 15. If lockout cylinders do not function properly, have quali- fied personnel correct the malfunction prior to any fur- ther operation. FREE WHEELING OPTION LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS To Disengage Drive Motors and Brakes (Free Wheel) SUSPECTED.

  • Page 61: Torque Hub, Drive

    SECTION 3 - CHASSIS & TURNTABLE TORQUE HUB, DRIVE 4. Inspect all geared components for chipped or broken teeth and for excessive or uneven wear patterns. Disassembly 5. Inspect carrier for damage, especially in anti-roll pin and planet shaft hole areas. 1.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE f. Repeat steps (a) through (e) for remaining two clus- k. Place second set of needle rollers into cluster gear. ter gears. l. Apply grease or petroleum jelly to tang side of two g. Clean and inspect all parts in accordance with thrust washers.

  • Page 63: Assembly

    SECTION 3 - CHASSIS & TURNTABLE o. Drive anti-roll pin flush into carrier hole, locking 2. Place bearing cone (4) into bearing cup (3) in small end planet shaft into place. of hub. p. Repeat steps (h) through (o) for remaining two clus- 3.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 5. Place bearing cone (6) over end of spindle and into 8. The disengage spacer and spring are installed into the bearing cup. counterbore of the spindle. 6. Place bearing shim (8) over end of spindle and against 9.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 11. Install thrust washers and thrust bearing (39, 40) on the 14. Place input shaft assembly (35) into spindle bore with portion of the spindle which extends into the internal unsplined end facing out. gear.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 17. Place o-ring (22) into cover assembly counterbore. Use 20. While holding ring gear, and cluster gears in mesh, place petroleum jelly or grease to hold o-ring in place. Slight small side of cluster gears into mesh with internal gear. stretching of o-ring may be necessary to insure proper On ring gear, locate hole marked ‘X’...
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 23. Install thrust washers and thrust bearing (39, 40) into 27. Install bolts (41) in remaining holes. Torque bolts to carrier counterbore. 47 ft. lbs. (64 Nm). 24. Place o-ring (22) into cover assembly counterbore. Use 28.
  • Page 68 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 69: Drive Brake - Ausco (Prior To S/N 0300056875)

    SECTION 3 - CHASSIS & TURNTABLE DRIVE BRAKE - AUSCO (PRIOR TO Assembly S/N 0300056875) NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. Disassembly 1. With shaft protrusion downward, disassemble the parts in the following order; bolts (24 alternately, washers (23), THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 1. Housing 8. Small Compression Ring 14. Stationary Disc 20. Bleeder Screw 2. Gasket 9. Large Compression Ring 15. Piston 21. Power Plate 3. Torque Pin 10. Shaft 16. Backup Ring 22. Protective Plug 4.

  • Page 71: Drive Brake - Mico (S/N 0300056875 To S/N 0300083332)

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE BRAKE - MICO (S/N 0300056875 TO 4. Install retaining ring (20) in cover plate (16). S/N 0300083332) 5. Press shaft (10) into bearing (18) until it bottoms on shoulder. Disassembly NOTE: Bearing (18) inner race and cover plate (16) must be sup- ported as indicated in Figure 1 during this operation.
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 8. Position return plate (13) on springs (14). 11. Install new case seal (4) in cover plate (16). 12. Position pressure plate (3) on cover plate (16) aligning NOTE: Discs (11 & 12) and return plate (13) must remain dry dowel pins (15) with holes in pressure plate.
  • Page 73 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 74: 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 75: Drive Brake (S/N 0300083332 To S/N 0300183033)

    SECTION 3 - CHASSIS & TURNTABLE DRIVE BRAKE (S/N 0300083332 TO Assembly S/N 0300183033) 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 76 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 77: Drive Motor (Prior To S/N 0300083332)

    SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE MOTOR (PRIOR TO S/N 0300083332) 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 78: Replacing The Drive Shaft Seal

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-7. 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 3120740 –...

  • Page 79: 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 80 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 81 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 82 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 83: 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 84 SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rota- tion is appr. 3,1 cm3. Figure 3-8. Flow Control Pilot Valves 3120740 – JLG Lift – 3-27...

