Oshkosh Corporation JLG E300AJ Service And Maintenance Manual
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Oshkosh Corporation JLG E300AJ Service And Maintenance Manual

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Service and Maintenance Manual
Models
E300AJ
E300AJP
PVC 2001
31215001
October 16, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Models E300AJ E300AJP PVC 2001 31215001 October 16, 2019 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: 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 mobile elevat- ing work platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION nance personnel pay strict attention to these warnings and COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A precautions to avoid possible injury to themselves or others,...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - October 16, 2019 31215001...

  • 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. Welding on JLG Equipment ............... . . 2-6 Do the Following When Welding on JLG Equipment .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.11 Battery Charger ..................3-57 Operating Instructions .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.18 Skyguard................... 4-51 Operation .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ............6-1 Introduction .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Wiring Harness Connector Labels ..............7-13 Connector Labels.
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-5 2-1.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-1. NPTF Thread ..................5-3 5-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-58. Installation of Head Seal Kit............... . . 5-78 5-59.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-13. DT/DTP Contact Removal ................7-11 7-14.
  • Page 15 LIST OF TABLES TABLE NO. TITLE PAGE NO. Dimensional Data - E300AJ ............... . . 1-2 Dimensional Data - E300AJP .
  • Page 16 LIST OF TABLES TABLE NO. TITLE PAGE NO. Machine Setup Descriptions ............... . 6-33 JLG Control System Flash Codes .
  • Page 17 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 18: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Machine Specification E300AJP Maximum Work Load (Capacity)  Machine Specification E300AJ ANSI Markets Maximum Work Load (Capacity)  Unrestricted: 500 lb (227 kg) ANSI Markets Maximum Work Load (Capacity) Unrestricted: 500 lb (227 kg) CE &...

  • Page 19: Dimensional Data

    SECTION 1 - SPECIFICATIONS 1.4 DIMENSIONAL DATA 1.5 LUBRICATION SPECIFICATIONS Refer to Section 1.8, Operator Maintenance, for specific lubri- Table 1-1. Dimensional Data - E300AJ cation procedures. Turning Radius (Inside) 5 ft. (1.52 m) Hydraulic Oil Turning Radius (Outside) 10 ft. 2 in. (3.1 m) Machine Height (Stowed) 6 ft.
  • Page 20 SECTION 1 - SPECIFICATIONS Table 1-3. Mobil DTE 11M Specs Table 1-6. Mobil EAL 224H Specs ISO Viscosity Grade Type Biodegradable Vegetable Oil Gravity, API 31.9 ISO Viscosity Grade 32/46 Pour Point, Max -40°F (-40°C) Specific Gravity 0.922 Flash Point, Min 330°F (166°C) Pour Point, Max -25°F (-32°C)

  • Page 21: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS 1.6 CRITICAL STABILITY WEIGHTS 1.7 MAJOR COMPONENT WEIGHTS Component DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR Platform and Support 97.5 TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MOD- Upper Boom Complete IFY THE MEWP IN ANY WAY TO AFFECT STABILITY.
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram 31215001...

  • Page 23: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE Swing Bearing/Worm Gear Teeth NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-9. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities;...
  • Page 24 SECTION 1 - SPECIFICATIONS Hydraulic Tank Wheel Drive Hub OIL LEVEL CHECK AND FILL Lube Point(s) - Level/Fill Plug Capacity - 25.5 oz. (0.75 L)(1/2 Full) Lube - EPGL  Interval - Check level every 3 months or 150 hrs of oper- Lube Point(s) - Fill Cap...

  • Page 25: Thread Locking Compound

    SECTION 1 - SPECIFICATIONS 1.9 THREAD LOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 26: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.10 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
  • Page 27 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 28 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
  • Page 29 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
  • Page 30 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
  • Page 31 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 32: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
  • Page 33 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 34 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...
  • Page 35 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
  • Page 36 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 37: 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 The Annual Machine Inspection must be performed by a Fac- those personnel that are responsible to place the machine in tory-Trained Service Technician on an annual basis, no later...

  • Page 38: 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 whenever there’s an Operator change. Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic...

  • Page 39: Component Disassembly And Assembly

    SECTION 2 - GENERAL Component Disassembly and Assembly 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 40: Lubrication

    SECTION 2 - GENERAL Lubrication Hydraulic Oil 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- JLG recommends Premier Hydraulic Fluid (VG 15), which able, consult your local supplier for an equivalent that meets has an SAE viscosity of 10W and a viscosity index of 140.

  • Page 41: 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 42: 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 43 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1, 2 1, 2 Hose/Cable Carrier Installations 1, 2 1, 2 Pivot Pins and Pin Retainers 1, 2 1, 2 Sheaves, Sheave Pins...
  • Page 44 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Functions/Controls Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Ground Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Function Control Locks, Enclosures, Guards, Boot or Detents...
  • Page 45 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership AEM Handbook Footnotes: Prior to each sale, lease, or delivery In service for 3 months;...
  • Page 46 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM. Fluid Properties Base...
  • Page 47 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 48: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS Wheel Installation It is extremely important to apply and maintain proper wheel Tire Damage mounting torque. For polyurethane foam filled tires, JLG Industries, Inc. recom- mends that when any of the following are discovered, mea- WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE sures must be taken to remove the JLG product from service TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS...

  • Page 49: Spindle

    SECTION 3 - CHASSIS & TURNTABLE The tightening of the nuts should be done in stages.  Insert the dust cap and check to make sure the cotter Following the recommended sequence, tighten nuts per pin is not going to interfere. Cap must be pressed all the wheel torque chart.
  • Page 50 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 2780241 C 1001180839 D Figure 3-1. Spindle Assembly 31215001...
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle Assembly 5. Hydraulic Tank 8. Drive Hub 2. Steer Angle Sensor 6. Drive Module 9. Drive Brake 3. Swing Bearing 7. Electrical Assembly 10. Drive Motor 4. Battery Figure 3-2. Chassis Component Location 31215001...
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE RIGHT SIDE VIEW WITH HUB REMOVED * Torque 35 ft. lbs. (48 Nm) **Medium Strength Threadlocking Compound 1001180906 D 1. Axle Assembly 3. Tie Rod 5. Thrust Washer 7. Sensor Switch 2. Spindle Assembly 4.
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 10** * Apply Medium Strength Threadlocking Compound **Apply High Strength Threadlocking Compound and Torque to 190 ft. lbs. (260 Nm) Note: Before installing brake and motor, apply a light coat of grease to the splined shafts 1001179774 J 1.

  • Page 54: Tilt Sensor

    SECTION 3 - CHASSIS & TURNTABLE RHT PWR MOD B- LFT PWR MOD W RHT PWR MOD P- LFT PWR MOD B- RHT PWR MOD W LFT PWR MOD V RHT PWR MOD U LFT PWR MOD B+ RHT PWR MOD B+ LFT PWR MOD U RHT PWR MOD V 11X TORQUE...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE Figure 3-6. Relay Figure 3-7. System Fuses 31215001...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE IP 409 LEFT BRAKE Figure 3-8. Brake Fuses 31215001...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE Figure 3-9. Drive Fuses 3-10 31215001...

  • Page 58: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE HUB Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll and Leak Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 59: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Remove the First Stage Sun Gear (10) if applicable. NOTE: On units with ratios greater than 36:1 numerically, there  NOTE: Refer to Figure 3-10., Main Assembly - Sheet 1 of 2, and will not be a separate First Stage Sun Gear (10), as the gear Figure 3-11., Main Assembly - Sheet 2 of 2, teeth will be integral to the Input Shaft (9).
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1F Ring Gear 9 Input Shaft 1G Housing 10 First Stage Sun Gear 4 Output Carrier Subassembly 11 Second Stage Sun Gear 5 Retaining Ring 18 O-ring 6 Cover Assembly 19 Flat Head Bolt 20 Retaining Ring 6G Retaining Ring Figure 3-11.

  • Page 61: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly Slide the Planet Gear Sub-assembly (4) out of the Output Carrier (4A) being careful to not drop the Needle Bear- ings (4C) in the process. NOTE: Refer to Figure 3-12., Output Carrier, and Figure 3-13., Planet Gear.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 4B Thrust Washer 4C Needle Bearing 4D Thrust Spacer 4F Planet Gear Figure 3-13. Planet Gear 31215001 3-15...

  • Page 63: Input Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly NOTE: The Roll Pins (4G) should not be reused when reassembling the unit. NOTE: Refer to Figure 3-14., Input Carrier Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A). Using a 1/8”...

  • Page 64: Hub Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub Spindle Disassembly If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end. NOTE: Refer to Figure 3-15., Hub Spindle. Remove Seal (1B) from Hub (1G). NOTE: The Seal (1B) should NOT be reused when reassembling the Place unit on bench with Spindle (1A) end down.

  • Page 65: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Pull Disengage Rod (6D) out from Cover (6A). Use appropriate tool to remove O-Ring (6E) from inter- NOTE: Refer to Figure 3-16., Cover Assembly. nal groove in Cover (6A). Remove two O-Ring Pipe Plugs (6F) from Cover (6A). Remove O-Ring (17) from groove in Cover (6A).

  • Page 66: Input Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Assembly Output Planet Gear Assembly NOTE: Refer to Figure 3-14., Input Carrier. NOTE: Refer to Figure 3-13., Planet Gear. Apply a liberal coat of grease to the bore of one Input Apply a liberal coat of grease to the bore of one Output Planet Gear (3F).

  • Page 67: Output Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Assembly Hub Spindle Assembly NOTE: Refer to Figure 3-12., Output Carrier. NOTE: Refer to Figure 3-15., Hub Spindle. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during (4A).

