Oshkosh Corporation JLG E600 Service And Maintenance Manual
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Oshkosh Corporation JLG E600 Service And Maintenance Manual

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Service and Maintenance Manual
Models
E600
E600J
E600JP
M600
M600J
M600JP
SN 0300219230 to Present
3121711
January 07, 2019 - Rev E
AS/NZS

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  • Page 1 Service and Maintenance Manual Models E600 E600J E600JP M600 M600J M600JP SN 0300219230 to Present 3121711 January 07, 2019 - Rev E AS/NZS...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - March 30, 2017 Revised B - August 22, 2017 Revised C - May 30, 2018 D - June 29, 2018 - Revised Covers Revised E - January 07, 2019 - Revised Pages 4-35, 4-36, 4-37, 4-39 Revised 3121711...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Inflation.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Battery Maintenance and Charging ..............3-46 Battery Maintenance, Quarterly.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Platform ................... 4-1 Platform Valve Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Pressure Setting..................5-57 Proportional Main Relief .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location ................1-3 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-1. Axle Lockout Cylinder ................5-4 5-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-58. Installation of Head Seal Kit............... . . 5-31 5-59.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-1. Voltage Measurement (DC) ............... . . 7-1 7-2.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-57. Soft Touch Harness - Sheet 1 of 2 ..............7-53 7-58.
  • Page 16 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Capacities .

  • Page 17: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES Table 1-1. Operating Specifications Table 1-2. Capacities Maximum Work Load (Capacity) Generator Fuel Tank (M Models Only) 13 gal. (49.2L) ANSI Markets Hydraulic Tank 15.9 gal.(60.2 L) Unrestricted: 500 lbs.

  • Page 18: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS 1.5 HYDRAULIC OIL Table 1-7. Mobil EAL Envirosyn H 32 Specs Table 1-5. Hydraulic Oil Type Synthetic Biodegradable Hydraulic System ISO Viscosity Grade S.A.E. Viscosity Operating Grade Density at 15° C .869 Temperature Range Pour Point, Max -38°F (-39°C) +0°...

  • Page 19: Torque Requirements

    SECTION 1 - SPECIFICATIONS 1.6 TORQUE REQUIREMENTS 1.8 SERIAL NUMBER LOCATION A serial number plate is affixed to the right side of the frame. If Table 1-10. Torque Requirements the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame at the Description Torque Value (Dry) Interval Hours...
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance and Lubrication Diagram 3121711...

  • Page 21: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.9 OPERATOR MAINTENANCE 2. Generator Engine (If Equipped) NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Diagram Table 1-12. Lubrication Specifications. Specification Multipurpose Grease having a minimum dripping point of 350 degrees F.
  • Page 22 SECTION 1 - SPECIFICATIONS 4. Hydraulic Filter 6. Wheel Drive Hub Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Level/Fill Plug or 300 hrs. thereafter or as indicated by Condition Capacity - 0.4 gal. (1.5 L) Indicator.
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121711...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5) 3121711...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121711...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 4 of 5) 1-10 3121711...
  • Page 27 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 3121711 1-11...
  • Page 28 SECTION 1 - SPECIFICATIONS NOTES: 1-12 3121711...

  • Page 29: General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this MAINTENANCE manual for servicing and maintenance procedures. General Annual Machine Inspection This section provides the necessary information needed by those personnel that are responsible to place the machine in The Annual Machine Inspection must be performed by a Fac- operation readiness and maintain its safe operating condition.

  • Page 30: Service And Guidelines

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

  • Page 31: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING your work to assure that nothing has been overlooked.

  • Page 32: Lubrication

    SECTION 2 - GENERAL Lubrication Hydraulic Oil 1. Refer to Section 1 for recommendations for viscosity Service applicable components with the amount, type, and ranges. grade of lubricant recommended in this manual, at the speci- fied intervals. When recommended lubricants are not avail- 2.

  • Page 33: Cylinder Drift

    SECTION 2 - GENERAL CYLINDER DRIFT Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...

  • Page 34: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on Filament wound bearings. an external structure, or component. Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment...
  • Page 35 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 36 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Ground Controls Function Control Locks, Guards, or Detents Foot switch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator Drive Brakes Swing Brakes...
  • Page 37 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications...
  • Page 38 SECTION 2 - GENERAL HYDRAULIC OPERATING FLUID CHART NOTE: DRIVE PERFORMANCE MAY BE REDUCED BELOW 0 DEG F. NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINES IN THE “HYDRAULIC FLUID OPERATION CHART” MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.

  • Page 39: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Tire Inflation Wheel Replacement The air pressure for pneumatic tires must be equal to the air The rims installed on each product model have been designed pressure that is stenciled on the side of the JLG product or rim for stability requirements which consist of track width, tire...

  • Page 40: Spindle, 2Wd

    SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Fol- way down. The unit should be checked again to assure it lowing the recommended sequence, tighten nuts per spins freely after the dust cap is installed. wheel torque chart.
  • Page 41 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle 2780245 C 1001180912 B Figure 3-1. Spindle Assembly 3121711...

  • Page 42: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB THE LEAK TEST (MAIN UNIT) The purpose of a leak test is to make sure the unit is airtight. You can tell if your unit has a leak if the pressure gauge read- Roll and Leak Testing ing on your leak checking fitting starts to fall after the unit has Torque-Hub units should always be roll and leak tested before...

  • Page 43: Tightening And Torquing Bolts

    SECTION 3 - CHASSIS & TURNTABLE Tightening and Torquing Bolts 2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug. If an air impact wrench is used to tighten bolts, extreme care 3. Crisscross around the bolt circle and tighten remaining should be taken to ensure that the bolts are not tightened bolts.

  • Page 44: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Lift out the Input Carrier Subassembly from Hub-Spin- dle Subassembly. NOTE: Refer to Figure 3-2., Main Disassembly Drawing 1, and Fig- 7. Remove the Input Shaft Subassembly out of the Hub- ure 3-3., Main Disassembly Drawing 2, Spindle Subassembly.
  • Page 45 SECTION 3 - CHASSIS & TURNTABLE NOTE: Discard the O-ring in the step below. Do not re-use it. 16. Slide the Planet Gear Subassembly (4F) out of the Hub- Spindle Subassembly being careful not to drop the Nee- dle Bearings (4C) in the process. 13.

  • Page 46: Output Planet Gear Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Planet Gear Disassembly 3. Remove the Thrust Spacer (4D) from the Planet Gear (4F). NOTE: Refer to Figure 3-4., Output Planet Gear Disassembly 4. Repeat Steps 1 through 3 for the remaining two Planet Gears (4F).

  • Page 47: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 3. Unscrew the Hex Head Bolts (6C) from the Disengage Cap (6B), if required. NOTE: Figure 3-5., Cover Disassembly 4. Remove the Disengage Cap (6B) from the Cover (6A). 1. Remove the O-Ring (17) from groove in the Cover (6A) Pull the Disengage Rod (6D) out of the Cover (6A).

  • Page 48: Housing-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Disassembly 5. Turn the unit over and carefully place the unit on a sup- port base until the Spindle (1A) rests on it. Ensure there is enough gap to lower the Housing (1D) down. NOTE: Refer to Figure 3-6., Housing Spindle Disassembly 1.
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Lip Seal 1C. Bearing Cup 1D. Housing 1F. Bearing Nut 1G. Housing 1H. Wheel Stud Figure 3-6. Housing Spindle Disassembly 3121711 3-11...

  • Page 50: Housing-Spindle Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Subassembly 6. Spray the Spindle (1A) seal diameter with alcohol and wipe with a clean rag. Apply a coat of oil to the Spindle (1A) seal lip diameter. NOTE: Refer to Figure 3-6., Housing Spindle Disassembly 7.

  • Page 51: Output Planet Gear Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Planet Gear Subassembly Cover Subassembly NOTE: Refer to Figure 3-4., Output Planet Gear Disassembly NOTE: Refer to Figure 3-5., Cover Disassembly 1. Apply a liberal coat of grease to the bore of the Planet 1.