  • Page 85: 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 DR: When pressure line is closed adjust the pressure of the max.

  • Page 86: Drive Motor (S/N 0300083332 To S/N 0300183033)

    SECTION 3 - CHASSIS & TURNTABLE 3.10 DRIVE MOTOR (S/N 0300083332 TO Shaft Seal Replacement S/N 0300183033) REMOVAL Description 1. Remove the snap ring (1) retaining the shaft seal and The drive motors are low to medium power, two-position axial support washer.

  • Page 87: Loop Flushing Valve

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

  • Page 88: 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 sys- Fill the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.

  • Page 89: 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 90 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring Figure 3-15. End Cap 28. O-ring 29. Angle Stop 13. Using an 8 mm internal hex wrench, remove the endcap 30.
  • Page 91 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 92 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-20. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer 23.

  • Page 93: Inspection

    SECTION 3 - CHASSIS & TURNTABLE SLIPPERS Inspect the running surface of the slippers. Replace any piston RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES assemblies with scored or excessively rounded slipper edges. FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO Measure the slipper foot thickness.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Cylinder Block Measurements Measurement 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) Minimum Cylinder Block Height (A) Cylinder Block Surface Flatness 0.002 0.002 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 95: 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 96 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 97 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the ing onto shaft with lettering facing out. Lubricate bear- slippers facing the swashplate.
  • Page 98 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- cap screws (26). Check to ensure the endcap will prop- the bearing with letters facing out. Press until bearing erly seat onto the housing without interference.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation Press seal into housing until it bottoms out.

  • Page 100: 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. 11/16 in Prior to installing the motor, inspect for damage incurred 27 ft.lbs.

  • Page 101: 3.11 Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.11 SWING BEARING 2. Check the turntable to bearing Attach bolts as follows: a. Elevate the fully retracted upper boom to full eleva- Turntable Bearing Mounting Bolt Condition Check tion. b. At the position indicated on Figure 3-33. try to insert NOTE: This check is designed to replace the existing bearing bolt the 0.0015”...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE Figure 3-33. Swing Bearing Tolerance Boom Placement (Sheet 1 of 2) 3120740 – JLG Lift – 3-45...
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 3-46 – JLG Lift – 3120740...

  • Page 104: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-36. Swing Bearing Tolerance Measuring Point Figure 3-35. Swing Bolt Feeler Gauge Check Swing Bearing Replacement Wear Tolerance 1. Removal. 1. From the underside of the machine, at rear center, with a. From Ground Control station, operate the boom the upper boom fully elevated and fully retracted, and adequately to provide access to frame opening to tower boom stowed, as shown in Figure 3-33., Swing...

  • Page 105: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE h. Carefully place the turntable on a suitably sup- 0100019 and install the bolts and washers through ported trestle. the turntable and inner race of the bearing. h. Following the Torque Sequence diagram shown in i.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 3120740 – JLG Lift – 3-49...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE 3-50 – JLG Lift – 3120740...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Machines built prior to S/N 0300068040 NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Machines built S/N 0300068040 to S/N 0300183033 Figure 3-39. Swing Bearing Torque Sequence 3120740 – JLG Lift – 3-51...

  • Page 109: Procedure For Setting Swing Gear Backlash

    SECTION 3 - CHASSIS & TURNTABLE 3.12 PROCEDURE FOR SETTING SWING GEAR 5. Apply JLG Threadlocker P/N 0100019 and pre-torque bolt to 30 ft. lbs. (42 Nm). BACKLASH Set backlash to 0.008 in. to 0.012 in. (0.2 mm - 0.3 mm) using the following procedure: 1.

  • Page 110: Swing Hub (Prior To S/N 0300068040)

    SECTION 3 - CHASSIS & TURNTABLE 10. Discard the shim. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING (1L) REMOVAL. 8. Remove Bearing Shim (1H) from the Output Shaft (1A). 9. The Output Shaft (1A) may now be pressed out of the Hub (1G).