  • Page 68: Cover Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Assembly Main Assembly NOTE: Refer to Figure 3-16., Cover Assembly.  NOTE: Refer to Figure 3-10., Main Assembly - Sheet 1 of 2 and Figure 3-11., Main Assembly - Sheet 2 of 2. Grease O-Ring (6E) and insert into internal groove in Cover (6A).
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Drive Hub - Sheet 1 of 2 3-22 31215001...
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 1A Spindle 1K Retaining Ring 3F Planet Gear 5 Retaining Ring 9 Input Shaft 1B Lip Seal 1L Spring 4A Output Carrier 6A Cover 10 Input Sun Gear 6B Disengage Cap 11 Output Sun Gear 1C Tapered Bearing Cone 1M Thrust Washer 4B Thrust Washer...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE Figure 3-19. Cup Pressing Tool Figure 3-20. Cup Pressing Tool 3-24 31215001...

  • Page 72: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE MOTOR Remove the screws (22) from the retaining plate (23). Remove the retaining plate (23) from the cover (21). Removal Remove the cover (21) from the shield end (18). Place machine on the firm level surface. Remove the seals (20) and (19).

  • Page 73: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Installation NOTE: Refer to Figure 3-21., Drive Motor. NOTE: The drive motor weighs approximately 95 lb (43 kg). Install the rotor (29) into the stator (2). Use suitable lifting device to support the drive motor. Install the gear key (32) on to the rotor shaft.
  • Page 74 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. Sensor 22. Screw 31.
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE TURNTABLE REF. 1001107650 C 1001153362A 1. Bolt 3. Bolt 5. Washer 7. Swing Motor 2. Bolt 4. Washer 6. Swing Bearing Figure 3-22. Swing Components 3-28 31215001...

  • Page 76: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE  3.7 SWING DRIVE NOTE: The swing drive must be removed from the machine to be Using a press, disassemble the pinion and gear assem- serviced. bly. Support the worm gear (30) on the press with the pinion (22) down allowing room for pinion to be pressed The swing drive has five major components;...

  • Page 77: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Install the bearing cone (1) on the hex end of the worm (31). Place a bearing cup (1) over the bearing and lightly Press the bearing cup (15) into the cap (19). tap the cup into the bore using a soft hammer. Place the bearing cup (17) into the housing (18).
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 1. Bearing 9. Grease Fitting 17. Bearing 25. Spacer 2. Oil Seal 10. Grease Fitting 18. Housing 26. Shim 3. Capscrew 11. Grease Fitting 19. Gear/Pinion Cap 27. Shim 4. Bolt 12. Bolt 20. Cover Plate 28.

  • Page 79: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING MOTOR Figure 3-24. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY. 3-32 31215001...
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufac-  turers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit....
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used 2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used 3. Seal Ring 8.

  • Page 82: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- Place the motor in a soft jawed vice, with coupling shaft nents read this entire section. It provides important infor- (12) pointed down and the vise jaws clamping firmly on mation on parts and procedures you will need to know to the sides of the housing (18) mounting flange or port...
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE Remove commutator (5) and seal ring (3) Remove seal Remove manifold (7) and inspect for cracks surface scor- ring from commutator, using an air hose to blow air into ing, brinelling or spalling. Replace manifold if any of ring groove until seal ring is lifted out and discard seal these conditions exist.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Remove rotor set (8) and wearplate (9), together to Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 retain the rotor set in its assembled form, maintaining degrees apart) and a roller vane centerline are on the the same rotor vane to stator contact surfaces.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bear- ing. Crocus cloth or fine emery paper may be used. Remove coupling shaft (12), by pushing on the output end of shaft.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE Remove thrust bearing (15) and thrust washer (14). Inspect housing (18) assembly for cracks, the machined Inspect for wear, brinelling, corrosion and a full comple- surfaces for nicks, burrs, brinelling or corrosion. Remove ment of retained rollers. burrs that can be removed without changing dimen- sional characteristics.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely.

  • Page 89: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square Replace all seals and seal rings with new ones each time with the press base and the bearing/ bushing is not cocked you reassemble the motor unit.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE Press a new dirt and water seal (20) into the housing (18) Assemble thrust washer (14) then thrust bearing (15) outer bearing counterbore. The dirt and water seal (20) that was removed from the motor. must be pressed in until its’...
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Be sure that a generous amount of clean corrosion resis- Apply a small amount of clean grease to a new seal ring tant grease has been applied to the lower (outer) hous- (4) and insert it into the housing (18) seal ring groove. ing bearing/bushing (19).
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Assemble wear plate (9) over the drive link (10) and NOTE: It may be necessary to turn one alignment stud out of the alignment studs onto the housing (18). housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE Assemble the manifold (7) over the alignment studs and Assemble a new seal ring (3) flat side up, into commuta- drive link (10) and onto the rotor set. Be sure the correct tor (5) and assemble commutator over the end of drive manifold surface is against the rotor set.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other compo- nents into place with a final torque of 25-30 ft.

  • Page 95: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor stator and vanes that cannot be read- ily assembled by hand can be assembled by the following procedures.

  • Page 96: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction A disassembled rotor set (8) that cannot be readily assem- IF THE STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS) THAN STATOR bled by hand and has a two piece stator can be assembled HALF (8D) THE STATOR VANES (8C) OR (8E)OF THE SAME LENGTH (HEIGHT) AS by the following procedures.

  • Page 97: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.9 SWING BEARING d. At the position indicated on Figure 3-26., Swing Bearing Feeler Gauge Check try and insert the 0.0015" feeler gauge between the bolt head and Turntable Bearing Mounting Bolt Condition Check hardened washer at the arrow indicated position.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE JIB ELEVATED PLATFORM ROTATED 90 DEGREES 90 DEGREES AJP MODEL MAIN BOOM FULLY ELEVATED AND FULLY RETRACTED LOWER BOOM FULLY ELEVATED NOTE: MEASURING POINT MAE41020 Figure 3-27. Swing Bearing Tolerance Boom Placement 31215001 3-51...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE MAIN BOOM FULLY EXTENDED MAIN BOOM HORIZONTAL LOWER BOOM FULLY ELEVATED NOTE: MEASURING POINT MAE41010 Figure 3-28. Swing Bearing Tolerance Boom Placement 3-52 31215001...

  • Page 100: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE At the same point, with the boom positioned over the Replacement of Swing Bearing side of the machine, the Upper Boom fully elevated and the Mid/Lower Boom fully elevated, Figure 3-27., Swing Removal. Bearing Tolerance Boom Placement using a magnetic a.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Installation. a. Install bearing to rotation box with two capscrews, JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8 BEARING NUTS so that fill plug of bearing is as close to gear as bolt AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS. pattern will allow.

  • Page 102: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Install bolts with High Strength Threadlocking Compound - 190 ft. lbs. (260 Nm). Figure 3-30. Swing Bearing Torque Sequence 31215001 3-55...

  • Page 103: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY MAINTENANCE AND CHARGING Battery Charging, Daily NOTE: To avoid excessive battery charging time, do not allow bat- teries to become completely discharged. TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING.

  • Page 104: Battery Charger

    SECTION 3 - CHASSIS & TURNTABLE 3.11 BATTERY CHARGER Operating Instructions The battery charger utilizes a microprocessor to monitor bat- tery condition and determine when to automatically start and ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTENSION CORD, stop charging. The 3-LED panel will light in sequence upon AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3-WIRE 12 AWG start up to indicate self-diagnostics, then display the proper CORD.

  • Page 105: Maintenance Instructions

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Instructions Battery Charger Fault Codes If a fault occurred during charging, the red “Fault” LED will For flooded lead-acid batteries, regularly check water flash with a code corresponding to the error. Refer to the levels of each battery cell after charging and add dis- table following for the flash codes and their removal.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-31. Battery Charger 31215001 3-59...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE * Apply to Battery Terminal Connections Only ** Apply to Contacts of Connectors Only 1001177627 B 1001177590 B 1001177626 B 1. Battery Terminal Grease 4. Battery Connector 7. Battery Hold Down 10. Right Cover 2.
  • Page 108 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 109: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    SECTION 3 - CHASSIS & TURNTABLE [5 Flashes] - Over Temperature Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge These symptoms indicate over-charging or high battery time will be extended significantly.

  • Page 110: Instructions For Using The Delta-Q Quiq Programmer Ctquiq Programming Kit

    SECTION 3 - CHASSIS & TURNTABLE Instructions for using the Delta-Q QuiQ Programmer CT QuiQ Programming Kit CONTENTS OF THE QUIQ PROGRAMMING KIT (JLG PART NUMBER: 2915230) • QuiQ USB Interface Module • QuiQ Programmer CT Installation CD • USB Cable •...

  • Page 111: Checking/Changing The Battery Charger Algorithm

    SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger Algorithm Disconnect the charger positive connector from the bat- tery pack. Apply AC power and after the LED test, the The charger is pre-loaded with programming algorithms Algorithm # will display for 11 seconds. for the specific batteries detailed in Table 3-4, Battery Algo- To change the algorithm, touch the connector to the rithms.

  • Page 112: Chassis Tilt Indicator System

    SECTION 3 - CHASSIS & TURNTABLE 3.12 CHASSIS TILT INDICATOR SYSTEM 3.13 DRIVE ORIENTATION SYSTEM The Chassis Tilt Indicator System measures the turntable angle The Drive Orientation System (DOS) is intended to indicate to with respect to level ground. The external tilt sensor is the operator conditions that could make the direction of mounted in the chassis.

  • Page 113: Hoods

    SECTION 3 - CHASSIS & TURNTABLE 3.14 HOODS The right hood weighs 15 lb (6.8 kg) and the left hood weighs 10.3 lb (4.7 kg). See Figure 3-34., Hoods.    Medium Strength Threadlocking Compound Torque 16-20 ft. lbs. (21-27 Nm) Figure 3-34.
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE 1001107820 C Figure 3-35. Drive Orientation Switch 31215001 3-67...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE COUNTERWEIGHT* RETAINING HOOK TURNTABLE RETAINING BOLT, NOTE A, NOTE B A - Torque 285 ft.lbs. (388 Nm) B - Apply High Strength Threadlocking Compound Figure 3-36. Counterweight 3-68 31215001...
  • Page 116 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 117: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM condition of the machine is when the use of multiple function 4.1 PLATFORM CONTROL ENABLE SYSTEM operation is allowed (at low boom angles). The platform controls make use of a time dependent enable circuit to limit the time availability of “live”...