  • Page 52: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly 10. Drive Roll Pin (4G) down into t he aligned roll pin holes. Pin should be flush with OD of spindle. NOTE: Refer to Figure 3-7., Main Assembly Drawing Install O-Ring (18) onto groove of Housing (1G). 12.
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 1E. Ring Gear 4F. Planet Gear Subassembly 9. Input Shaft 1N. Thrust Washer 4G. Roll Pin 10. Sun Gear 1P. O-ring 4H. Thrust Washer 11. Sun Gear 4B. Thrust Washer 5. Retaining Ring 12. Sun Gear 4C.
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Hub Assembly - Sheet 1 of 2 3-16 3121711...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1P. O-ring 4D. Thrust Spacer 6F. Oil Plug 8B. Thrust Washer 1B. Lip Seal 1R. Ring Gear 4E. Planet Shaft 6G. Retaining Ring 9. Input Shaft 1C. Tapered Bearing Cup 2. Thrust Spacer 4F.

  • Page 56: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE MOTOR 7. Remove the screws (22) from the retaining plate (23). 8. Remove the retaining plate (23) from the cover (21). Removal 9. Remove the cover (21) from the shield end (18). 1.

  • Page 57: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Installation 1. Install the drive motor to the machine. NOTE: Refer to Figure 3-10., Drive Motor. 1. Install the rotor (29) into the stator (2). INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT, 2.
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 1. Not Included 10. Shaft Seal 19. Seal 28. O-Ring 2. Stator 11. Bearing 20. Seal 29. Rotor 3. Terminal Board 12. Washer 21. Cover 30. Retainer Clip 4. Nut 13. Speed Sensor 22. Screw 31.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Drive Hub Assembly 2. Hub Seal 3. Motor Adapter Plate 4. Motor Seal 5. Drive Motor Assembly 6. Drive Brake Assembly 8. Drive Module 9. AC Drive Electrical Plate Figure 3-11. Drive Components 3121711 3-21...

  • Page 60: Oscillating Axle Lockout Test (If Equipped)

    SECTION 3 - CHASSIS & TURNTABLE 3.5 OSCILLATING AXLE LOCKOUT TEST (IF 3.6 OSCILLATION CYLINDER BLEEDING EQUIPPED) NOTE: The oscillating axle must be checked daily for proper oper- ation. Bleeding Procedure LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS 1.
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE This Page Left Blank Intentionally 3121711 3-23...
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 1001174527 C 1001174492 C 1001174528 C 1001174524 C 1001174525 C 1001173384 D Figure 3-12. Oscillating Axle - Sheet 1 of 2 3-24 3121711...
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Weldment 6. Wear Pad 12. Bushing 1A. Steer Cylinder Mounting Block Assembly 7. Lockout Cam 13. Thrust Washer 2. Lockout Cylinder Assembly 8. Lockout Valve Assembly 14. Bolt 3. Bolt 9. Pin Keeper 15.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE Figure 3-14. Axle Oscillation Lockout Valve - Sheet 1 of 2 3-26 3121711...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 8. Drive Adapter Assembly 14. Bearing 21. Drive Motor Assembly 2. Tie-Rod 8A Wheel Stud 15. Cotter Pin 22. Mount 3. Bolt 9. Thrust Washer 16. Rotary Angle Sensor Switch 23. Lockout Cam 4.

  • Page 66: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll, Leak and Brake Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 1. Housing Assembly 1H. Thrust Washer 3D. Thrust Spacer 9. Sun Gear 19. Female Tube 1A. Output Shaft 1I. Retaining Ring 3E. Shaft Planet 10. Hydraulic Motor 20. Tubing 1B. Lip Seal 1J. Pipe Plug 3F.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Swing Motor Assembly - Sheet 1 of 2 3-30 3121711...
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 101. Bolt 110. Drive Link 118. Housing 102. End Cover 112. Coupling Shaft 118A O-Ring 103. Commutator Seal 113. Bushing 121. Plug 104. Seal Ring 114. Thrust Washer 122. O-Ring 105. Commutator and Ring Assembly 115.

  • Page 70: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 3. Using a wrench, loosen jam nut on Elbow Fitting (17) and remove fitting from Motor Control Valve (31). NOTE: Refer to Figure 3-19., Motor Control Valve 4. Using a wrench, remove Fitting (21) from Brake Housing. 5.

  • Page 71: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 3. Remove Thrust Washer (11) from between Brake/ Motor Subassembly and Carrier. NOTE: Refer to Figure 3-20., Motor and Brake 4. Remove one O-Ring Plug (13) from Motor (10) and one O-Ring Plug (13) from Brake Housing (6).
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 6. Remove Motor (10) from Brake Housing (6) by removing 9. Remove Brake Piston (8-2) from Brake Housing (6) by four Bolts (15) incrementally until spring pressure is slowly pressurizing brake port in Brake Housing (6) with relieved.

  • Page 73: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 3. Remove O-ring (5) from between Ring Gear (2) and Housing Subassembly. NOTE: Refer to Figure 3-22., Main Assembly 4. Remove four Dowel Pins (14) from Housing Subassem- bly. 1. With the unit resting on the Output Shaft (Pinion) (1A), remove the Carrier Subassembly.

  • Page 74: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-shaft Disassembly NOTE: The Lip Seal (1B) may or may not be pressed out of the Housing (1G) by the Bearing Cone (1D) during this step. NOTE: Refer to Figure 3-23., Hub Shaft 4. Remove the Bearing Cone (1D) from the Housing (1G). 1.

  • Page 75: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 3. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A). NOTE: Refer to Figure 3-24., Carrier 4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F).

  • Page 76: Hub-Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly Carrier Sub-Assembly NOTE: Refer to Figure 3-23., Hub Shaft NOTE: Refer to Figure 3-24., Carrier 1. Press Bearing Cup (1E) into Motor end of Housing (1G) 1. Apply a liberal coat of grease to the bore of Planet Gear using an appropriate pressing tool.

  • Page 77: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly prevent them from being “shaved” when Piston (8-2) is installed into Brake Housing (6). NOTE: Refer to Figure 3-22., Main Assembly 5. Apply grease sparingly to Piston (8-2) O.D. and the cylin- der bore of Brake Housing (6).

  • Page 78: Motor Control Valve Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly Procedure for Setting Gear Backlash NOTE: Ensure mounting plate and mounting location of the base 1. Lay assembly down with motor ports facing up. Remove plate are clean and painted with a uniform coating of min- the two plastic plugs in the motor ports on new motors, imum thickness (no runs, drips, etc.).

  • Page 79: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 5. Tighten the Setscrew (3) until the pinion is completely 7. Lower the boom to horizontal and fully extend the snug against the shim and bearing and then back off the boom. setscrew. 8. Swing the turntable over the side. 6.

  • Page 80: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE 4. Assure that the 0.0015" feeler gauge will not penetrate Wear Tolerance under the bolt head to the bolt shank. 1. With the boom positioned over the side of the machine, 5. Swing the turntable 90 degrees, and check some the Boom horizontal with telescope fully extended, selected bolts at the new position.
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE FRAME REF. 0270752 C 1001175087 B 1. Swing Motor Assembly 7. Shoulder Screw 13. Bulkhead Fitting 19. Clamp Bar 2. Turntable Stop 8. Washer 14. Adapter Fitting 20. Hose 3. Chain 9. Nut 15. Hose 21.

  • Page 82: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE Replacement of Swing Bearing NOTE: If Mobiltac 375NC is not available, Tribol Molub-Alloy 936 Open Gear Compound or Mobilith SHC Bearing Grease or Multi-Purpose Grease (MPG) can be substituted, however Removal of the swing bearing is as follows: the service interval will be shorter.

  • Page 83: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE 11. Following the torque sequence shown in Figure 3- 28., Swing Drive Installation Swing Bearing Torque Sequence tighten the bolts to an initial torque of 130 ft. lbs. (175 Nm). Then following the 1. Coat the threads of the socket head bolts securing the same sequence, tighten the bolts to 190 ft.

  • Page 84: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.9 BATTERY MAINTENANCE AND CHARGING Optional On Board Generator Battery Maintenance, Quarterly 1. Open battery compartment cover to allow access to bat- EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY. tery terminals and vent caps.

  • Page 85: Removing The Battery Box

    SECTION 3 - CHASSIS & TURNTABLE Removing the Battery Box NOTE: The battery box and batteries complete weigh approxi- mately 668 pounds (303 kg). To remove the battery box, perform the following steps. 3. Using a forklift, lift the battery box up enough to clear 1.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Figure 3-31. Batteries and Battery Charger 3-48 3121711...

  • Page 87: Battery Charger

    SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY CHARGER Operating Instructions JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTENSION CORD, FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3-WIRE 12 AWG CORD.

