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Oshkosh Corporation JLG H600SJ Service And Maintenance Manual

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Service and Maintenance Manual
Models
EC600SJ,
H600SJ,
EC600SJP,
H600SJP
PVC 2001
31215028
Sepetember 12, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Models EC600SJ, H600SJ, EC600SJP, H600SJP PVC 2001 31215028 Sepetember 12, 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: Bhydraulic System Safety

    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 - September 12, 2019 31215028...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Lubrication and Information ............... . 2-4 Hydraulic System .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Motor Control Valve Assembly..............3-42 Tube Fitting Assembly Procedures .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Platform ................... 4-1 Platform Valve Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Pressure Setting..................5-45 Proportional Main Relief .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Dielectric Grease Application ............... 7-5 Installation .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location ................1-3 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-3. Cylinder Barrel Support ................5-14 5-4.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-60. Rod Seal Installation................5-41 5-61.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-34. Load Sensing System Harness (LSS) - Sheet 2 of 2 ........... . 7-31 7-35.
  • Page 15 LIST OF TABLES TABLE NO. TITLE PAGE NO. DTE 10 Excel 15 Specs ................1-2 Mobil EAL Envirosyn H 32 Specs .
  • Page 16 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 17: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES Machine Specifications Generator Fuel Tank (H Models Only) 13 gal. (49.2L) Hydraulic Tank 15.9 gal.(60.2 L) Maximum Work Load (Capacity) 12.4 gal. (46.9 L) to full mark ANSI Markets Drive Hub 0.4 gal.

  • Page 18: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS 1.6 HYDRAULIC OIL Table 1-2. Mobil EAL Envirosyn H 32 Specs Hydraulic System S.A.E. Viscosity Type Synthetic Biodegradable Operating Grade ISO Viscosity Grade Temperature Range Density at 15° C .869 +0° to + 180° F (-18° to +83° C) Pour Point, Max -38°F (-39°C) +0°...

  • Page 19: Torque Requirements

    SECTION 1 - SPECIFICATIONS 1.7 TORQUE REQUIREMENTS 1.9 SERIAL NUMBER LOCATION A serial number plate is affixed to the right side of the frame. If the serial number plate is damaged or missing, the machine Description Torque Value (Dry) Interval Hours serial number is stamped on the left side of the frame at the Wheel Lugs 170 ft.
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance and Lubrication Diagram 31215028...

  • Page 21: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.10 OPERATOR MAINTENANCE Generator Engine (If Equipped) NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Diagram Table 1-5. Lubrication Specifications. Specification Multipurpose Grease having a minimum dripping point of 350 degrees F.
  • Page 22 SECTION 1 - SPECIFICATIONS Hydraulic Filter Wheel Drive Hub Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Level/Fill Plug or 300 hrs. thereafter or as indicated by Condition Capacity - 0.4 gal. (1.5 L) Indicator.

  • Page 23: Threadlocking Compound

    SECTION 1 - SPECIFICATIONS 1.11 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 High Strength (Red) 271™ Vibra-TITE™ 140 262™ Vibra-TITE™ 131 Medium - High Strength (Red) 0100071 NOTE: Loctite®...

  • Page 24: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.12 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 25: Sae Fastener Torque Chart (Continued)

    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 26 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 27: Sae Fastener Torque Chart (Continued)

    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 28: Sae Fastener Torque Chart (Continued)

    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 29: Sae Fastener Torque Chart (Continued)

    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 30: 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 31: Metric Fastener Torque Chart (Continued)

    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 32 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 33: Metric Fastener Torque Chart (Continued)

    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 34: General

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

  • Page 35: Service And Guidelines

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

  • Page 36: Component Disassembly And Reassembly

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

  • Page 37: 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 Premium Hydraulic Fluid, which has an able, consult your local supplier for an equivalent that meets SAE viscosity of 10W and a viscosity index of 168.