  • Page 118: Platform

    SECTION 4 - BOOM & PLATFORM 4.7 PLATFORM Remove the bolts and washer securing the platform support cover to the platform support. Remove plat- form support cover. Support Removal MAF17790 MAF17720 Figure 4-1. Location of Components Platform Support Remove the bolts and locknut securing the support to the rotator.

  • Page 119: Support Installation

    SECTION 4 - BOOM & PLATFORM Using a suitable brass drift and hammer, remove the Apply Medium Strength Threadlocking Compound to rotator shaft, then remove the support from the rotator. the bolts and locknuts securing the support to the rota- tor and install the bolts and locknuts MAF17740 MAF17730...
  • Page 120 SECTION 4 - BOOM & PLATFORM Position the platform on the platform support and install the bolts securing the platform to the platform support. Connect the electrical cables to the platform control console 31215001...
  • Page 121 SECTION 4 - BOOM & PLATFORM A, B, D NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. MAF17750 C, D A Torque to 40 ft.lbs. (55 Nm) B Medium Strength Threadlocking Compound C Torque to 250-270 ft.

  • Page 122: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM 4.8 BOOM MAINTENANCE NOTE: When removing the retaining pin from the rod end of the upper lift cylinder, make sure the cylinder is properly sup- ported. Removal of the Main Boom Remove the retaining bolt, keeper, and pin that secures the upper lift cylinder rod end to the main boom.
  • Page 123 SECTION 4 - BOOM & PLATFORM 1. Tower Lift Cylinder 4. Upper Lift Cylinder 7. Boom Assembly 2. Tower Upright 5. Master Cylinder 8. Jib Rotator 3. Upper Upright 6. Platform Level Cylinder 9. Jib Figure 4-3. Boom Assembly 31215001...

  • Page 124: Inspection

    SECTION 4 - BOOM & PLATFORM NOTE: The telescope cylinder weighs approximately 53 lb (24 kg). Assembly of the Main Boom Lubricate the boom sections as shown in Figure 4-4., Using a suitable lifting device, remove telescope cylin- Boom Lubrication Instructions. der from the rear of the boom sections.

  • Page 125: Installation Of The Main Boom

    SECTION 4 - BOOM & PLATFORM MODERATELY APPLY BOOM GREASE TO OUTER MODERATELY APPLY BOOM GREASE TO SURFACE OF WEAR PADS ON FLY BOOM (8X) ALL FOUR OUTER SURFACES OF FLY JLG PN 3020022 BOOM TUBE IN SPECIFIED LOCATION JLG PN 3020022 12”...
  • Page 126 SECTION 4 - BOOM & PLATFORM  JIB ROTATE RETURN HOSE JIB ROTATE SUPPLY HOSE A/C CABLE ROUTED ON TOP OF JIB CYL HOSES POSITION BOTH LEVEL CYL HOSES TO THE OUTSIDE OF PUSH TUBE AS SHOWN PLATFORM SUPPLY HOSE PLATFORM RETURN HOSE LOWER BOOM CONTROL HARNESS JIB CYL EXTEND HOSE...
  • Page 127 SECTION 4 - BOOM & PLATFORM ORIENT CLAMP BLOCK SECTIONS USING ALIGNMENT HOLES AS SHOWN CLAMP BLOCK INSTALLATION INSTRUCTIONS TO PROVIDE ORIENTATION OF THREADED STUDS, LOOSELY INSTALL THREADED STUD INTO CLIP NUT UNTIL FIRST SECTION OF CLAMP BLOCK IS INSTALLED 2.
  • Page 128 SECTION 4 - BOOM & PLATFORM Figure 4-7. Boom Thread Locking Compound Location 4-12 31215001...
  • Page 129 SECTION 4 - BOOM & PLATFORM A - Torque 41 ft. lbs. (55 Nm) B - Torque 72 ft. lbs. (97 Nm) Figure 4-8. Boom Torque Values 31215001 4-13...
  • Page 130 SECTION 4 - BOOM & PLATFORM Link 6. Upper Upright Weldment Level Link 7. Tower Upright Weldment 3. Lower Boom 8. Tower Lift Cylinder 4. Mid Boom 9. Bumper 5. Timing Link 10. Hose Channel Protector Figure 4-9. Lower Boom 4-14 31215001...
  • Page 131 SECTION 4 - BOOM & PLATFORM Figure 4-10. Lower Boom Thread Locking Compound Location 31215001 4-15...
  • Page 132 SECTION 4 - BOOM & PLATFORM A - Torque 41 ft. lbs. (55 Nm) B - Torque 72 ft. lbs. (97 Nm) Figure 4-11. Lower Boom Torque Values 4-16 31215001...
  • Page 133 SECTION 4 - BOOM & PLATFORM 1. Platform Rotator Jib Rotator 3. Upper Jib Link Jib Link Jib Cylinder Platform Support Jib Rotator Center Bolt Platform Rotator Center Bolt Figure 4-12. AJP Jib 31215001 4-17...
  • Page 134 SECTION 4 - BOOM & PLATFORM A,E,F B,E,F NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A - Torque to 35 ft. lbs. (48 Nm) B - Torque to 85 ft. lbs. (115 Nm) C - Torque to 250 ft.

  • Page 135: Wear Pads

    SECTION 4 - BOOM & PLATFORM 4.9 WEAR PADS 4.10 TILT SENSOR CHECK Shim up wear pads until snug to adjacent surface. Replace wear pads when worn to thickness shown PERFORM TILT SENSOR CHECK PROCEDURE A MINIMUM OF EVERY SIX below MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.
  • Page 136 SECTION 4 - BOOM & PLATFORM NOTE: UPPER BOOM ANGLE TO BE 1° BELOW HORIZONTAL TO 3° ABOVE HORIZONTAL TO ACTIVATE SWITCH. UPPER BOOM ANGLE TO BE 1° TO 4° BELOW HORIZONTAL TO RESET SWITCH. NOTE: LOWER BOOM ANGLE TO BE 1° TO 5°...

  • Page 137: Boom Cleanliness Guidelines

    SECTION 4 - BOOM & PLATFORM 4.12 BOOM CLEANLINESS GUIDELINES The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris The following are guidelines for internal boom cleanliness for toward the nearest exiting point from the boom. Make machines that are used in excessively dirty environments.

  • Page 138: Articulating Jib Boom

    SECTION 4 - BOOM & PLATFORM 4.14 ARTICULATING JIB BOOM Inspection NOTE: When inspecting pins and bearings refer to Section 2.5, Removal Pins and Composite Bearing Repair Guidelines. For platform/support removal see platform/support removal diagram. See Section 4.7, Platform. Inspect articulating fly boom pivot pin for wear, scoring, tapering and ovality, or other damage.

  • Page 139: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 4.15 BOOM SYNCHRONIZING PROCEDURE If the Lower Boom assembly does not fully lower: NOTE: For location of components See Figure 4-16., Location of Components - Articulating Jib Boom. Remove all personnel from the platform. Pull the red knob located under the main control valve.

  • Page 140: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.16 ROTARY ACTUATOR Tools Required for Assembly/Disassembly there are Upon assembly and disassembly of the actuator Theory Of Operation basic tools required. The tools and their intended func- tions are as follows: The rotary actuator is a simple mechanism that uses the slid- Flashlight - helps examine timing marks, component ing spline operating concept to convert linear piston motion failure and overall condition.
  • Page 141 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 142 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.

  • Page 143: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Install the end cap (4) removal tools provided with the Helac seal kit. Remove the capscrews (113) over end cap lock pins (109). Using a metal bar, or something similar, un-screw the end cap (4) by turning it counterclock-wise. Using a 1/8”...
  • Page 144 SECTION 4 - BOOM & PLATFORM Remove the stop tube if included. The stop tube is an Prior to removing the shaft, (2), use a felt marker to available option to limit the rotation of the actuator. clearly indicate the timing marks between shaft and pis- ton.
  • Page 145 SECTION 4 - BOOM & PLATFORM To remove the piston (3) use a rubber mallet and a plas- Remove the wear guides (302) from the end cap (4) and tic mandrel so the piston is no damaged. shaft (2). At the point when the piston gear teeth come out of To remove the main pressure seals (205), it is easiest to engagement with the housing gear teeth, mark the pis- cut them using a sharp razor blade being careful not to...

  • Page 146: Inspection

    SECTION 4 - BOOM & PLATFORM Remove the wiper seal (304.1) from its groove in the end Inspection cap (4) and shaft (2). 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 147: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular Gather all the components and tools into one location motion.
  • Page 148 SECTION 4 - BOOM & PLATFORM Install the inner T-seal (200) into the piston (3) using a 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 149 SECTION 4 - BOOM & PLATFORM Looking from the opposite end of the housing (1) you Install 2 bolts in the threaded holes in the flange. Using a can see if your timing marks are lining up. When they do, bar, rotate the shaft in a clockwise direction until the tap the piston (3) in until the gear teeth mesh together.
  • Page 150 SECTION 4 - BOOM & PLATFORM Install the O-ring (204) and backup ring (207) into the Place the lock pins (109) provided in the Helac seal kit in inner seal groove on the end cap (4). the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.

  • Page 151: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Strength Threadlocking Compound should be applied to the shank of the three bolts at the time of installation. Torque the 1/4-inch bolts 110 to 120 in. lbs.  Refer to Figure 4-19., Rotator Counterbalance Valve. (12.4 to 13.5 Nm).

  • Page 152: Greasing Thrust Washers

    SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on After the actuator is assembled but before it is put into a hydraulic test bench. The breakaway pressure — the pres- service, the thrust washer area must be packed with sure at which the shaft begins to rotate —...

  • Page 153: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding With an operator in the platform, open both bleed nip- ples 1/4 turn. Hydraulically rotate the platform to the After installation of the actuator on the equipment, it is end of rotation (either clockwise or counterclockwise), important that all safety devices such as tie rods or safety and maintain hydraulic pressure.

  • Page 154: Troubleshooting

    SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s  pressure specifications. Load may be above maximum ...