  • Page 88: Maintenance Instructions

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Instructions Battery Charger Fault Codes If a fault occurred during charging, the red "Fault" LED will 1. For flooded lead-acid batteries, regularly check water flash with a code corresponding to the error. Refer to the table levels of each battery cell after charging and add dis- following for the flash codes and their removal.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 1. Battery Charger Assembly 2. AC Voltage - Input Cable 3. Battery Charge Signal Cable 4. DC Power Cable to Batteries Figure 3-32. Battery Charger 3121711 3-51...
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is not Indicates the battery failed to charge within the allowed connected or that the AC voltage is too low. It could also time.

  • Page 91: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    SECTION 3 - CHASSIS & TURNTABLE 3. Confirm that dirt or mud is not blocking the cooling fins 4. If the output voltage of the charger seems excessive, of the charger. Clean the charger. Rinse the charger with return the charger for service. Contact JLG to get the a low pressure hose if required.

  • Page 92: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.11 GENERATOR Dynamo and Dynamo Voltage Regulator NOTE: Throughout the Generator section, the abbreviation RBS is used. RBS stands for Rotary Battery System, which is the generator system. The engine-driven generator is designed to produce a DC output directly without the need of a separate rectifier.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE 1. Glow Plug Relay 8. Temperature Sensor 2. Fuel Control Relay 9. Voltage Regulator 3. Start Control Relay 10. Alternator 4. Fuel Solenoid 11. Starter 5. Fuel Pump 12. Starter Solenoid 6. Low Oil Pressure Switch 13.

  • Page 94: Start Battery

    SECTION 3 - CHASSIS & TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead-acid start battery (not supplied with the system), which provides starting power and power for the RBS controls. This battery is charged by the engine dynamo and dynamo regulator when the engine is running.

  • Page 95: Fuel Control Relay

    SECTION 3 - CHASSIS & TURNTABLE Fuel Control Relay Glow Plug Control Relay The glow plug control relay energizes the glow plug. It is The fuel control relay energizes the hold coil of the fuel energized by the engine/generator controller, pin J2-27. solenoid.

  • Page 96: Fuel Pump

    SECTION 3 - CHASSIS & TURNTABLE Fuel Pump Engine Low Oil Pressure Switch The fuel pump runs in parallel with the fuel solenoid hold coil which is run by the fuel control relay. The pump runs whenever the engine runs, and keeps the fuel filter filled.

  • Page 97: Alternator Output Current Sensor

    SECTION 3 - CHASSIS & TURNTABLE engine temperature shutdown 248°F (120°C) for the The engine/generator controller interface is via a J2 35-pin engine. The signal is also used in determining if the air connector. glow plug should be energized. The engine oil temperature sensor is connected to the engine/generator controller at pins J2-8 and J2-19.

  • Page 98: Warnings And Safety Precautions

    SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Controller Interface Pin Assignments System Settings Pre-heat CALL TO START SETTINGS Inhibit run Low battery voltage call to start level 48.0 VDC Engine temp. switch Low battery voltage remove call to start level 54.0 VDC + Output voltage Low temperature call to start level...

  • Page 99: Rbs Start

    SECTION 3 - CHASSIS & TURNTABLE RBS Start RBS shutdown Call to start Manual 48V DC applied to the input Call to start removed Manually Inhibit run input applied Automatic 1 Low battery voltage (below 48VDC) Automati- 1 Battery voltage above 54VDC and cally: finish charging current below 30ADC 2 Low engine temperature (below 5°C)

  • Page 100: Rbs Alarms And Flash Codes

    SECTION 3 - CHASSIS & TURNTABLE RBS Alarms and Flash Codes In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. Table 3-5. RBS Alarms and Flash Codes Flash Code Problem RBS Condition Below 7psi...

  • Page 101: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-6. Troubleshooting Flash Code Problem Solution Unit Off / Disabled (engine will not crank) Check position of selector switch. Verify that the inhibit run is released. Check the warning LED. Remedy fault if present and restart the RBS. Check the start battery voltage.

  • Page 102: Apu Engine Start Battery Boosting

    SECTION 3 - CHASSIS & TURNTABLE APU Engine Start Battery Boosting Always connect the POSITIVE (+) of the booster battery to DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID LEVEL IN THE the POSITIVE (+) of the APU start battery, and the NEGATIVE BATTERY.

  • Page 103: Supplementary Fuse For Apu

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SUPPLEMENTARY FUSE FOR APU 2. where the harness attaches to the rear cover of the gen- erator and the connection point for the new inline fuse. The purpose of this section is to describe the procedure to add a supplementary fuse for the Engine Generator Con- troller for the APU.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. 6. Re-install the harness with the new fuse in place. 5.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE COUNTERWEIGHT Figure 3-34. Counterweight 3121711 3-67...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-68 3121711...

  • Page 107: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM Support Removal Platform Valve Removal 1. Tag and disconnect the hydraulic lines from the plat- form control valve. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports. 2.

  • Page 108: Support Installation

    SECTION 4 - BOOM & PLATFORM 4. Remove the bolts and locknuts securing the support to Support Installation the rotator. 1. Using a suitable lifting device, support the platform sup- port and position it on the rotator. NOTE: The platform support weighs approximately 77 lbs. (35 kg). 2.

  • Page 109: Platform Valve Installation

    SECTION 4 - BOOM & PLATFORM 5. Position the platform on the platform support and 4. Install cover onto the platform support securing the install the bolts securing the platform to the platform hardware. support.Torque the bolts to 75 ft. lbs. (102 Nm). 5.
  • Page 110 SECTION 4 - BOOM & PLATFORM A,B,D NOTE: If any rotator bolts are replaced, replace all bolts on the rotator and torque them. Torque to 40 ft.lbs. (55 Nm) JLG Thread locker P/N 0100011 Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 75 ft.

  • Page 111: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM 4.2 BOOM MAINTENANCE Removal NOTE: The main boom assembly weighs approximately 1993 lbs. (904 kg). 1. Raise the boom to horizontal and make sure that it is adequately supported with a lifting device or blocking. 2.
  • Page 112 SECTION 4 - BOOM & PLATFORM UPRIGHT LIFT CYLINDER POWER MASTER TRACK CYLINDER MAIN BOOM BOOM LINK TOWER LINK TOWER BOOM UPPER WEAR PADS BOOM FLY SECTION BOOM BASE SECTION TELE CYLINDER LOWER WEAR PADS Figure 4-3. Boom Assembly - Sheet 1 of 3 3121711...
  • Page 113 SECTION 4 - BOOM & PLATFORM BOOM BASE SECTION WEAR PADS BOOM FLY SECTION TELE CYLINDER POWER TRACK BOOM BASE SECTION BOOM FLY SECTION BOOM SLAVE REST CYLINDER TOWER BOOM TOWER PLATFORM LINK ROTATOR Figure 4-4. Boom Assembly - Sheet 2 of 3 3121711...
  • Page 114 SECTION 4 - BOOM & PLATFORM BOOM PIVOT WITH JIB UPPER SLAVE JIB LINK CYLINDER CYLINDER LOWER ROTATOR JIB LINK COVER PLATE BOOM WITH SIDE SWING ROTATOR UPPER JIB LINK SLAVE CYLINDER CYLINDER PIVOT COVER PLATE ROTATOR LOWER JIB LINK Figure 4-5.

  • Page 115: Installation

    SECTION 4 - BOOM & PLATFORM 6. Connect the hydraulic lines running to the master cylin- der as tagged during removal. 7. Connect the hydraulic lines running to the telescope cyl- inder as tagged during removal. MASTER CYLINDER PIVOT PIN Install the covers on the side of the upright to conceal the pivot pins.
  • Page 116 SECTION 4 - BOOM & PLATFORM 12.0 RESET DETAIL B SEE DETAIL B SWITCH TO RESET WHEN BOOM IS 2° - 7° ABOVE HORIZONTAL. 4.8° IS THE PREFERRED RESET ANGLE SWITCH RESET 30.0° TRIP DETAIL A SWITCH TO TRIP WHEN BOOM IS 9°...
  • Page 117 SECTION 4 - BOOM & PLATFORM SWITCH TO ACTIVATE WHEN BOOM IS EXTENDED 18±1” (46±2.5 CM) Figure 4-7. Transport Limit Switch (CE Only) 3121711 4-11...

  • Page 118: Platform Rotator

    SECTION 4 - BOOM & PLATFORM 4.3 PLATFORM ROTATOR Theory of Operation The rotary actuator is a simple mechanism that uses the slid- ing spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular piston sleeve (03).