  • Page 111: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Also at this time locate and mark the 4 counter beamed holes in the face of the Hub (1G). This is for identification 1. With the Hub Shaft Sub-assembly resting on the Shaft later in the assembly.
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 6. With shoulder side of Ring Gear (4) facing down, place 9. Thrust Washer (10) is installed onto the Input Gear (8) Ring Gear over (into mesh with) large gears. Be sure that and should locate on the gear teeth shoulder. punch marks remain in correct location during Ring Gear installation.

  • Page 113: Hub Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 12. The Cover (6) is now installed on this assembly. Taking 15. Torque Shoulder Bolts (13) to 23-27 ft.-lbs. and regular care to correctly align Pipe Plug hole (20) with those in Grade 8 Bolts (12) to 23-27 ft.– lbs. the Hub (1J), usually 90°...
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE 3. Invert Hub (1G) and press Bearing Cup (1E) into inter- 6. The Bearing Cone (1F) is an interference fit and has to be counterbore of housing (1G). pressed or tapped on. 7. Pipe Plugs (1J & 1K) should be checked and/or installed 4.

  • Page 115: Carrier Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 9. Retaining ring (11) installed into the groove provided in 11. Upon completion of Step 10, rap the internal end of the the Output Shaft (1A). This Retaining Ring (1l) should Output Shaft (1A) twice with a piece of soft metal rod. never be reused in a repair or rebuild.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE 3. Place Spacer washer into opposite side of Cluster Gear 6. While keeping Thrust Washers in place, slide Cluster and against Needle Rollers. Gear into Carrier with the larger gear on the side with the small pin hole.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 3-60 – JLG Lift – 3120740...

  • Page 118: Swing Brake - Ausco (Prior To S/N 0300064566)

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BRAKE - AUSCO (PRIOR TO Assembly S/N 0300064566) NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. Disassembly 1. With the shaft protrusion downward, Disassemble the parts in the following order; bolts (24) alternately, wash- ers (23), power plate (21), and gasket.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Figure 3-41. Swing Brake Assembly (Ausco) (Prior to S/N 0300064566) 3-62 – JLG Lift – 3120740...

  • Page 120: Swing Motor (Eaton) (Prior To S/N 0300068040)

    SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING MOTOR (EATON) (PRIOR TO S/N 0300068040) Cleanliness is extremely important when repairing hydraulic motors. Work in a clean area. Before disconnecting the hydrau- lic lines, clean the port area of the motor. Before disassembly, drain oil from the motor.

  • Page 121: Reassembly

    SECTION 3 - CHASSIS & TURNTABLE Apply just enough heat to remove screw, do not over heat the Reassembly motor housing or mounting flange. Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent.

  • Page 122: Motor Timing

    SECTION 3 - CHASSIS & TURNTABLE BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PASSAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS. IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE. 3. Lightly stretch, lubricate and install the second of the three larger diameter seals in the groove in the Geroler.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 1. Capscrew 11. Housing 2. Exclusion Seal 12. Seal 3. Mounting Flange 13. Drive 4. Backup Ring 14. Spacer Plate 5. Pressure Seal 15. Seal 6. Seal 16. Geroler 7. Bearing Race 17. Seal 8.

  • Page 124: Swing Hub (S/N 0300068040 To S/N 0300183033)

    SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING HUB (S/N 0300068040 TO 12. The cluster gear (3F) can now be removed from the car- rier (3A). THe thrust washers (3B) will be removed with S/N 0300183033) the cluster gear (3F). 13.
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE 3. Place O-ring (5) into hub counterbore. Use petroleum 6. With shoulder side of ring gear (4) facing down, place jelly to hold O-ring in place. Also at this time locate and ring gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during ring gear mark the 4 counter beamed holes in the face of the hub installation.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE 8. Input gear (8) is installed, meshing with teeth of the large diameter cluster gear (3F). The counterbore on the input gear (8) locates on the shoulder of the thrust BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O- spacer (9).

  • Page 127: Hub Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 14. Pipe plugs (20) are to be installed into cover (6) using a 2. Press bearing cup (1C) into hub (1G) taking care to lubricant of some sort. insure cup start square with the bore of the hub. 15.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE 5. The shaft seal (1B) is installed over the output shaft (1A) 8. Bearing spacer (1H) is installed around the output shaft and into the counterbore of the hub (1G). Care should (1A) and locates on bearing cone (1F). be taken to insure the seal (1B) is being correctly installed (smooth face up and located just flush with the counterbore face).