  • Page 155: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.17 POWERTRACK MAINTENANCE Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the power- track. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be different.
  • Page 156 SECTION 4 - BOOM & PLATFORM To remove a link, the rivets holding the links together must be removed. Use a right-angle pneumatic die MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS grinder with a ¼” ball double cut bur attachment. TO PROTECT THEM.
  • Page 157 SECTION 4 - BOOM & PLATFORM After grinding it may be neccesary to help the rivet out Using a flat head screwdriver between the links, twist by using a center punch with a hammer. the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.

  • Page 158: Installing A New Link

    SECTION 4 - BOOM & PLATFORM Remove the link from the other section of the power- Installing a New Link track using a screwdriver. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section. 4-42 31215001...
  • Page 159 SECTION 4 - BOOM & PLATFORM Spread apart the half-shear (female) end of the new link After the new link is installed in the powertrack the and slide the peanut end of the track section into it. a round half-shears will not fit properly in the peanut cut- screwdriver may be necessary to do this.
  • Page 160 SECTION 4 - BOOM & PLATFORM Pull the moving end out over the track so that the new Push pin thru center hole then slide washer on pin. connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs.
  • Page 161 SECTION 4 - BOOM & PLATFORM Install the snap ring in the groove on the pin. Repeat the NOTE: When installing snap rings make sure they are seated in pin installation steps for all center holes that have the pin groove and closed properly. rivets removed.
  • Page 162 SECTION 4 - BOOM & PLATFORM NOTE: Maximum tightening torque is 18-20 in. lbs. Pull up on the other end of the round bar and slide the new poly roller onto the bar. 4-46 31215001...

  • Page 163: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Install a new 8-32 x 0.500 self threading screw on the Replacing Fixed End Brackets other side. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.
  • Page 164 SECTION 4 - BOOM & PLATFORM Parts used: Bracket Center Pin and Center Pin Snap Ring. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING Take the new bracket and install bracket center pin and snap ring.

  • Page 165: Replacing Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. Remove existing pins and center rivet. Remove the rivet the same way as shown in the link removal instructions.
  • Page 166 SECTION 4 - BOOM & PLATFORM Install radius pins into their original locations and install NOTE: When installing snap rings make sure they are seated in snap rings. Repeat with other moving end if replacing as pin groove and closed properly. well.

  • Page 167: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.18 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 168: 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 169 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 170: Basic Hydraulic Information & Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 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 171: 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. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- Hold the fitting over a suitable catch can.

  • Page 172: Hydraulic Connection Assembly And Torque Specification

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512 TORQUE SPECIFICATION Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.

  • Page 173: Straight Thread Types, Port Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Straight Thread Types, Port Connections Flange Connection Types ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162 MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162 6149, DIN 3852 Figure 5-10.

  • Page 174: Assembly And Torque Specifications

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly and Torque Specifications Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.

  • Page 175: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN- MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR Thread Tapered (NPTF) Connections. ALIGNMENT.

  • Page 176: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for British Standard Pipe Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT Thread Tapered (BSPT) Connections procedure requirements. Inspect components to ensure male and female port NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are threads are free of rust, splits, dirt, foreign matter, or...

  • Page 177: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.
  • Page 178 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel Type/Fitting Identification Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 179 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass Type/Fitting Identification Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 180 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-11...

  • Page 181: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
  • Page 182 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel Type/Fitting Identification Torque Thread ØA* ØB* [Ft-Lb] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16 0.69...
  • Page 183 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method. Refer to FFWR and TFFT Methods for procedure require- Ensure proper O-ring is installed.
  • Page 184 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench Type/Fitting Identification Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in) (mm)

  • Page 185: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
  • Page 186 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-9. DIN 24°Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance (mm)

  • Page 187: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. Remove the locknut from the bulkhead assembly. Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening.
  • Page 188 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12 Torque...
  • Page 189 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5...
  • Page 190 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-21...
  • Page 191 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Torque the fitting or nut to value listed in Table 5-12 thru Assembly Instructions for O-Ring Boss (ORB) Table 5-17 while using the Double Wrench Method. Fittings a. The table headings identify the straight thread O- ring port and the type on the other side of the fit- Inspect components to ensure that male and female ting.
  • Page 192 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF)
  • Page 193 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31...
  • Page 194 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 195 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
  • Page 196 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52 (55)
  • Page 197 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-17. O-ring Boss (ORB) - Table 6 of 6 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 3/8-24 0.37 9.52 7/16-20...
  • Page 198 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-29...

  • Page 199: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Torque the fitting or nut to value listed in Table 5-18, Assembly Instructions for Adjustable Port End Table 5-19, Table 5-20, Table 5-21, Table 5-22, or  Metric (MFF) Fittings Table 5-23 while using the Double Wrench Method. a.
  • Page 200 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 201 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 202 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
  • Page 203 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
  • Page 204 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 205 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...
  • Page 206 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-37...

  • Page 207: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the type on the other side of the fitting.
  • Page 208 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 209: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Torque the fitting or nut to value listed in Table 5-25, Assembly instructions for Adjustable Port End Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5- (BSPP) Fittings 30 while using the Double Wrench Method. a.
  • Page 210 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 FORM A**(SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 211 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-26. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37°...
  • Page 212 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-27. British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS BSPP...
  • Page 213 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 FORM A** (SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end BSPP Torque...
  • Page 214 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-29. British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 215 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end BSPP Torque...
  • Page 216 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-47...

  • Page 217: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. See Figure for O-ring installation instructions. Pre-lubricate the O-ring with Hydraulic Oil. Position flange and clamp halves.
  • Page 218 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws Flange Size...
  • Page 219 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws CLASS 10.9 Screws...

  • Page 220: Double Wrench Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.

  • Page 221: Ffwr And Tfft Methods

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: Lubricate the o-ring with a light coat of hydraulic oil. Tighten the swivel nut to the mating fitting until no lat- eral movement of the swivel nut can be detected;...

  • Page 222: O-Ring Installation (Replacement)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads during replacement or installation.

  • Page 223: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.3 HYDRAULIC CYLINDERS Using the hook spanner wrench, unscrew the cylinder head from the barrel. Platform Level Cylinder Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.
  • Page 224 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 25-30 ft. lbs. (34-40 Nm) 1001203949-B MAE39260B 1. Barrel 6. Rod Seal 11. O-ring 16. Bearing 21. Phase Valve 2. Rod 7. Backup Ring 12. Piston 17. Cartridge Valve 22.
  • Page 225 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 226 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 227 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal in the outer piston diameter cable cylinder head groove. groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)....

  • Page 228: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Jib Lift Cylinder Using the hook spanner wrench unscrew the cylinder head from the barrel. DISASSEMBLY Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 229 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 30-35 ft.lbs. (41-47 Nm) 1001108429 C 1. Barrel 5. Retaining Ring 9. O-ring 13. Piston Seal 17. Bearing 2. Rod 6. Rod Seal 10. Backup Ring 14. Piston Ring 18.
  • Page 230 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 231 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 232 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston rings and seal in the outer piston diam- cable cylinder head groove. Install the new retaining eter groove.

  • Page 233: Main Boom Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Lift Cylinder Using the hook spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 234 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 25-30 ft.lbs. (40-41 Nm) **Torque to 14.4 ft.lbs. (19.5 Nm) *** Torque to 19-21 ft.lbs. (26-28 Nm) 1001106880 E 1. Barrel 6. Rod Seal 11. O-ring 16. Spacer 20. Cartridge Valve 2.
  • Page 235 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 236 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 237 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal and spacer in the outer piston diameter groove. (A tube, with I.D. slightly larger than cable cylinder head groove.

  • Page 238: Master Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder Using a hook spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 239 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001105989 C 1. Barrel 5. Retaining Ring 9. O-ring 12. Piston 15. Nut 2. Rod 6. Rod Seal 10. Backup Ring 13. Piston Seal 16. Bearing 3. Head 7. Backup Ring 11. O-ring 14.
  • Page 240 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 241 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 242 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal in the outer piston diameter cable cylinder head groove. groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)....

  • Page 243: Tower Boom Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Tower Boom Lift Cylinder Using a hook spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 244 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 19-21 ft.lbs. (26-28 Nm) **Torque to 25-30 ft.lbs. (34-40 Nm) *** Torque to 14.4 ft.lbs. (19.52 Nm) 1001107886 D 1. Barrel 6. Rod Seal 11. O-ring 16. Cartridge Valve 20.
  • Page 245 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 246 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 247 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal and o-ring in the outer and inner cable cylinder head groove. Install a new retaining ring piston diameter groove.

  • Page 248: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Cylinder EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, DISASSEMBLY HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK With the barrel clamped securely, apply pressure to the SURFACE IN A DIRT FREE WORK AREA.
  • Page 249 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001108310 C 1. Barrel 5. Retaining Ring 9. O-ring 12. Piston 15. Nut 2. Rod 6. Rod Seal 10. Backup Ring 13. Piston Seal 16. Bearing 3. Head 7. Backup Ring 11. O-ring 14.
  • Page 250 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 251 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY Use a soft mallet to tap a new wiper seal into the appli- cable cylinder guide gland groove. Install the new NOTE: Prior to cylinder assembly, ensure that the proper cylinder retaining ring into the applicable cylinder guide gland seal kit is used.
  • Page 252 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Remove the cylinder rod from the holding fixture. Place new piston seal and o-ring in the outer piston EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, diameter groove. (A tube, with I.D. slightly larger than HEAD, AND PISTON.

  • Page 253: Telescope Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, DISASSEMBLY HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK With the barrel clamped securely, apply pressure to the SURFACE IN A DIRT FREE WORK AREA.
  • Page 254 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 20 ft.lbs. (27 Nm) **Torque to 25-30 ft.lbs. (34-40 Nm) 1001120974 C 1. Barrel 6. Rod Seal 11. O-ring 15. Nut 19. Cartridge Valve 2. Rod 7. Backup Ring 12.
  • Page 255 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 256 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 257 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seals and o-ring in the outer piston diameter groove. (A tube, with I.D. slightly larger than cable cylinder head groove.