  • Page 119: Tools Required For Assembly/Disassembly

    SECTION 4 - BOOM & PLATFORM Tools Required for Assembly/Disassembly 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 there are Upon assembly and disassembly of the actuator a torch.
  • Page 120 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.
  • Page 121 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 122: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 4. Install the end cap (4) removal tools provided with the Helac seal kit. 1. Remove the cap screws (113) over end cap lock pins (109). 5. Using a metal bar, or something similar, un-screw the end cap (4) by turning it counter clock-wise.
  • Page 123 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 124 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 125 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 126: 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 127 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 128 SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using a 8. 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 129 SECTION 4 - BOOM & PLATFORM 10. Looking from the opposite end of the housing (1) you 12. 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 130 SECTION 4 - BOOM & PLATFORM 15. Coat the threads on the end of the shaft with anti-seize 18. Tighten the end cap (4). In most cases the original holes grease to prevent galling. for the lock pins will line up. 19.

  • Page 131: Greasing Thrust Washers

    SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers 3. Insert the tip of a grease gun into one port and apply grease to the shaft flange. Continue applying until 1. After the actuator is assembled but before it is put into grease flows from the opposite port.

  • Page 132: Jib Rotator

    SECTION 4 - BOOM & PLATFORM 4.4 JIB ROTATOR Disassembly 1. Remove all hydraulic fittings Drain the oil from both Operating Principle sides of the piston through the pressure ports. 2. Place the actuator horizontally on a clean work bench Helac’s helical hydraulic rotary actuators use our sliding spline with ample room to place the internal parts as they are technology which converts linear piston motion into powerful...
  • Page 133 SECTION 4 - BOOM & PLATFORM Before the shaft and piston gearing are completely dis- engaged, note the orientation between the spline teeth: small punch marks on the face of the piston and the root of a spline tooth on the shaft gearing indicate timing as seen below A considerable amount of torque may be required to...
  • Page 134 SECTION 4 - BOOM & PLATFORM 1. Housing 111. Grease Fitting 205. Bearing Seal 2. Shaft 112. Grease Relief Valve 206. Exclusion Seal 3. Piston Sleeve 400. Stop Tube 301. Piston Bearing 4. End Cap 200. Rod Seal 302. Shaft Bearing 5.
  • Page 135 SECTION 4 - BOOM & PLATFORM DRILL 17/64 DIAMETER THRU 1.00 BREAK EDGES, BOTH SIDES 4-PLACES EQUALLY SPACED .050 x 45° ON A 2.780 BOLT CIRCLE TYPICAL 3.330 2.20 DRILL & TAP 3/8-16 UNC THRU 2 PLACES EQUALLY SPACED ON A 2.780 BOLT CIRCLE Figure 4-12.

  • Page 136: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 3. Lightly coat the thrust washers (304) with grease and install them on the shaft (02) and end cap (04) prior to seal installation. Inspect all parts for wear, damage, cracks, etc. 4. Lightly coat all sealing and working surfaces with a good HOUSING grade of hydraulic oil.
  • Page 137 SECTION 4 - BOOM & PLATFORM 11. Apply a generous amount of anti-seize to the splines at the end of the shaft. Locate the correct position of the locknut to align its bolt circle with that of the end cap. If the bolt circles do not align, unthread the end cap no more than a half a pitch of the shaft splines.

  • Page 138: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Threadlocker P/N 0100011 should be applied to the shank of the three bolts at the time of installation. Refer to Figure 4-13., Rotator Counterbalance Valve. 4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4 to 13.5 Nm).

  • Page 139: 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 pres- sure at which the shaft begins to rotate — should be approxi- mately 400 psi (28 bar).
  • Page 140 SECTION 4 - BOOM & PLATFORM Table 4-1. Troubleshooting Problem Cause Solution 126. 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 141: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.5 SKYGUARD Function Test SKYGUARD ONLY Operation Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2). When the SkyGuard sensor is activated, functions in use at From the Platform Control Console in an area free from obstruc- the time of actuation will reverse or cutout.

  • Page 142: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains CLOSED while the Sky- Guard sensor is actively engaged, a power or ground wire may If SkyGuard does not function when the sensor is engaged, not be making good contact or may be loose or broken.

  • Page 143: Bolt-On External Fall Arrest

    SECTION 4 - BOOM & PLATFORM BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The Bolt-On External Fall Arrest system is designed to provide GAP SHOWING: GAP SHOWING: a lanyard attach point while allowing the operator to access INCORRECT INCORRECT areas outside the platform.
  • Page 144 SECTION 4 - BOOM & PLATFORM 2. Attach the fall arrest cable to the right hand bracket 5. Use the two jam nuts to prevent the cable from rotating Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel- shown below.
  • Page 145 SECTION 4 - BOOM & PLATFORM 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 4-15. Bolt-On External Fall Arrest System 3121711 4-39...
  • Page 146 SECTION 4 - BOOM & PLATFORM NOTES: 4-40 3121711...

  • Page 147: Basic Hydraulic Information & Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 148: Dip Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.

  • Page 149: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.2 HYDRAULIC CYLINDERS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder Axle Lockout Cylinder seal kit is used. See your JLG Parts Manual. DISASSEMBLY NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 150 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 22-24 ft.lbs. (30-33 Nm) ** Torque to 22 ft.lbs. (30 Nm) 1001163580 E 1. Rod 4. Cartridge Valve 7. Wiper Seal 2. O-ring Plug 5. Barrel 8. Rod Seal 3.

  • Page 151: Slave Cylinder (E/M600 Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder (E/M600 only) 5. Mark cylinder head and barrel with center punch marks for later realignment. Remove cylinder head capscrews. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK CAPSCREWS SURFACE IN A DIRT FREE WORK AREA.
  • Page 152 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 50-55 ft.lbs. (68-75 Nm) ** Torque to 5 ft.lbs. (7 Nm) *** Torque to 30 ft.lbs. (41 Nm) 1683867 E 1. Cartridge Valve 6. Head 11. Piston 16. Back-up Ring 21.
  • Page 153 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 9.
  • Page 154 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Lubrication is not required with nickel plated pins and ASSEMBLY bearings. Install pin into the composite bearing dry. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 155 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. WEAR WEAR T-SEAL RING RING O-RING WIPER SEAL CYLINDER MALLET HEAD NOTE: When installing wiper seal, ensure the seal is installed properly.
  • Page 156 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS b. Tap each space once; this means the tapered bush- 21. After the cylinder has been reassembled, the rod should ing is tapped 3 times as there are 3 spaces between be pushed all the way in (fully retracted) prior to the re- the capscrews.

  • Page 157: Slave Cylinder (E/M600J/Jp)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder (E/M600J/JP) 5. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 158 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 443 ft.lbs. (600 Nm) ** Torque to 42 ft.lbs. (70 Nm) *** Torque to 11 ft.lbs. (15 Nm) 1001140596 A 1. Barrel 6. Wear Ring 11. Backup ing 16. O-ring 21.
  • Page 159 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 9.
  • Page 160 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Lubrication is not required with nickel plated pins and ASSEMBLY bearings. Install pin into the composite bearing dry. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 161 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new retain- WEAR PISTON WEAR ing ring into the applicable cylinder head gland groove. RING SEAL RING...

  • Page 162: Jib Lift Cylinder (E/M600J/Jp)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Jib Lift Cylinder (E/M600J/JP) 5. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 163 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft.lbs. (70 Nm) ** Torque to 11 ft.lbs. (15 Nm) ** *Torque to 369 ft.lbs. (500 Nm) 1001140282 A 1. Barrel 6. Bushing 11. Retainer 16. O-ring 21. Piston Seal 2.
  • Page 164 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 165 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. 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 166 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than cable cylinder head gland groove.

  • Page 167: Main Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Lift Cylinder 5. Mark cylinder head and barrel with center punch marks for later realignment. Remove cylinder head capscrews. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK CAPSCREWS SURFACE IN A DIRT FREE WORK AREA.
  • Page 168 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS **** * Torque to 18-20 ft.lbs. (24-27 Nm) ** Torque to 30-35 ft.lbs. (41-47 Nm) *** Torque to 50-55 ft.lbs. (68-75 Nm) ****Torque to 30 ft.lbs. (41 Nm) 1683876 G 1. Counterbalance Valve 6.
  • Page 169 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or holding fixture as close to the piston as possible. 1. Clean all parts thoroughly in an approved cleaning sol- 9.
  • Page 170 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Lubrication is not required with nickel plated pins and ASSEMBLY bearings. Install pin into the composite bearing dry. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 171 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston and insert capscrews through the drilled holes in the cable cylinder head gland groove.
  • Page 172 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 18. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the re- EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, installation of any holding valve or valves.