  • Page 129: Carrier Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 10. A soft metal punch should be used to insure that this Carrier Sub-Assembly retaining ring (1I) is completely seated in the groove of 1. Apply a coat of grease or petroleum jelly to cluster gear the output shaft (1A).
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE 4. Place second set of needle rollers into cluster gear. 7. Line up cluster gear and thrust washer with hole in car- rier and slide planet shaft through. Line up chamfered side of hole in planet shaft with pin hole in carrier. 5.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE 3-74 – JLG Lift – 3120740...

  • Page 132: Swing Brake (S/N 0300068040 To S/N 0300183033)

    SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING BRAKE (S/N 0300068040 TO 8. Position plate (12) on spring (13). S/N 0300183033) NOTE: Discs (10 & 11) and plate (12) must remain dry during installation. No oil residue must be allowed to contami- Disassembly nate disc surfaces.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Items Included in Repair Kit 1. Capscrew 11. Rotor Disc 2. Pressure Plate 12. Return Plate 3. Case Seal 13. Springs 4. O-ring 14. Spring Retainer 5. Backup Rings 15. Dowel Pin 6. Piston 16.

  • Page 134: Swing Motor (S/N 0300068040 To S/N 0300183033)

    SECTION 3 - CHASSIS & TURNTABLE 3.18 SWING MOTOR (S/N 0300068040 TO 2. remove cap screws and seal washers. 3. Remove end cap. S/N 0300183033) 4. Remove seal from end cap. Disassembly Cleanliness is extremely important when repairing these motors. Work in a clean area. Before disconnecting lines, clean port area of motor.
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE 13. Reposition motor in vise. Clamp across ports as shown above. Do not clamp side of housing. Excessive clamp- ing pressure on side of housing causes distortion. 14. Remove cap screws from mounting flange. These screws are assembled with Loctite to hold them in place.

  • Page 136: Inspection And Cleaning

    SECTION 3 - CHASSIS & TURNTABLE d. Wash screws with non-petroleum base solvent. Blow dry with compressed air. Assembly SHAFT END 1. If you remove plug and seal, lubricate seal and install on plug. Some plugs have two o-ring grooves but require only one o-ring.
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE 9. Apply 3 or 4 drops of Loctite sealant at top of threads for each of the four holes in housing. Do not allow parts with Loctite applied to come on contact with metal parts other than those for assembly.Wipe off excess Loc- tite from housing face, using a non petroleum base sol- vent.

  • Page 138: Timing Procedure

    SECTION 3 - CHASSIS & TURNTABLE Standard rotation align any star point with tooth marked on drive (see figure below). 11. After removing bullet, clamp motor in vise as shown above. Make sure shaft cannot fall out. Install dry screws and alternately torque them immediately to 250 in/lbs (28 Nm).
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 1. Rotate gerotor to line up with bolt holes. Be careful not 3. Install 73 mm (2.875 in.) seal in end cap. Carefully place to disengage star from drive or disturb gerotor seal. end cap on gerotor. 2.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Capscrew 15. Drive Spacer (When Applicable) Exclusion Seal 16. Gerotor Mounting Flange 17. Seal Backup Ring (-008, -009 Motors) 18. Spacer Plate Pressure Seal 19. Drive Seal 20. Seal Bearing Race 21. Housing Needle Bearing Thrust 22.

  • Page 141: 3.19 Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.19 ROTARY COUPLING 4. Remove center body (1) from housing (3). 5. Cut off old seals (2, 4, 5). Use the following procedure to install the seal kit. 6. Assemble lip seals (2) in direction shown in Figure 3-47., Rotary Coupling Seal Installation.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 5. Seal 2. Seal 6. Thrust Ring 3. Housing 7. Snap Ring 4. O-ring 8. Valve Block (Axle Oscillation) Figure 3-48. Rotary Coupling Cutaway 3120740 – JLG Lift – 3-85...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Figure 3-49. Rotary Coupling Port Location (7 Port) 3-86 – JLG Lift – 3120740...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Rotary Coupling Port Location (9 Port) 3120740 – JLG Lift – 3-87...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 1. JLG Threadlocker 6. Rotary Coupling 11. Ring 16. O-ring 2. Bolt 7. Spool 12. Seal 17. Valve 3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 4. Bolt 9. Plug 14. Bearing 19.