  • Page 258: Cylinder Removal And Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.4 CYLINDER REMOVAL AND INSTALLATION Main Boom Lift Cylinder Installation NOTE: Coat I.D. of bushings with specified lubricant prior to Main Boom Lift Cylinder Removal installing pins. NOTE: The Main Boom weighs approximately 450 lb (204kg). NOTE: The Main Boom Lift Cylinder weighs approximately 97 lb (44kg).

  • Page 259: Main Boom Telescope Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Removal NOTE: Care should be taken when removing the telescope cylinder, do not leave cylinder rest on powertrack Place machine on flat and level surface, with Main Boom which could cause damage to powertrack.

  • Page 260: Main Boom Telescope Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Installation Phase Check Cartridge The phase valve is a back-to-back pair of check valves, one of Attach a hydraulic power supply to the telescope cylin- which is mechanically actuated. This valve is installed in the der ports.

  • Page 261: Pressure Setting Procedure

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.5 PRESSURE SETTING PROCEDURE SWING RIGHT / LEFT – 750 PSI (52 BAR) Adjustments made at the Main Valve Bank MAIN PRESSURE RELIEF VALVE – 3000 PSI (207BAR) SWING RELIEF VALVE MAE39420 Install pressure gauge at port MP of Main Valve Bank.
  • Page 262 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS STEER RIGHT – 1400 PSI (97 BAR) STEER LEFT – 2000 PSI (138 BAR) STEER LEFT RELIEF VALVE STEER RIGHT RELIEF VALVE MAE39420 MAE39420 Install pressure gauge at port MP of Main Valve Bank. Install pressure gauge at port MP of Main Valve Bank.

  • Page 263: Adjustments Made At The Boom Function Valve Bank

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Adjustments made at the Boom Function Valve JIB LIFT DOWN – 1200 PSI (83 BAR) Bank JIB LIFT UP – 2000 PSI (138 BAR) JIB DOWN RELIEF VALVE Install pressure gauge at port MP of Main Valve Bank. JIB UP RELIEF VALVE Install pressure gauge at port MP of Main Valve Bank.
  • Page 264 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS PLATFORM LEVEL UP – 3000 PSI (207 BAR) Install a pressure gauge in one of the following loca- tions: a. At port M15 of Boom Function Valve PLATFORM LEVEL UP RELIEF VALVE Refer to the Main Pressure Relief Valve procedure and temporarily set Main Pressure Relief Valve to 3300 psi (227.5 Bar).
  • Page 265 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS c. At end of platform level up hose (do not use this PLATFORM LEVEL DOWN – 1200 PSI (83 BAR) location if port 15 was chosen in step 2.) PLATFORM LEVEL UP HOSE Activate Platform Level Up and hold.
  • Page 266 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS After loosening relief valve jam nut, adjust valve clock- wise to increase pressure or counterclockwise to reduce pressure accordingly. Tighten relief valve jam nut. Repeat step 3 and verify the pressure setting. OPTION 2: Disconnect, cap, and plug the platform level down hose and adapter either at the platform level master cylinder,...
  • Page 267 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS TT-SWG-RT (OUTSIDE COIL) TT-SWG-LT (INSIDE COIL) TWR-LFT-UP STEER-RT (INSIDE COIL) STEER-LT (OUTSIDE COIL) MAIN-LFT-UP FLOW-CNTL MAE39160 NOTE: Coil Resistance (@ 68° F [20° C]) is 7.2 Ohms for Tower Lift Up, Main Lift Up, and Flow Control. All other coils have 9.8 Ohms resistance.
  • Page 268 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 3, 9 2, 9 2, 9 1, 9 2, 9 MAE39170 Table 5-33. Main Valve Torque Description Ft. lbs. Description Ft. lbs. Solenoid Valve (Steer) Relief Valve (Steer) Solenoid Valve 47.5 Relief Valve (Swing) (Flow Control/Main and Tower Lift Dump) Solenoid Valve (Swing) Load Shuttle Valve (Swing)
  • Page 269 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS TELE-OUT (OUTSIDE COIL) TELE-IN (INSIDE COIL) PLTF-ROT-RT (OUTSIDE COIL) JIB-LEFT (INSIDE COIL) PLTF-ROT-LT (INSIDE COIL) JIB-RIGHT (OUTSIDE COIL) JIB-UP (OUTSIDE COIL) JIB-DN (INSIDE COIL) PLTF-LVL-UP (OUTSIDE COIL) PLTF-LVL-DN (INSIDE COIL) MAE39430 NOTE: Coil Resistance (@ 68° F [20° C]) is 9.8 Ohms ± 15%. Figure 5-81.
  • Page 270 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 12 13 11 11 E300AJ E300AJP 2 11 ONLY 11 11 Table 5-2. Boom Function Valve Torques Description Ft. Lbs. Description Ft. Lbs. Description Ft. Lbs. Solenoid Valve Manual Valve Port Plug Solenoid Valve Hand Pump Port Plug...
  • Page 271 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001180909-D MAE39270D Ft. lbs. 16-19 22-26 1. Boom Function Valve 2. High Pressure Filter 3. Hydraulic Tank 4. Electric Motor & Pump 5. Main Control Valve Figure 5-83. Hydraulic Components Location 5-102 31215001...

  • Page 272: Initial Hydraulic Pump Start-Up Procedure

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.6 INITIAL HYDRAULIC PUMP START-UP Insert the other end of the pressure test hose into the hydraulic reservoir’s breather/filler port. PROCEDURE This procedure must be used when the hydraulic pump or pump/motor assembly is removed or replaced to ensure there is no air trapped in the hydraulic system.
  • Page 273 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Continue activating the platform rotate switch momen- NOTE: An audible change in the tone of the gear pump should be tarily until the assistant sees a clear, uniform stream of heard when the air is purged from the gear pump. hydraulic fluid flowing from the test hose into the hydraulic reservoir.
  • Page 274 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 31215001 5-105...

  • Page 275: Hydraulic Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC SCHEMATICS PLATFORM LEVEL CIRCUIT MASTER CYLINDER SLAVE CYLINDER BARREL: 2.95" [75mm] BARREL: 2.95" [75mm] ROD: 1.26" [32mm] ROD: 1.26" [32mm] STROKE: 11.5" [293mm] STROKE: 11.8" [299mm] TELESCOPE CYLINDER BARREL: 1.97" [50mm] JIB LIFT CYLINDER ROD: 1.26"...
  • Page 276 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFT CYLINDER ELECTRIC MOTOR EXT. GEAR PUMP Sheet 1001179242 Figure 5-85. Hydraulic Schematic (E300AJP) - Sheet 2 of 4 31215001 5-107...
  • Page 277 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS PLATFORM LEVEL CIRCUIT MASTER CYLINDER SLAVE CYLINDER TELESCOPE CYLINDER JIB LIFT CYLINDER PLATFORM ROTATOR Sheet 1001179242 Figure 5-86. Hydraulic Schematic (E300AJ) - Sheet 3 of 4 5-108 31215001...
  • Page 278 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS UPPER LIFT CYLINDER LOWER LIFT CYLINDER STEER CYLINDER SWING MOTOR ELECTRIC MOTOR RETURN FILTER Sheet 1001179242 Figure 5-87. Hydraulic Schematic (E300AJ) - Sheet 4 of 4 31215001 5-109...
  • Page 279 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 280: Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM smooth control of: acceleration, deceleration, creep and max.- 6.1 JLG CONTROL SYSTEM ANALYZER KIT speed for all boom, drive, and steering functions. INSTRUCTIONS The main lift, swing, and drive are controlled by individual joy- sticks, with steering being controlled by a rocker switch built Introduction into the top the drive joystick.

  • Page 281: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer With the machine power on and the analyzer connected prop- Connect the four pin end of the cable supplied with the erly, the analyzer will display the following: 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 282: 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...

  • Page 283: 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 284: 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 285 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 286 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 287 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P1.10 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 288 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P1.10 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;...
  • Page 289 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P1.10 Default Configuration Digit Number Description Number  SKYGUARD: NO: No Sky Guard system installed.   YES: Sky Guard system installed. SOFT TOUCH: NO: No Soft Touch system installed. ...
  • Page 290 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P1.10 Default Configuration Digit Number Description Number ALERT BEACON: OFF FOR CREEP  15* * Only visible if Skyguard is 20 FPM FOR CREEP selected. TEMP OUTPUT: NO:...
  • Page 291 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings - Table 6-3. Machine Configuration Programming Settings - Version P1.10 Version P1.10 E300 E300 Charger Interlock Model Number Market Plat Lvl Ovr Cut Batteries BOLD TEXT indicates the default setting. Plain text indicates another available selec- tion.