  • Page 173: Master Cylinder (E/M600)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder (E/M600) 4. Using a hook spanner wrench, loosen the setscrew and remove setscrew from the cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SPANNER NUT SURFACE IN A DIRT FREE WORK AREA.
  • Page 174 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1683865 C 1. Lock Nut 6. O-ring 11. Bushing 15. Guide 2. O-ring 7. Spacer 12. O-ring 16. Seal 3. Wear Ring 8. Barrel 13. Backup Ring 17. Wiper Seal 4. Piston 9.
  • Page 175 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 176 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. 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 177 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 12. Place new piston seal, wear rings and o-ring in the outer cable cylinder head gland groove. and inner piston diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 178: Master Cylinder (E/M600J/Jp)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder (E/M600J/JP) 4. Using a hook spanner wrench, loosen the setscrew and remove setscrew from the cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SPANNER NUT SURFACE IN A DIRT FREE WORK AREA.
  • Page 179 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1683866 D 1. Lock Nut 6. O-ring 11. Bushing 15. Guide 2. O-ring 7. Wiper Seal 12. O-ring 16. Seal 3. Wear Ring 8. Barrel 13. Backup Ring 4. Piston 9. Bushing 14.
  • Page 180 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 181 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. 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 182 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal, wear rings and o-ring in the outer cable cylinder head gland groove. and inner piston diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 183: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Cylinder 5. Using a pin-face spanner wrench, unscrew the cylinder head from both ends of the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 184 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque Head to 590 ft.lbs. (800 Nm) 1001140281 A 1. Barrel 5. Wear Ring 9. Wiper Seal 13. Backup Ring 2. Rod 6. T-seal 10. O-Ring 14. O-Ring 3. Head 7. O-Ring 11.
  • Page 185 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a ASSEMBLY vise or similar holding fixture as close to the piston as NOTE: Prior to cylinder assembly, ensure that the proper cylinder possible.
  • Page 186 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder guide gland groove. Install the new EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, retaining ring into the applicable groove of the cylinder HEAD, AND PISTON.

  • Page 187: Telescope Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder 4. Remove bolts and valve assembly from the barrel end. Discard o-rings. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 188 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 11 14 * Torque to 9 ft.lbs. (12 Nm) 1684009 D 1684010 E 1. Valve Assembly 6. Barrel 11. Piston 16. O-ring 21. Back-up Ring 2. Valve Seal 7. Rod 12. Support Plate 17.
  • Page 189 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, carefully withdraw the 12. Remove and discard backup ring and o-ring from the complete rod assembly from the cylinder barrel. inside groove of piston. Remove and discard wear ring and piston seal from the outside groove of the piston.
  • Page 190 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. 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 191 SECTION 5 - BASIC HYDRAULIC INFORMATION & 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. and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 192 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 15. Place new cap seal and wear rings in the outer piston 16. Position the cylinder barrel in a suitable holding fixture. diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal).
  • Page 193 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1. Hydraulic Tank 6. Filter Indicator 2. Filter & Pressure Switch 7. Tank Strap 3. Suction Strainer 8. Electric Motor 4. Magnetic Plug 9. Hydraulic Pump 5. Sight Gauge 10. Contactor Module 11.

  • Page 194: Cylinder Removal And Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.3 CYLINDER REMOVAL AND INSTALLATION 1. Main Boom 3. Master Cylinder 5. Slave Cylinder 7. Main Telescope Cylinder 9. Steer Cylinder 2. Upright Level 4. Main Lift Cylinder 6. Jib Lift Cylinder 8.

  • Page 195: Main Boom Telescope Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Removal 7. Remove four bolt which attach cover plate on the rear of the upright and remove upright cover plate. 1. Place machine on a flat and level surface, with main boom in the horizontal position.

  • Page 196: Main Boom Telescope Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Installation 7. Install four bolts, two blocks and shims to attach tele- scope cylinder barrel ens support to boom assembly. 1. Attach hydraulic power supply to telescope cylinder ports.

  • Page 197: Main Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Lift Cylinder Removal 7. Remove bolt and keeper pin from barrel end attach pin. Carefully drive out barrel end attach pin using suitable 1. Place machine on a flat and level surface, with main brass drift.

  • Page 198: Main Boom Lift Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Lift Cylinder Installation 5. Use auxiliary power to extend cylinder rod until attach pin hole aligns with hole in the boom. NOTE: The main boom weighs approximately 1816 lbs. (824 kg). 6.

  • Page 199: Master Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder Removal 6. Remove bolt and keeper pin from cylinder rod pin. Care- fully drive out rod pin using suitable brass drift. 1. Place machine on a flat and level surface, with main boom in the horizontal position.

  • Page 200: Master Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder Installation 5. Use a suitable drift to drive cylinder rod attach pin through aligned holes, take care to align the grooved pin holes. Install keeper pin and bolt. NOTE: The main boom weighs approximately 1816 lbs. (824 kg). 1.

  • Page 201: Slave Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder Removal 7. Remove bolt and keeper pin from cylinder barrel attach pin. Carefully drive out rod pin using suitable brass drift. 1. Place machine on a flat and level surface, with main boom to the lowest position.

  • Page 202: Slave Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder Installation 4. Use a suitable drift to drive cylinder rod attach pin through aligned holes in slave cylinder and rotator. Secure rod end attach pin with screw. NOTE: The main boom weighs approximately 1816 lbs. (824 kg). 1.

  • Page 203: Pressure Setting

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.4 PRESSURE SETTING Swing Proportional Main Relief - 3200 psi (220 Bar) 1. Connect the pressure gauge at the MP port on the main valve. Lift Down - 1100 psi (76 Bar) Lift Up - 2500 (172 Bar) 2.
  • Page 204 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-94. Main Control Valve - Hydraulic 5-58 3121711...
  • Page 205 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS JIB Plus Model * Torque to 20 ft.lbs. (28 Nm) Straight Boom Model * Torque to 20 ft.lbs. (28 Nm) JIB Model * Torque to 20 ft.lbs. (28 Nm) 1. JIB Right 8.
  • Page 206 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ROTATOR ACTUATOR ARTICULATING JIB ROTATOR ACTUATOR 14.3 CU.IN. BORE: 2500” 4.908 SQ IN 14.3 CU.IN ROTATOR MOTION CONTROL VALVE ROD: 1.500” 1.676 SQ IN ROTATOR MTION CONTROL VALVE PILOT RATION: 3:1 ANNULUS: 3.141 AQ IN PILOT RATIO: 3:1 SRPING SETTING: 2500 PSI CYL.
  • Page 207 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAIN TELE CYLINDER PORT BLOCK IS REGEN IN EXTEND ONLY BORE :3.000" 7.068 SQ IN ROD : 2.250" 3.976 SQ IN ANNULUS: 3.092 SQ IN CYL. STROKE: 234.625" (E600) CYL. STROKE: 207.375" (E600J) MAIN LIFT CYL.
  • Page 208 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTES: 5-62 3121711...

  • Page 209: Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION smooth control of: acceleration, deceleration, creep and max.- speed for all boom, drive, and steering functions. The motor controller will control current output, as pro- grammed for smooth operation and maximum cycle time. WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT Ground control speeds for all boom functions can also be pro- WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER...

  • Page 210: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 6.2 TO CONNECT THE JLG CONTROL SYSTEM Using the Analyzer ANALYZER With the machine power on and the analyzer connected prop- erly, the analyzer will display the following: Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer.

  • Page 211: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS DRIVE SYSTEM TEST BOOM ACCESS LEVEL SYSTEM PERSONALITIES DATALOG MACHINE SETUP...

  • Page 212: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 213: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press the UP DOWN arrow keys to adjust its value, for example: CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT BOOM CONTROL SYSTEM JOYSTICK BOOM LENGTH ANGLE MODULE...
  • Page 215 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP VOLT VERSION VALVE...
  • Page 216 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 217 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number TILT: 5 DEGREES+CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also disallows the tower lift up, drive, telescope ANSI USA, out and lift up.
  • Page 218 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. 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). market selections.
  • Page 219 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number CHARGER INTERLOCK: DRIVE ONLY: Drive function is disabled when battery charger is plugged in. CUTOUT ALL: Drive and bottom function is disabled when battery charger is plugged in. PLAT LVL OVR CUT: NO: Platform level functions above elevation.
  • Page 220 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings E600 E600 Display Units Model Number Market Alert Beacon Batteries Temp Cutout Wheel Drive Tilt Charger Interlock Plat Lvl Ovr Cut Ground Alarm BOLD TEXT indicates the default setting.