  • Page 146: Tilt Alarm Switch (Prior To S/N 0300065534)

    SECTION 3 - CHASSIS & TURNTABLE 3. With the electrical connections complete, using bubble Table 3-9. Coupling Port Information Table (7 port) level on top of indicator, slowly tighten or loosen the three flange nuts until indicator is level. Operating Proof Port Port Size...

  • Page 147: 3.22 Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.22 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 148 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 149: 3.23 Dual Fuel System

    SECTION 3 - CHASSIS & TURNTABLE 3.23 DUAL FUEL SYSTEM If no matching symptom is available, analyze the complaint and develop a plan for diagnostics utilizing the wiring dia- grams, technical assistance, and repair history. Intermittent conditions may be resolved by using a check IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT sheet to pinpoint the circuit or electrical system component.

  • Page 150: Efi Diagnostics (Prior To S/N 0300065534)

    SECTION 3 - CHASSIS & TURNTABLE EFI Diagnostics (Prior to S/N 0300065534) ECM and Sensors The EFI diagnostics are designed to assist in locating a faulty CRANKSHAFT POSITION (CKP) SENSOR circuit or component. When a malfunction is detected by the The crankshaft position (CKP) sensor provides a signal used by Engine Control Module (ECM), a diagnostic trouble code (DTC) the engine control module (ECM) to calculate the ignition...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. 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 152 SECTION 3 - CHASSIS & TURNTABLE ENGINE COOLANT TEMPERATURE (ECT) SENSOR HEATED OXYGEN SENSOR The heated oxygen sensor is mounted in the exhaust stream The engine coolant temperature (ECT) sensor is a g thermistor where it can monitor the oxygen content of the exhaust gas. (a resistor which changes value based on temperature) The oxygen present in the exhaust gas reacts with the sensor mounted in the engine coolant stream.
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE 3-96 – JLG Lift – 3120740...
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE INTAKE AIR TEMPERATURE (IAT) SENSOR If the ECM detects a voltage that is significantly lower than the estimated MAP value for 2 or more consecutive seconds, DTC The intake air temperature (IAT) sensor is a thermistor which 14 will be set.
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE The ECM is designed to maintain exhaust emission levels to • When measuring voltages, use only a digital voltmeter government mandated standards while providing excellent with an input impedance of at least 10 megohms. operation and fuel efficiency.

  • Page 156: Engine Performance Module (Epm)

    SECTION 3 - CHASSIS & TURNTABLE USE OF CIRCUIT TESTING TOOLS • It can be programmed to provide up to four specific speeds with use of a matching toggle switch. Do not use a test light to diagnose the engine electrical sys- tems unless specifically instructed by the diagnostic proce- •...
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Diagnostics Fault Codes Diagnostic Trouble Description Code Closed Loop Multiplier High (LPG) HO2S Open/Inactive (Bank 1) HO2S Open/Inactive (Bank 2) Closed Loop Multiplier High Bank 1 (Gasoline) Closed Loop Multiplier Low Bank 1 (Gasoline) Closed Loop Multiplier Low (LPG) Closed Loop Multiplier High (Natural Gas) Closed Loop Multiplier Low (Natural Gas)
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Diagnostics Fault Codes Diagnostic Trouble Description Code BP High Pressure BP Low Pressure Crank Sync Noise Never Crank Synced At Start Camshaft Sensor Loss Camshaft Sensor Noise Knock Sensor Open Excessive Knock Signal Injector Driver #1 Open (2.5L) Injector Driver #1 Open (4.2L) Injector Driver #1 Shorted (2.5L)
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Diagnostics Fault Codes Diagnostic Trouble Description Code Coil Driver #1 Open (2.5L) Coil Driver #1 Open (4.2L) Coil Driver #1 Shorted (2.5L) Coil Driver #1 Shorted (4.2L) Coil Driver #2 Open (2.5L) Coil Driver #2 Open (4.2L) Coil Driver #2 Shorted (2.5L) Coil Driver #2 Shorted (4.2L)
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Diagnostics Fault Codes Diagnostic Trouble Description Code A/D Loss RTI 1 Loss Flash Checksum Invalid RAM failure External 5V Ref Lower Than Expected External 5V Ref Higher Than Expected RTI 2 Loss RTI 3 loss 3120740 –...