  • Page 292: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM  6.2 MACHINE PERSONALITY SETTINGS  NOTE: Personality settings can be adjusted within the adjustment  range in order to achieve optimum machine performance. Table 6-4. Personality Ranges/Defaults - Version P1.10 FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration...
  • Page 293 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults - Version P1.10 FUNCTION PERSONALITY RANGE DEFAULTS BOOM LIFT ACCELeration 0.1 to 5.0s 2.5s DECELeration 0.1 to 5.0s 2.5s MINimum UP speed 1 to 15% MAXimum UP speed 36 to 100% CREEP maximum UP speed 16 to 35% MINimum DOWN speed...
  • Page 294 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults - Version P1.10 FUNCTION PERSONALITY RANGE DEFAULTS CREEP maximum DOWN speed 16 to 20% JIB SWING ACCELeration 0.1 to 5.0s 2.0s DECELeration 0.1 to 5.0s 1.0s MlNimum LEFT speed 1 to 15% MAXimum LEFT speed 26 to 50% CREEP Maximum LEFT speed...
  • Page 295 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Personality Ranges/Defaults - Version P1.10 FUNCTION PERSONALITY RANGE DEFAULTS Telescope OUT 31 to 60% Jib UP 31 to 60% Jib DOWN 21 to 60% Jib SWING 21 to 60% Platform LEVEL 31 to 60% Platform ROTATE 19 to 50% ALARM/HORN...
  • Page 296 SECTION 6 - JLG CONTROL SYSTEM ANALYZER MENU NOTE: The layout shown includes all possible analyzer screens. Please note that STRUCTURE some screens may not be available depending upon machine configura- tion. HELP : (001) MENU : HELP : PRESS ENTER SYSTEM OK LOG : *(XXXXX) X : XXXXXXXXXXXXXX...
  • Page 297 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : TRACTION VOLTAGE/CUR OPER CONTROLS OPTIONS PLATFORM LOAD CAN STATISTICS SYSTEM INPUTS RIGHT MOTOR BATTERY SOC JOYSTICK DRIVE H&T LIGHTS SW PLATFORM LOAD XXXHz XXX%...
  • Page 298 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DEBUG UGM I/O CALIBRATION DATA DATALOG VERSIONS CAN STATISTICS PLATFORM LOAD CAN1 STATISTICS DEBUG DIAG UGM TILT X DATALOG TIME DATALOG CYCLES RX/SEC: XXXXX DIGITAL INPUTS XXXX COUNTS...
  • Page 299 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : OPERATOR ACCESS MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES DRIVE STEER SWING TOWER LIFT LIFT TELESCOPE DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE ACCEL X.X SEC...
  • Page 300 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : PERSONALITIES MENU: MODEL MODEL MARKET BATTERIES TILT GROUND ALARM MACHINE SETUP E 00 E 00 ANSI USA 310AH FLOOD 5 DEGREES ALARM/HORN JIB SWING SKYGUARD SOFTTOUCH COMBINED H & T LIGHTS LOAD SYSTEM FUNCTION CUTOUT DISPLA Y UNITS...

  • Page 301: Machine Orientation When Performing Test

    SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN PERFORMING Telescope: Main Lift at full elevation, Telescope Retracted. Telescope Out, record time. Telescope In, record time. Turn TEST Platform Speed Control Knob fully counterclockwise to enter creep mode; creep light on Panel must be energized. Verify Drive (Below elevation): Test should be done on a smooth, that machine will Telescope Up and Down.

  • Page 302: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM Test Notes Table 6-5. Function Speeds Personality settings can be adjusted anywhere within Function Speed (In Seconds) the adjustment range in order to achieve optimum Main Lift Up 24-27 machine performance. Main Lift Down 20-23 Stop watch should be started with the function move- Turntable Swing Right &...
  • Page 303 SECTION 6 - JLG CONTROL SYSTEM Figure 6-7. Control Module Location 6-24 31215001...
  • Page 304 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-8. Analyzer Connecting Points 31215001 6-25...
  • Page 305 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION UNALLOCATED (JIB RT) DIGITAL INPUT UNALLOCATED (JIB LT) DIGITAL INPUT UNUSED (BATTERY VOLTAGE) BATTERY VOLTAGE DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT UNALLOCATED (BASKET STOW SWITCH) DIGITAL INPUT CHASSIS TILTED INDICATOR LAMP OUTPUT FUNCTION ENABLE INDICATOR LAMP OUTPUT...
  • Page 306 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION LIFT / SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE LIFT CENTER TAP ANALOG INPUT LIFT SIGNAL ANALOG INPUT SWING SIGNAL ANALOG INPUT NATURAL SWING CENTER TAP ANALOG INPUT UNUSED ANALOG INPUT LIFT / SWING JOYSTICK RETURN GROUND UNUSED GROUND...
  • Page 307 SECTION 6 - JLG CONTROL SYSTEM 1001192212 F Figure 6-11. Power Module - LH 6-28 31215001...
  • Page 308 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR 1001178339 G Figure 6-12. Power Module - RH 31215001 6-29...
  • Page 309 SECTION 6 - JLG CONTROL SYSTEM Connector DRIVE ENABLE RELAY (VOTE) DRIVE ENABLE RELAY GROUND (VOTE) 1001182700 R Figure 6-13. Ground Control Module - Sheet 1 of 3 6-30 31215001...
  • Page 310 SECTION 6 - JLG CONTROL SYSTEM 1001182700 R Figure 6-14. Ground Control Module - Sheet 2 of 3 31215001 6-31...
  • Page 311 SECTION 6 - JLG CONTROL SYSTEM Connector 1001182700 R Figure 6-15. Ground Control Module - Sheet 3 of 3 6-32 31215001...

  • Page 312: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Help Descriptions and Fault Flash Codes Table 6-6. Machine Setup Descriptions Table 6-7. JLG Control System Flash Codes MODEL NUMBER... Displays/adjusts machine model NOTE: all Code Description personalities reset to default when model number is altered 2-1...

  • Page 313: 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 314 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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 315 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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 BOOM ELEV SW OPEN/CLOSED State of Boom Elevation Switch #1 TOWER ELEV SW OPEN/CLOSED State of Boom Elevation Switch #2...
  • Page 316 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. 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 317 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) JIB LIFT UP SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input [MACHINE SETUP ' Jib = YES] JIB LIFT DN SW OPEN/CLOSED...
  • Page 318 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLATFORM LOAD PLATFORM LOAD STATE: OK/OVER LOAD LSS Status (DISPLAY ONLY IF MACHINE PLATFORM LOAD ACTUAL: XXX.XKG...

  • Page 319: 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 320 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. 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 321 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer PLATFORM RT VALVE SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay) PLATFORM LEVEL UP SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay) PLATFORM LEVEL DOWN SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay)
  • Page 322 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. 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 323 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. 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 324: Calibrating Steer

    SECTION 6 - JLG CONTROL SYSTEM 6.4 CALIBRATING STEER 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 325 SECTION 6 - JLG CONTROL SYSTEM Hit Enter. The screen will read: Hit Enter. The screen will read: The display will read Left Steer Maximum value. Activate the steer control until the tire and wheel are Hit Enter. The screen will read: straight in relationship with the chassis, then leave off the control.

  • Page 326: Calibrating Tilt Sensor

    SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATING TILT SENSOR Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 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 327: Calibrating Load Sensing

    SECTION 6 - JLG CONTROL SYSTEM When prompted, swing turntable 180° to opposite end 6.6 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 Position the Platform/Ground select switch to the Plat- form position.
  • Page 328 SECTION 6 - JLG CONTROL SYSTEM Use the arrow keys to reach LOAD SENSING. The screen Hit Enter. The screen will read: will read: Hit Enter. The screen will read: Hit Enter. The screen will read: 31215001 6-49...
  • Page 329 SECTION 6 - JLG CONTROL SYSTEM Hit Enter. The screen will read: Hit Enter. The screen will read: Hit Enter. The screen will read: After few seconds, the screen will read: Hit ESC twice to go back to CALIBRATIONS 6-50 31215001...
  • Page 330 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution EVERYTHING OK The UGM determines that platform station Occurrence of active DTC (EVERYTING OK) OR ground station (GROUND MODE OK) is selected and no system faults exist, including Power Mod- ule check;...
  • Page 331 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 0048 BATTERY CHARGE LOW Battery SOC < 10% Battery SOC > Discharged; speed restrictions removed after controls ini- tialized 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:...
  • Page 332 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 2217 D/S JOY. CENTER TAP BAD The PM detects that the drive/steer center tap The PM detects that the drive/steer center tap voltage is not between 3.31 volts and 3.75 volts voltage is between 3.31 and 3.75 volts and no and reports the fault to the UGM...
  • Page 333 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 2262 FUNCTION PROBLEM - PLATFORM LEVEL The machine is in Platform mode and the Plat- Platform Level Up input = LOW while the UP PERMANENTLY SELECTED form Level Up input = High at Startup machine is not Enabled...
  • Page 334 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 23172 FUNCTION PROBLEM - JIB SWING RIGHT The machine is in Ground mode and the Jib Swing Jib Swing Right input = LOW and the machine is PERMANENTLY SELECTED Right input = High at Start Up not in the Enabled state.
  • Page 335 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 2568 TEMPERATURE CUTOUT ACTIVE – AMBIENT Low Temperature Cutout = Active Low Temperature Cutout = Inactive; speed TEMPERATURE TOO LOW restrictions removed after controls are initialized 2576 PLATFORM LEVEL PREVENTED –...
  • Page 336 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 3378 HEAD TAIL LIGHT - SHORT TO BATTERY MACHINE SETUP -> H & T LIGHTS =YES; Power cycle UGM detects a short to battery at head/tail light relay output 3382 PLATFORM LEVEL UP VALVE - SHORT TO...
  • Page 337 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 33108 TOWER LIFT UP VALVE - SHORT TO BATTERY The UGM detects a short to ground at the tower lift Power cycle up output 33109 TOWER LIFT DOWN VALVE - SHORT TO...
  • Page 338 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 33305 STEER RIGHT - SHORT TO GROUND The UGM detects a short to ground at steer right Power cycle output. 33314 FLOW CONTROL VALVE - OPEN CIRCUIT The UGM detects an OC at this output Power cycle 33315...
  • Page 339 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 4229 REAR RIGHT MOTOR TEMPERATURE - OUT The Power Module reports that motor tempera- Traction module no longer reporting fault; Creep OF RANGE ture sensor is out of range due to Open-Circuit restriction removed after controls initialized (Temp Out of Range –...
  • Page 340 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 46100 REAR LEFT BRAKE RETURN - SHORT TO BAT- Traction Module detects an overcurrent condition Power cycle TERY on pin A4, indicating a short between B+ and the Electric Brake FET 46130 MAIN CONTACTOR / REAR RIGHT BRAKE...
  • Page 341 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 7725 PUMP MOTOR - NOT RESPONDING The Master Traction Module detects that the Power cycle pump motor feedback is not responding when the pump is being commanded 7730 PUMP MOTOR OUTPUT - OUT OF RANGE...
  • Page 342 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 7766 REAR RIGHT MOTOR - FEEDBACK FAILURE After main contactor is closed, Power Module Power cycle detects that the motor voltage feedback circuits are damaged 7769 REAR LEFT MOTOR - ROTATION OPPOSITE...
  • Page 343 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat 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 >...
  • Page 344 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 9910 FUNCTIONS LOCKED OUT - PLATFORM The UGM software version type is ‘P’ The UGM has Not all of the trigger conditions are met MODULE SOFTWARE VERSION IMPROPER received valid version information from the PM.
  • Page 345 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 9979 FUNCTIONS LOCKED OUT - GROUND MOD- Ground software has been installed on a UGM Power cycle ULE SOFTWARE VERSION IMPROPER with a ST10F274 processor (Hardware Rev < 6), which does not have guaranteed flash storage in the sector where Constant Data is written.
  • Page 346 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 99248 REAR RIGHT MODULE - EEPROM FAILURE Applicable Power Module determines at Startup Power cycle that an internal EEPROM error exists or UGM fails to successfully verify or write to/read back Indi- rect Table three times 99249...
  • Page 347 SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Diagnostic Trouble Codes DTC Cat DTC Text Fault Description Solution 99269 REAR LEFT MODULE - DRIVE COMMAND Power Modules determine that an inconsistency Power cycle ERROR has occurred between the Drive direction/enable bits and Drive magnitude/direction command 99273 FUNCTIONS LOCKED OUT –...
  • Page 348 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 349: 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 350: 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 351: 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 352: Automatic Switches

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Remove proximity switch from its mount. APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS Reconnect harness if it was disconnected for step a, and turn on machine. NOTE: This section is not applicable for battery terminals. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer.