  • Page 221: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Machine Orientation When performing test Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5 to 5.0s...
  • Page 222 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS BOOM LIFT ACCELeration 0.1 to 5.0s 2.0s DECELeration 0.1 to 5.0s 1.5s MINimum UP speed 40 to 55% MAXimum UP speed 57 to 70% CREEP maximum UP speed 41 to 56% MINimum DOWN speed 40 to 55%...
  • Page 223 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS JIB LIFT ACCELeration 0.1 to 5.0s 1.5s DECELeration 0.1 to 5.0s 0.5s MlNimum UP speed 40 to 50% MAXimum UP speed 53 to 100% CREEP maximum UP speed 41 to 52% MINimum DOWN speed 40 to 50%...
  • Page 224 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS PLATFORM ROTATE ACCELeration 0.1 to 5.0s 0.5s DECELeration 0.1 to 5.0s 0.5s MlNimum LEFT speed 40 to 50% MAXimum LEFT speed 52 to 100% CREEP Maximum LEFT speed 41 to 51% MINimum RIGHT speed 40 to 50%...
  • Page 225 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. Figure 6-2. Analyzer Flow Chart, Version 1.3 - Sheet 1 of 5 3121711 6-17...
  • Page 226 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: DIAGNOSTICS: TRACTIONS UGM I/O NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration. Figure 6-3. Analyzer Flow Chart, Version 1.3 - Sheet 2 of 5 6-18 3121711...
  • Page 227 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. Figure 6-4. Analyzer Flow Chart, Version 1.3 - Sheet 3 of 5 3121711 6-19...
  • Page 228 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. Figure 6-5. Analyzer Flow Chart, Version 1.3 - Sheet 4 of 5 6-20 3121711...
  • Page 229 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. Figure 6-6. Analyzer Flow Chart, Version 1.3 - Sheet 5 of 5 3121711 6-21...

  • Page 230: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM 6.4 MACHINE ORIENTATION WHEN PERFORMING Jib Swing: Platform level and centered with boom. Jib Lift Horizontal and swing fully to left stop. Swing right to end stop, TEST record time. Swing left to end stop, record time. Turn Platform Speed Control Knob fully counterclockwise to enter Creep Drive (Below elevation): Test should be done on a smooth, mode;...

  • Page 231: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Help Descriptions and Fault Flash Codes Table 6-5. Machine Setup Descriptions Table 6-6. JLG Control System Flash Codes MODEL NUMBER Displays/adjusts machine model NOTE: all person- Code Description alities reset to default when model number is altered Faulty Footswitch/EMS Drive/Steer inputs/Footswitch Interlocks...
  • Page 232 SECTION 6 - JLG CONTROL SYSTEM Figure 6-7. Control Module Location 6-24 3121711...
  • Page 233 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-8. Analyzer Connecting Points 3121711 6-25...
  • Page 234 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR AWDA ENABLE 1001196520 C Figure 6-9. Platform Control Module - Sheet 1 of 2 6-26 3121711...
  • Page 235 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR 1001196520 C Figure 6-10. Platform Control Module - Sheet 2 of 2 3121711 6-27...
  • Page 236 SECTION 6 - JLG CONTROL SYSTEM 1001192212 D Figure 6-11. Power Module - LH 6-28 3121711...
  • Page 237 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR 1001178339 E Figure 6-12. Power Module - RH 3121711 6-29...
  • Page 238 SECTION 6 - JLG CONTROL SYSTEM Connector OSC AXEL PRESSURE SWITCH OSC AXEL PRESSURE SWITCH GROUND 1001182700 I Figure 6-13. Ground Control Module - Sheet 1 of 3 6-30 3121711...
  • Page 239 SECTION 6 - JLG CONTROL SYSTEM 1001182700 I Figure 6-14. Ground Control Module - Sheet 2 of 3 3121711 6-31...
  • Page 240 SECTION 6 - JLG CONTROL SYSTEM Connector 1001182700 I Figure 6-15. Ground Control Module - Sheet 3 of 3 6-32 3121711...

  • Page 241: 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 or DOWN arrow keys alter a value if allowed. selected by pressing ENTER ;...
  • Page 242 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLAT LVL DEMAND UP/DOWN XXX%/CREEP Direction and percentage of input command (or CREEP if applicable) from Function Speed Pot or Ground% PLAT LVL OUTPUT UP/DOWN XXX%...
  • Page 243 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) SYSTEM INPUTS OSC AXLE PRESS SW CLOSED/OPEN Closed for High Pressure OSC AXLE PRESS HIGH/LOW Pressure high if input = high...
  • Page 244 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) VOLTAGE/CUR BATTERY SOC XXX%/DISCHARGED/DEEP DISCHARGED UGM calculated battery State-of-Charge; display percentage unless Discharged or Deeply Discharged BATTERY VOLTAGE XX.XXV...
  • Page 245 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) JIB SWING LT SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input [MACHINE SETUP ' Jib Swing = YES] JIB SWING RT SW OPEN/CLOSED...
  • Page 246 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) CAN STATISTICS CAN 1 STATISTICS RX/SEC: XXX CAN 1 STATISTICS TX/SEC: XXX CAN 1 STATISTICS BUS OFF: XXX...

  • Page 247: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM System Self Test operator to close the lower lift up switch. When the con- troller sees that the lower lift up switch has been closed, The system self test is utilized to locate typical problems. See it will move on to the next input, lower lift down LLD.
  • Page 248 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run while running certain “critical” checks are made. CHECK GROUND/ PLATFORM SELECT The analyzer must be connected to the active control station to run the system test CHECK CAN WIRING The system test cannot run unless the CAN Bus is operating properly BATTERY VOLTAGE TOO LOW...
  • Page 249 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer HEAD/TAIL LIGHTS SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay); dis- played if the head/tail light option is configured. VOTE RELAY SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay);...
  • Page 250 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP TELE IN OPEN or CLOSED (advanced test after switch toggles) CL TELE OUT OPEN or CLOSED (advanced test after switch toggles) OP TELE OUT OPEN or CLOSED (advanced test after switch toggles) CL DRIVE ORIENT...
  • Page 251 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP JIB DOWN OPEN or CLOSED (advanced test after switch toggles) CL JIB SWING LEFT OPEN or CLOSED (advanced test after switch toggles) OP JIB SWING LEFT OPEN or CLOSED (advanced test after switch toggles) CL JIB SWING RIGHT...

  • Page 252: Calibrating Steer

    SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATING STEER 8. Use the arrow keys to reach STEER SENSOR. The screen will read: When calibrating steering, each individual wheel must be cali- brated in order to make the tire and wheel parallel with the frame.
  • Page 253 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 14. Hit Enter. The screen will read: 15. The display will read Left Steer Maximum value. 11. Activate the steer control until the tire and wheel are 16.

  • Page 254: Calibrating Tilt Sensor

    SECTION 6 - JLG CONTROL SYSTEM 6.6 CALIBRATING TILT SENSOR 9. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 10. Use the arrow keys to reach TILT SENSOR. The screen will read: A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE- FOLLOWING PROCEDURE IS PERFORMED.

  • Page 255: Calibrating Load Sensing

    SECTION 6 - JLG CONTROL SYSTEM 12. When prompted, swing turntable 180° to opposite end 6.7 CALIBRATING LOAD SENSING of chassis. NOTE: Calibration sub-menu LOAD SENSING is visible only if MACHINE SET-UP sub-menu LOAD SYSTEM is selected to 1. Position the Platform/Ground select switch to the Plat- form position.
  • Page 256 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach LOAD SENSING. The screen 10. Hit Enter. The screen will read: will read: 11. Hit Enter. The screen will read: 9. Hit Enter. The screen will read: 6-48 3121711...
  • Page 257 SECTION 6 - JLG CONTROL SYSTEM 12. Hit Enter. The screen will read: 14. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 15. After few seconds, the screen will read: 16. Hit ESC twice to go back to CALIBRATIONS. 3121711 6-49...