  • Page 161: Fuel System

    SECTION 3 - CHASSIS & TURNTABLE Fuel System much oxygen is in the exhaust gas. The ECM changes the air/ fuel ratio to the engine by control-ling the amount of time that the fuel injector is "ON." The best mixture to minimize exhaust FUEL INJECTOR emissions is 14.7 parts of air to 1 part of gasoline by weight, The Electronic Fuel Injection (EFI) fuel injector is a solenoid-...
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-56. Typical Fuel System FUEL PRESSURE REGULATOR pressure and could cause engine problems or component damage. The fuel pressure regulator is a relief valve mounted in the fuel filter.
  • Page 163 SECTION 3 - CHASSIS & TURNTABLE FUEL PUMP ELECTRICAL CIRCUIT changed with the ECM calibration software. When an engine speed is selected with the toggle switch, the ECM sends the When the key is first turned "ON," the ECM energizes the fuel appropriate signal to the governor.
  • Page 164 SECTION 3 - CHASSIS & TURNTABLE CAMSHAFT POSITION (CMP) SENSOR • Remote mounting capability The CMP sensor uses a variable reactor sensor to detect cam- • No mechanical load on the engine shaft position. The CMP signal is created as piston #1 is a pre- •...

  • Page 165: Ford Lpg System (S/N 0300077500 To S/N 03000140000)

    SECTION 3 - CHASSIS & TURNTABLE 3.25 FORD LPG SYSTEM (S/N 0300077500 TO Megajector S/N 03000140000) The megajector is an electronic pressure regulator. This elec- tronic regulator outputs a specific pressure needed at the mixer to maintain the desired air to fuel ratio. The megajector NOTE: +20°...
  • Page 166 SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid Figure 3-57. LPG System Components (S/N 0300077500 to S/N 03000140000) 3120740 – JLG Lift – 3-109...

  • Page 167: Lockoff Solenoid

    SECTION 3 - CHASSIS & TURNTABLE Lockoff Solenoid b. Fuel System Hoses - Make sure all fuel system hoses are in good condition. They should be The lockoff solenoid is used to reduce the possibility of back- clamped tight, free from kinks with no cuts, pinches, fires.

  • Page 168: Electric Governor Installation And Adjustments - Ford Lrg425 Engine

    SECTION 3 - CHASSIS & TURNTABLE DTC 363 - Megajector Internal Actuator Fault Detection. Mounting-Actuator a. Connections - Check power, ground, and CAN cir- The Actuator may be mounted in any attitude - there is no pre- cuits at the Megajector in addition to all electrical ferred orientation.
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE spring-loaded direction. Also, the Actuator can be mounted in shaft are available on many industrial carburetors to deal with any attitude. this problem. Any tendency on the butterfly stick must be cor- rected. The needed travel of the carburetor determines how far out on the Actuator arm the rod is to be attached.
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE h. Removes ground from the overspeed relay if this then at times, will activate the over speed cutout and shut the point is exceeded. A 20 turn pot is provided to engine off. The ideal gain setting will provide a compromise adjust this set point.(usually around 5000 RPM) between quick response and good stability.
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE Factory: 2. Hold the linkage back by hand, so as to control engine speed manually. Start engine, set vehicle controls to This adjustment is made by turning the plastic screw clock- wise (CW) to increase governor sensitivity, counterclockwise obtain High Engine speed, gradually release the linkage, and adjust the speed-set as needed to set the speed as (CCW) to decrease sensitivity.
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE 3120740 – JLG Lift – 3-115...

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Jlg 800aj

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