  • Page 353: Dielectric Grease Application

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS When applied to electrical connections, dielectric grease helps AMP Faston to prevent corrosion of electrical contacts and improper con- ductivity between contacts from moisture intrusion. Open and This connector system is typically used on operator switches at sealed connectors benefit from the application of dielectric JLG.

  • Page 354: Mini Fit Sr

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Mini Fit Sr Exceptions This connector system is typically used on control modules at Some waterproof connector applications do benefit from JLG. Follow the general guidance for installation. dielectric grease, and some non waterproof connectors do not benefit from dielectric grease.

  • Page 355: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 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 7-5.). Proceed as follows: Connectors Silicone Dielectric Compound must be used on the AMP con- nections for the following reasons: •...
  • Page 356 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 After all required contacts have been inserted, the 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 7-9.).

  • Page 357: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 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. Pry open the wedge lock to the open position.
  • Page 358 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. Connector Installation 7-10 31215001...

  • Page 359: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.7 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-13. DT/DTP Contact Removal Figure 7-12. DT/DTP Contact Installation Remove wedgelock using needle nose pliers or a hook Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 360: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal Grasp contact about 25mm behind the contact crimp With rear insert toward you, snap appropriate size barrel.

  • Page 361: Wiring Harness Connector Labels

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.8 WIRING HARNESS CONNECTOR LABELS Component Labels Every component on the vehicle has a unique identification. A Connector Labels standard prefix letter is assigned according to the table below, followed by a unique sequential number. An optional suffix Connectors between harnesses are identified by the prefix "X"...
  • Page 362 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 363: Electrical Harness

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL HARNESS 1001245673-B Figure 7-18. Platform Console Harness - Sheet 1 of 5 MAF17760B 31215001 7-15...
  • Page 364 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW11 SW546-2 SW292 SW07-2 SW546-1 SW07-1 SW495 SW05 SW09 SW06 SW08 TOP, LOADING VIEW OF CONNECTOR SW16-2B SW16-2A SW16-1A GD819 1001245673-B SW16-1B MAF18270B Figure 7-19. Platform Console Harness - Sheet 2 of 5 7-16 31215001...
  • Page 365 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW16-1B-EMS SW11-DRIVE ORIENT CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 5-2-6 18 AWG X5B (13) 122-1 DOS 18 AWG CO01-J2 (4) 5-14-10 SW PWR 18 AWG SW546-2 (1) 5-14-9 SW PWR 18 AWG...
  • Page 366 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW546-2-SKYGUARD/SOFTTOUCH OVERRIDE CONN- WIRE WIRE LABEL GAUGE JACKET COLOR 5-14-10SW PWR 18 AWG SW11(2) 5-14-11SW PWR 18 AWG SW07-2 (1) SW05-PLATFORM ROTATE CONN- WIRE WIRE LABEL GAUGE JACKET COLOR 23-0 PLAT ROT LFT 18 AWG CO01-J1 (8) 5-14-3 SW PWR...
  • Page 367 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-19...
  • Page 368 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001245673-B MAF18280B Figure 7-20. Platform Console Harness - Sheet 3 of 5 7-20 31215001...
  • Page 369 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW03-2- HORN SW305-TORQUE/SPEED MODE CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 49-0-1 HORN 18 AWG CO01-J1 (31) 120-2 AWDA MAN 18 AWG CO01-J1 (28) 5-14-1 SW PWR 18 AWG SW06 (2) WHT 120-1 TORQUE/SPEED MODE 18 AWG...
  • Page 370 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001245673-B MAF18290B Figure 7-21. Platform Console Harness - Sheet 4 of 5 7-22 31215001...
  • Page 371 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO01-J7-BLACK X6A-OPTIONS CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 81-0GND MODE RX 18 AWG X5B (11) 23-0-3 PLAT ROT LFT 18 AWG CO01-J7 (33) 5-11-3 18 AWG SW16-2A(2A) 24-0-3 PLAT ROT RHT...
  • Page 372 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X5B-TO BOOM CABLE X821B CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR CAN1 HIGH 18 AWG MS820 (11) CAN1 LOW 18 AWG X821A(2) CAN1 LOW 18 AWG MS820 (6) CAN1 HIGH 18 AWG...
  • Page 373 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO01-J2-GRAY CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 14 AWG FC-8 (2) 3-18-1 SKYG PWR 20 AWG X5A(1) 3-18-2 SOFTT SENSE 20 AWG X5A(3) 122-1 DOS 18 AWG SW11(1) CONN-...
  • Page 374 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO01-J1-NATURAL CONN- WIRE WIRE LABEL GAUGE JACKET COLOR 29-0 TWR LFT UP 18 AWG SW06 (3) 29-30 TWR LFT DN 18 AWG SW06 (1) 13-0 MAIN TELE IN 18 AWG SW09 (3) 14-0 MAIN TELE OUT 18 AWG SW09 (1)
  • Page 375 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW546-1 SW07-2 SW546-2 SW07-1 SW08 SW06 SW09 SW05 SW04 SW16-2A SW16-2B SW495 SW292 GD819 SW03-1 SW02 SW305 SW11 SW03-2 SW16-1A SW16-1B X821B X821A CO01-J7 CO01-J8 FC-8 IP821 MS820 AH12+ X798 AH12- CO01-J2 CO01-J1 1001245673-B MAF18300B...
  • Page 376 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-28 31215001...
  • Page 377 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS T391 Figure 7-24. Load Sensing System Harness (LSS) - Sheet 2 of 2 31215001 7-29...
  • Page 378 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-30 31215001...
  • Page 379 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AH82 Figure 7-26. Main Valve Harness - Sheet 2 of 3 31215001 7-31...
  • Page 380 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV26 Figure 7-27. Main Valve Harness - Sheet 3 of 3 7-32 31215001...
  • Page 381 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-33...
  • Page 382 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-34 31215001...
  • Page 383 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HV30 Figure 7-29. Boom Valve Harness - Sheet 2 of 2 31215001 7-35...
  • Page 384 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-36 31215001...
  • Page 385 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001245672-A MAF17770A Figure 7-30. Turntable Harness - Sheet 1 of 4 31215001 7-37...
  • Page 386 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FC-3 MS-3 FC-2 S572 MS423-2 X4-A X756 S541 S593 S594 RL-1 CO1-J8 S721 RL-2 CO1-J12 CO1-J1 S542 S795 S794 S524 S557 S740 CO1-J7 1001245672-A MS423-1 MAF18240A X240 Figure 7-31. Turntable Harness - Sheet 2 of 4 7-38 31215001...
  • Page 387 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X4-A-BOOM CABLE MS423-1-CAN CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR CAN1 HI 18 AWG CO1-J7 (13) CAN 1 LO 18 AWG S593(2) CAN1 LO 18 AWG CO1-J7 (24) CAN 1 HI 18 AWG...
  • Page 388 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CO1-J12 CO1-J1-NATURAL CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 300-1 ALERT PWR 18 AWG X742 (1) 83-1-1 CAN2 HIGH 18 AWG X756 (2) 84-1-1 CAN2 LOW 18 AWG X756 (3) 300-2 ALERT GND...
  • Page 389 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FC-2-15A 12V SYSTEM S572 CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 3-0 CONSTANT 12V 12 AWG MS-3 (4) 5-10-0 IGN 12 AWG MS-3 (5) 3-0 CONSTANT 12V 12 AWG S794 (1) 5-10-1 IGN...
  • Page 390 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS S557 CONN- WIRE WIRE LABEL GAUGE JACKET COLOR 4-0 INSTR GRND 12 AWG MS-3 (6) 4-0-3 INSTR GND 14 AWG MS597 (1) 4-0-1 INSTR GND 12 AWG CO1-J8 (1) 4-0-2 INSTR GND 18 AWG RL-1 (5) S721...
  • Page 391 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-43...
  • Page 392 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X742 CO270-J2 CO270-J3 SN242 X6-B S804 X2-B S543 FC-5 X3-A MS597 X793 1001245672-A MAF18250A X720 Figure 7-32. Turntable Harness - Sheet 3 of 4 7-44 31215001...
  • Page 393 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X2-B-TO CHAS HARN X720-GND CNTL PNL LED CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 2-0 B- 12 AWG MS-3 (3) 205 RED LED 18 AWG CO270-J2 (3) 1-0 B+ 12 AWG...
  • Page 394 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MS597-IGN/GND 12V BUSS CO270-J3-DELTA-Q CHARGER PWR CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 4-0-3 INSTR GND 14 AWG S557 (1) 12 AWG X2-B (6) 4-20 14 AWG X4-A(18) 1-8 GND...
  • Page 395 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS MS-3 FC-2 CO1-J7 FC-3 MS423-1 FC-4 S572 S541 SEE DETAIL A CO1-J8 CAN 3-WAY T RL-1 X240 RL-2 RECEPTACLE CLIP CONNECTOR X756 MOUNTING S594 S721 CO1-J1 CO1-J12 S524 S557 S593 S542 S794 X4-A S795 X3-A...
  • Page 396 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS LB86 7-48 31215001...
  • Page 397 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-49...
  • Page 398 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-50 31215001...
  • Page 399 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GD139 Figure 7-36. Ground Panel Harness - Sheet 2 of 3 31215001 7-51...
  • Page 400 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW100-B1 Figure 7-37. Ground Panel Harness - Sheet 3 of 3 7-52 31215001...
  • Page 401 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-53...
  • Page 402 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-54 31215001...
  • Page 403 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CH-2 Figure 7-39. Chassis Traction Harness - Sheet 2 of 3 31215001 7-55...
  • Page 404 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X603A Figure 7-40. Chassis Traction Harness - Sheet 3 of 3 7-56 31215001...
  • Page 405 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-57...
  • Page 406 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X2-A 7-58 31215001...
  • Page 407 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SN276 31215001 7-59...
  • Page 408 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-60 31215001...
  • Page 409 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 31215001 7-61...
  • Page 410 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001120484-C MAF17780C NOTE: The wire referenced is part of fuse holder Figure 7-44. Platform Work Light Harness 7-62 31215001...
  • Page 411 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS J8_1 CONN- WIRE WIRE LABEL GAUGE JACKET COLOR 12 AWG J8(1) 16 AWG LIGHTS(3) YEL/RED 12 AWG J8(2) SEE NOTE IP396(2) IP396 CONN- WIRE WIRE LABEL GAUGE JACKET COLOR SEE NOTE LIGHTS(4) SEE NOTE J8_1(2) LIGHTS...
  • Page 412 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-64 31215001...
  • Page 413 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X506 Figure 7-46. SkyGuard Harness - Sheet 2 of 2 31215001 7-65...
  • Page 414 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-66 31215001...
  • Page 415 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS S474 Figure 7-48. Security Lock Harness - Sheet 2 of 2 31215001 7-67...
  • Page 416 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001225580-D MAE40200D Figure 7-49. Skyguard (Bar) 6 Pin Harness 7-68 31215001...
  • Page 417 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X5B-INTERFACE S192 CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR 18 AWG IP114 (1) P4-1 18 AWG RL503 (86) 18 AWG X500 (2) P4-2 18 AWG RL502 (86) 18 AWG X500 (3)
  • Page 418 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001235091-A MAE39390A Figure 7-50. Eboom Clearsky CAN Harness 7-70 31215001...
  • Page 419 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X1-TCU CONN- WIRE CONN- WIRE WIRE LABEL GAUGE JACKET WIRE LABEL GAUGE JACKET COLOR COLOR CAN IL-3 18 AWG X1 (7) CAN IL-2 18 AWG MS423-1A (B) CAN IL-1 18 AWG MS423-1B (B) 2-0 IGN 18 AWG X2 (3)