  • Page 258: Calibration Of Motor (With New Zapi Module)

    SECTION 6 - JLG CONTROL SYSTEM 6.8 CALIBRATION OF MOTOR (WITH NEW ZAPI 8. The screen will read: MODULE) 1. Position the Platform/Ground select switch to the Plat- form position. 2. Plug the analyzer into the connector at the base of the platform control box.
  • Page 259 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 12. After few seconds, the screen will read: 13. Hit ESC twice to go back to CALIBRATIONS. 11. The screen will read: 3121711 6-51...

  • Page 260: Lss System

    SECTION 6 - JLG CONTROL SYSTEM 6.9 LSS SYSTEM The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR: ture.

  • Page 261: Diagnostic Menu

    SECTION 6 - JLG CONTROL SYSTEM Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus. To access a sub-menu, press the The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT Load Sensing System.

  • Page 262: Calibration Procedure

    SECTION 6 - JLG CONTROL SYSTEM Calibration Procedure 5. Press the ENTER key to view the menu. Upon entry 1. Remove everything from the platform, except perma- to the Calibration Menu, the JLG Control System will link nently fixed JLG Accessories, to allow the Load Sensing to the Analyzer and the screen will read: System to record its’...
  • Page 263 SECTION 6 - JLG CONTROL SYSTEM NOTE: Accessory weight will reset to 0 lbs. each time the machine is re-calibrated and will need to be re-entered. NOTE: Pressing the ESC key after starting calibration and before calibration is complete will display the CAL FAILED NOTE: The Accessory weight will be temporarily stored in the Con- message.
  • Page 264 SECTION 6 - JLG CONTROL SYSTEM 9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg).
  • Page 265 SECTION 6 - JLG CONTROL SYSTEM 12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-13. Pipe Rack Capacity Reductions PLATFORM OVRLD ENTER . The control system will default to an esti- Capacity PLATFORM OVRLD RESTRICT mate of unrestricted capacity, which can be adjusted if...
  • Page 266 SECTION 6 - JLG CONTROL SYSTEM 14. Press ENTER . If calibration is successful, the screen will read: 6-58 3121711...

  • Page 267: Testing & Evaluation

    SECTION 6 - JLG CONTROL SYSTEM Testing & Evaluation 6. Confirm Control System Capacity Indication (optional for vehicles with Dual Capacity Ratings). For vehicles Refer to Troubleshooting if the Load Sensing System fails to equipped with a Capacity Select switch on the Platform meet these guidelines.

  • Page 268: Troubleshooting

    SECTION 6 - JLG CONTROL SYSTEM Troubleshooting The following tables are furnished to provide possible resolu- tions for common difficulties. Difficulties are classified as Gen- eral, Calibration, Measurement Performance, and Host System Functionality. Table 6-14. LSS Troubleshooting Chart Difficulty Possible Resolution Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.

  • Page 269: Resetting The Msso System

    SECTION 6 - JLG CONTROL SYSTEM 6.10 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read: 1. Use the following procedure to reset the MSSO system. 2. Position the Platform/Ground select switch to the desired position.
  • Page 270 SECTION 6 - JLG CONTROL SYSTEM 12. Press Enter . The screen will read: 13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu. 6-62 3121711...
  • Page 271 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution EVERYTHING OK The UGM determines that platform station (EVERY- Occurrence of active DTC TING OK) OR ground station (GROUND MODE OK) is selected and no system faults exist, including Power Module check;...
  • Page 272 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 0046 TORQUE CUTBACK - EXCESSIVE TILT UGM detects that the machine is ascending an The UGM detects that the grade in direction of inclination of greater than or equal to: travel is more than 3 degrees less than the 28 degrees for period of greater than 1 second.
  • Page 273 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 2216 D/S JOY. OUT OF RANGE HIGH The PM detects that the drive or steer joystick sig- The PM no longer reports the fault nal voltage >...
  • Page 274 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 2258 FUNCTION PROBLEM - TOWER LIFT DOWN The machine is in Platform mode and the Tower Lift Tower Lift Down input = LOW while the machine is PERMANENTLY SELECTED Down input = High at Startup not Enabled...
  • Page 275 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 23171 FUNCTION PROBLEM - JIB SWING LEFT PER- The machine is in Ground mode and the Jib Swing Jib Swing Left input = LOW and the machine is not MANENTLY SELECTED Left input = High at Start Up in the Enabled state.
  • Page 276 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 2568 TEMPERATURE CUTOUT ACTIVE – AMBIENT Low Temperature Cutout = Active Low Temperature Cutout = Inactive; speed restric- TEMPERATURE TOO LOW tions removed after controls are initialized 2576 PLATFORM LEVEL PREVENTED –...
  • Page 277 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 3382 PLATFORM LEVEL UP VALVE - SHORT TO The UGM detects a short to ground at the platform Power cycle GROUND level up output 3383 PLATFORM LEVEL UP VALVE - OPEN CIRCUIT The UGM detects an open circuit at the platform...
  • Page 278 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 33110 TOWER LIFT DOWN VALVE - OPEN CIRCUIT The UGM detects an open circuit supporting the UGM no longer detects open circuit; Tower Down Solenoid Inhibits and restrictions removed after CntrlIni;...
  • Page 279 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 33315 FLOW CONTROL VALVE - SHORT TO BATTERY The UGM detects a short to 12V battery at this out- Power cycle 33316 FLOW CONTROL VALVE - SHORT TO GROUND The UGM detects a short to ground at this output Power cycle 33406...
  • Page 280 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 4232 REAR LEFT MOTOR TOO HOT - PLEASE WAIT The UGM determines that the drive motor tempera- Power Module no longer report fault and UGM ture reported by the PM >...
  • Page 281 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 4480 LSS BATTERY VOLTAGE - NOT CALIBRATED The shear beam is reporting a Sensor Supply Voltage Possible sensor hardware issue. calibration error. The machine will assume the platform is over- loaded.
  • Page 282 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution CANBUS FAILURE - LOAD SENSING SYSTEM The control system has lost communication with the Check wiring to load sensor. MODULE load sensing system load pin. The machine will assume the platform is over- loaded.
  • Page 283 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 7754 REAR RIGHT MOTOR STALLED The UGM or Power Module(s) detects that the motor UGM and Right Power Module shall clear the fault is stalled during active traction. after drive joystick returns to neutral (and com- For the UGM commanded speed ≥...
  • Page 284 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution CHASSIS TILT SENSOR OUT OF RANGE Fault CHASSIS TILT SENSOR NOT CALIBRATED (813) is Not all of the trigger conditions are met; not present and either of the external tilt sensor X or Y axis ? ABS [35 º] for 4 seconds.
  • Page 285 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 8223 LSS STRAIN GAUGE 2 - STAGNANT The control system has determined that the strain Possible sensor hardware issue. gauge 2 reading in the load sensor is stagnant (not changing).
  • Page 286 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 8227 LSS STRAIN GAUGE 2 - OUT OF RANGE HIGH The shear beam is reporting an out of range high Possible sensor hardware issue. issue with the strain gauge 2 reading.
  • Page 287 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 8231 LSS STRAIN GAUGE 2 - NOT CALIBRATED The shear beam is reporting a calibration issue with Possible sensor hardware issue. the strain gauge 2 sensor. If the platform is not overloaded the machine will be placed in to creep.
  • Page 288 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 8235 LSS STRAIN GAUGE 2 - NOT INSTALLED The shear beam is reporting a not installed issue Possible sensor hardware issue. with the strain gauge 2 sensor. If the platform is not overloaded the machine will be placed in to creep.
  • Page 289 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution FUNCTIONS CUTOUT - PLATFORM OVER- The Platform is Overloaded and MACHINE SETUP -> UGM determines that the Platform is not Over- LOADED LOAD SYSTEM = CUTOUT PLATFORM, Platform Mode loaded;...
  • Page 290 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 9910 FUNCTIONS LOCKED OUT - PLATFORM MOD- The UGM software version type is ‘P’ The UGM has Not all of the trigger conditions are met ULE SOFTWARE VERSION IMPROPER received valid version information from the PM.
  • Page 291 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 9979 FUNCTIONS LOCKED OUT - GROUND MODULE Ground software has been installed on a UGM with a Power cycle SOFTWARE VERSION IMPROPER ST10F274 processor (Hardware Rev < 6), which does not have guaranteed flash storage in the sector where Constant Data is written.
  • Page 292 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 99249 REAR RIGHT MODULE - PROTECTION FAILURE Applicable Power Module determines that an inter- Power cycle nal failure exists in the hardware protection circuit 99250 REAR RIGHT MODULE - CHECK POWER CIR- Applicable Power Module determines at Startup...
  • Page 293 SECTION 6 - JLG CONTROL SYSTEM Table 6-15. Diagnostic Trouble Codes DTC Text Fault Description Solution 99273 FUNCTIONS LOCKED OUT – REAR LEFT MOD- The UGM software version type is ‘P’ The UGM has Not all of the trigger conditions are met ULE SOFTWARE VERSION IMPROPER received valid version information from all Power Modules.
  • Page 294 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-86 3121711...

  • Page 295: 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 296: 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 Figure 7-2. Resistance Measurement audible continuity testing. • First test meter and leads by touching leads together. •...

  • Page 297: Current Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement CHECKING SWITCHES Basic Check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected.

  • Page 298: Automatic Switches

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1. Remove proximity switch from its mount. 7.4 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS 2. Reconnect harness if it was disconnected for step a, and turn on machine. NOTE: This section is not applicable for battery terminals. 3.

  • Page 299: Installation Of Dielectric Grease

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: Curing-type sealants might also be used to prevent short- Deutsch HD, DT, DTM, DRC Series ing and would be less messy, but would make future pin The Deutsch connector system is commonly used for harsh removal more difficult.

  • Page 300: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Exclusions Figure 7-6. Use of Seal Plugs A limited number of connectors do not benefit from dielectric AMP Mate-N-Lok grease, or may be permanently damaged by application.
  • Page 301 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity. and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric mistakenly applied to this connector system, the low-force grease and create electrical contact.

  • Page 302: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as-shipped, Applying Silicone Dielectric Compound to AMP position (See Figure 7-7.). Proceed as follows: Connectors Silicone Dielectric Compound must be used on the AMP con- nections for the following reasons: •...
  • Page 303 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 304: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 2.
  • Page 305 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13. Connector Installation 3121711 7-11...

  • Page 306: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. 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 307: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp 1. With rear insert toward you, snap appropriate size barrel.

  • Page 308: Wiring Harness Connector Labels

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.7 WIRING HARNESS CONNECTOR LABELS Connector Labels Connectors between harnesses are identified by the prefix "X" and a sequentially assigned number. An optional suffix (letters & numbers) may be added when multiple terminations occur at one device or when there are optional connections.
  • Page 309 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Table 7-1. Wiring Harness Connector Labels Table 7-1. Wiring Harness Connector Labels Components Category Label Components Category Label Other Switches Disconnect Audible Alarms Horns Foot Battery Batteries HVAC Battery Terminals Control Module Ground Park brake Pump pot...
  • Page 310 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-16 3121711...
  • Page 311 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21. Platform Console Harness - Sheet 2 of 4 3121711 7-17...
  • Page 312 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Platform Console Harness - Sheet 3 of 4 7-18 3121711...
  • Page 313 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-23. Platform Console Harness - Sheet 4 of 4 3121711 7-19...
  • Page 314 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-20 3121711...
  • Page 315 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-21...
  • Page 316 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV61 Figure 7-26. Upper Valve Harness - Sheet 2 of 2 7-22 3121711...
  • Page 317 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-23...
  • Page 318 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-24 3121711...
  • Page 319 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-25...
  • Page 320 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-26 3121711...
  • Page 321 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS T391 Figure 7-31. Load Sensing System Harness (LSS) - Sheet 2 of 2 3121711 7-27...
  • Page 322 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-28 3121711...
  • Page 323 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV59 Figure 7-33. Lower Valve Harness - Sheet 2 of 3 3121711 7-29...
  • Page 324 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV60 Figure 7-34. Lower Valve Harness - Sheet 3 of 3 7-30 3121711...
  • Page 325 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-31...
  • Page 326 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO66-J1 Figure 7-36. Turntable Harness - Sheet 2 of 3 7-32 3121711...
  • Page 327 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS S541 Figure 7-37. Turntable Harness - Sheet 3 of 3 3121711 7-33...
  • Page 328 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-34 3121711...
  • Page 329 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-35...
  • Page 330 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MS423-3 Figure 7-40. Ground Panel Harness - Sheet 2 of 3 7-36 3121711...
  • Page 331 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW101-1B Figure 7-41. Ground Panel Harness - Sheet 3 of 3 3121711 7-37...
  • Page 332 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-38 3121711...
  • Page 333 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X638 Figure 7-43. Traction Harness - Sheet 2 of 4 3121711 7-39...
  • Page 334 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO210-A Figure 7-44. Traction Harness - Sheet 3 of 4 7-40 3121711...
  • Page 335 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO211-A Figure 7-45. Traction Harness - Sheet 4 of 4 3121711 7-41...
  • Page 336 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-42 3121711...
  • Page 337 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-43...
  • Page 338 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-44 3121711...
  • Page 339 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS LB264 Figure 7-49. Chassis Head/Tail Light Harness - Sheet 2 of 2 3121711 7-45...
  • Page 340 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-46 3121711...
  • Page 341 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-47...
  • Page 342 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-48 3121711...
  • Page 343 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS RL619 Figure 7-53. Generator Ign Harness - Sheet 2 of 2 3121711 7-49...
  • Page 344 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-50 3121711...
  • Page 345 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X506 Figure 7-55. SkyGuard Harness - Sheet 2 of 2 3121711 7-51...
  • Page 346 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-56. Gen to Plate Interface Harness 7-52 3121711...
  • Page 347 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-53...
  • Page 348 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X7B-12 Figure 7-58. Soft Touch Harness - Sheet 2 of 2 7-54 3121711...
  • Page 349 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121711 7-55...
  • Page 350 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW292 Figure 7-60. Console Harness with SkyGuard and 1 CELL LSS - Sheet 2 of 4 7-56 3121711...
  • Page 351 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW04 Figure 7-61. Console Harness with SkyGuard and 1 CELL LSS - Sheet 3 of 4 3121711 7-57...
  • Page 352 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-62. Console Harness with SkyGuard and 1 CELL LSS - Sheet 4 of 4 7-58 3121711...
  • Page 353 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-63. Gen 2 Plate Interface Harness 3121711 7-59...
  • Page 354 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 7-60 3121711...
  • Page 355 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2: PLATFORM CONSOLE SHEET 1 1001179395 H Figure 7-64. Electrical Schematic - Sheet 1 of 16 3121711 7-61...
  • Page 356 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 Figure 7-65. Electrical Schematic - Sheet 2 of 16 7-62 3121711...
  • Page 357 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 2 1001179395 H Figure 7-66. Electrical Schematic - Sheet 3 of 16 3121711 7-63...
  • Page 358 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 Figure 7-67. Electrical Schematic - Sheet 4 of 16 7-64 3121711...
  • Page 359 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 3 1001179395 H Figure 7-68. Electrical Schematic - Sheet 4 of 16 3121711 7-65...
  • Page 360 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 Figure 7-69. Electrical Schematic - Sheet 5 of 16 7-66 3121711...
  • Page 361 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 4 1001179395 H Figure 7-70. Electrical Schematic - Sheet 6 of 16 3121711 7-67...
  • Page 362 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 Figure 7-71. Electrical Schematic - Sheet 7 of 16 7-68 3121711...
  • Page 363 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 5 1001179395 H Figure 7-72. Electrical Schematic - Sheet 8 of 16 3121711 7-69...
  • Page 364 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 6 Figure 7-73. Electrical Schematic - Sheet 9 of 16 7-70 3121711...
  • Page 365 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 6 1001179395 H Figure 7-74. Electrical Schematic - Sheet 10 of 16 3121711 7-71...
  • Page 366 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 7 Figure 7-75. Electrical Schematic - Sheet 11 of 16 7-72 3121711...
  • Page 367 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 7 1001179395 H Figure 7-76. Electrical Schematic - Sheet 12 of 16 3121711 7-73...
  • Page 368 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 8 Figure 7-77. Electrical Schematic - Sheet 13 of 16 7-74 3121711...
  • Page 369 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 8 1001179395 H Figure 7-78. Electrical Schematic - Sheet 14 of 16 3121711 7-75...
  • Page 370 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 9 Figure 7-79. Electrical Schematic - Sheet 15 of 16 7-76 3121711...
  • Page 371 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 9 1001179395 H Figure 7-80. Electrical Schematic - Sheet 16 of 16 3121711 7-77...
  • Page 372 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SHEET 10 1001179395 H Figure 7-81. Electrical Schematic - Sheet 16 of 16 7-78 3121711...
  • Page 374 3121711 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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