  • Page 420: Electrical Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.10 ELECTRICAL SCHEMATICS SHEET 2: FUNCTION ABBREVIATION SHEET 3: PLATFORM CONSOLE WIRING Console Harness with SKYGUARD and 1 Cell LSS SHEET 4: PLATFORM AND BOOM COMPONENTS SHEET 5: TURNTABLE, AND UGM WIRING Main Valve Harness...
  • Page 421 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Abbreviation Description Abbreviation Description X1B-12 SOFT TOUCH TO X1A CONNECTOR C03-J1-RL LEFT POWER MODULE HV-13 TEL IN C04-J1-RL RIGHT POWER MODULE HV-14 TEL OUT FC-1 10 AMP FUSE HV-21 SWING LEFT FC-2 CONSTANT 12 V HV-22 SWING RIGHT...
  • Page 422 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW305 WHT 120-1 TORQUE/SPEED MODE WHT 5-14-1 SW PWR WHT 120-2 AWDA MAN SW06 WHT 5-14-1 SW PWR WHT 29-0 TWR LFT UP WHT 29-30 TWR LFT DN WHT 5-14-2 SW PWR SW09 WHT 3-8 PLAT IGN 12AWG WHT 13-0 MAIN TELE IN...
  • Page 423 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FC-8 BLK 14AWG BLK 14AWG WHT 3-18-1 SKYG PWR 5A SKYG FUSE WHT 1-36 SKYG GND SHEET 10 WHT 3-18-2 SOFTT SENSE 20AWG WHT 124-1 SKYG INPUT#1 20AWG WHT 124-2 SKYG INPUT#2 20AWG WHT 124-5 SOFTT 20GXL WHT 124-5-1 SOFTT OUT 20AWG WHT 3-8 PLAT IGN 12AWG...
  • Page 424 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS LSS MODULE OPTIONAL LOCATED UNDER CONSOLE BOX GENERIC FOOT SWITCH TO SHEET 3 15 POS MATE IN CONSOLE T394 1-28 LSS GND T395 3-20 LSS PWR TO SHEET 3 T391 15 POS YEL TP CAN CABLE MATE T392...
  • Page 425 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS LSS MODULE OPTIONAL LOCATED UNDER CONSOLE BOX X50B X50A SHIELD TO TURNTABLE HARNESS TO SHEET 5 BLU BLK BLK WHT YEL BLK RED BLK ORN BLK BOOM_4 ALL WIRES ARE AWG UNLESS OTHERWISE NOTED SHEET 4 1001245671-A MAF17950A...
  • Page 426 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ANALYZER PORT HV13 BLK 4-13-2 RTN WHT 13-0-3 TELE IN BLK 4-13 RTN HV14 BLK 4-13-1 RTN WHT 14-0-3 TELE OUT BLK 4-0-1 INSTR GND 12AWG HV21 WHT 38-5-1 CURNT FBACK YEL 5-10-1-1 SWITCHED PWR 12GXL WHT 21-0-1 SWG LFT BLK PLAT GND 12GXL YEL PLATFORM PWR 12GXL...
  • Page 427 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS IF CLEARSKY INSTALLED, SEE MS423-1B, SHT10-F8 SEE MS423-1A, SHT10-F8 GRN CAN1 LO MS423-1 GROUND_CONTROL_6-[2,D] TO MDI YEL CAN1 HI YEL CAN1 HI GROUND_CONTROL_6-[2,D] GRN CAN1 LO MS423-3 X4-A S593 GRN CAN1 LO GRN CAN1 LO YEL CAN1 HI S594...
  • Page 428 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM ROTATE PLATFORM LEVEL SIDESWING JIB LIFT MAIN LIFT TOWER LIFT LED LT CO66-J4 WHT 26-0-1 PLAT LVL DN WHT 25-0-1 PLAT LVL UP WHT 23-0-1 PLAT ROT LFT WHT 24-0-1 PLAT ROT RHT WHT 27-0-1 JIB UP WHT 28-0-1 JIB DN WHT 32-0-1 SIDE SWG LFT...
  • Page 429 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM LEVEL SIDESWING JIB LIFT MAIN LIFT TOWER LIFT SWING TELESCOPE ENABLE GD139 WHT METER PWR BLK METER GND GRN CAN1 LO YEL CAN1 HI LB595 BLK 4-56 WHT 206 YEL LED LED INDICATOR WHT 207 GRN LED BATTERY LEVEL...
  • Page 430 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CHASSIS TO TURNTABLE HARNESS YEL CAN2 HI YEL CAN2 HI S551 TO TURNTABLE HARNESS GRN CAN2 LO GRN CAN2 LO S552 GRN 84-1 CAN2 LOW TT_VALVE_5-[8,D] MS-4 YEL 83-1 CAN2 HIGH YEL CAN2 HI TT_VALVE_5-[8,D] GRN CAN2 LO MS-6...
  • Page 431 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS STEER SENSOR ZAPI #1 RIGHT (MASTER) CO210-A RED BRAKE2-IN-2 RED BRAKE1-IN-2 X599A SN276 RED EPDM 4 AWG RED EPDM 2 AWG RED 201-1 STR SNR RED 18/3 CABLE RED EPDM 4 AWG RED BRAKE1-IN BLU STEER-SIG BLU 18/3 CABLE...
  • Page 432 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CONNECTS TO TERMINAL IN INVERTER WHT IGN 48 V X642 CONNECTS TO X598A WHT 8-8-1 ON SHEET 7 E1 S629 X628 WHT 8-8-3 - X626 CONNECTS TO TH2-2 RED 11-15 INV B+AWGEPDM GENERIC ON SHEET 7 A4 INVERTER...
  • Page 433 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLUG HARNESS BETWEEN PLATFORM BOARD AND EXISTING HARNESS YEL-RED 12AWG YEL-RED 12AWG TO SHEET 3 TO SHEET 3 YEL-RED 12AWG YEL-RED 12AWG BLK 12AWG BLK 12AWG CJ01-8 CJ01-8 BLK 16AWG BLK 16AWG J8_1 CONNECTS TO TERMINAL IN INVERTER X642...
  • Page 434 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HARNESS,GEN 2 PLAT INTERFACE PLTFM SNSR PLTFM SNSR PLTFM SNSR RELAY #1 RELAY #2 S191 S192 WHT P2 WHT P6 TO SHEET 9 WHT P1 WHT P3 18 OHM IP114 NOTE: IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE OF THE PLATFORM CONSOLE BOX, SEE SHEET 8 SHEET 9 Figure 7-63.
  • Page 435 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HARNESS,EBOOM CLEARSKY CAN CONNECT TMR SEE X793, SHT5-G8 RED 1-0 BAT BLK 0-0 GND YEL CAN IH-3 MS423-1B YEL CAN 1H-1 GRN CAN IL-1 SEE MS423-1, SHT5-H7 S001 MS423-1A YEL CAN IH-2 GRN CAN IL-3 GRN CAN IL-2 TO CAN TEE, SHT5-H7...
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