  • Page 38: 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 39: 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 40 SECTION 2 - GENERAL Table 2-2. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields Extend/Retract Chain or Cable Systems...
  • Page 41 SECTION 2 - GENERAL Table 2-2. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Ground Controls Function Control Locks, Guards, or Detents Foot switch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator Drive Brakes Swing Brakes...
  • Page 42 SECTION 2 - GENERAL Table 2-2. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications Function Test of All Systems 21, 22...
  • Page 43 SECTION 2 - GENERAL HYDRAULIC OPERATING FLUID CHART NOTE: DRIVE PERFORMANCE MAY BE REDUCED BELOW 0 DEG F. NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINES IN THE “HYDRAULIC FLUID OPERATION CHART” MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.
  • Page 44 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 45: 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- sures must be taken to remove the JLG product from service WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE immediately and arrangements must be made for replace-...

  • Page 46: Spindle, 2Wd

    SECTION 3 - CHASSIS & TURNTABLE Wheel nuts should be torqued after first 50 hours of Hub should rotate freely when spun by hand. operation and after each wheel removal. Check torque The hub should not be noticeably loose when moved every 3 months or 150 hours of operation.
  • Page 47 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle 2780245 C 1001180912 B Figure 3-1. Spindle Assembly 31215028...

  • Page 48: Drive Hub

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

  • Page 49: Tightening And Torquing Bolts

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

  • Page 50: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Lift out the Input Carrier Subassembly from Hub-Spin- dle Subassembly. NOTE: Refer to Figure 3-2., Main Disassembly Drawing 1, and Fig- Remove the Input Shaft Subassembly out of the Hub- ure 3-3., Main Disassembly Drawing 2, Spindle Subassembly.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE NOTE: Discard the O-ring in the step below. Do not re-use it. Slide the Planet Gear Subassembly (4F) out of the Hub- Spindle Subassembly being careful not to drop the Nee- dle Bearings (4C) in the process. Remove the O-ring (18) from between the Housing (1D) and the Ring Gear (1E).

  • Page 52: Output Planet Gear Disassembly

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

  • Page 53: Cover Disassembly

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

  • Page 54: Housing-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Disassembly Turn the unit over and carefully place the unit on a sup- port base until the Spindle (1A) rests on it. Ensure there is enough gap to lower the Housing (1D) down. NOTE: Refer to Figure 3-6., Housing Spindle Disassembly Set the unit on a bench so that the Spindle (1A) flange is down.
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Lip Seal 1C. Bearing Cup 1D. Housing 1F. Bearing Nut 1G. Housing 1H. Wheel Stud Figure 3-6. Housing Spindle Disassembly 3-11 31215028...

  • Page 56: Housing-Spindle Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Subassembly Spray the Spindle (1A) seal diameter with alcohol and wipe with a clean rag. Apply a coat of oil to the Spindle (1A) seal lip diameter. NOTE: Refer to Figure 3-6., Housing Spindle Disassembly If necessary, install Boot Seal (1Q) onto Housing (1D), NOTE: Spray a light film of oil on all component parts during apply a small amount to grease to the flap of the boot...

  • Page 57: Output Planet Gear Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Planet Gear Subassembly Cover Subassembly NOTE: Refer to Figure 3-4., Output Planet Gear Disassembly NOTE: Refer to Figure 3-5., Cover Disassembly Apply a liberal coat of grease to the bore of the Planet Install two Pipe Plugs (6F) into the Cover (6A).

  • Page 58: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly Drive Roll Pin (4G) down into t he aligned roll pin holes. Pin should be flush with OD of spindle. NOTE: Refer to Figure 3-7., Main Assembly Drawing Install O-Ring (18) onto groove of Housing (1G). Place Ring Gear (1E) onto Housing (1D).
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1E. Ring Gear 4F. Planet Gear Subassembly 9. Input Shaft 1N. Thrust Washer 4G. Roll Pin 10. Sun Gear 1P. O-ring 4H. Thrust Washer 11. Sun Gear 4B. Thrust Washer 5. Retaining Ring 12. Sun Gear 6G.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Hub Assembly - Sheet 1 of 2 3-16 31215028...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1P. O-ring 4D. Thrust Spacer 6F. Oil Plug 8B. Thrust Washer 1B. Lip Seal 1R. Ring Gear 4E. Planet Shaft 6G. Retaining Ring 9. Input Shaft 1C. Tapered Bearing Cup 2. Thrust Spacer 4F.

  • Page 62: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.4 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 63: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Installation Install the drive motor to the machine. NOTE: Refer to Figure 3-10., Drive Motor. Install the rotor (29) into the stator (2). INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT, Install the gear key (32) on to the rotor shaft.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 1. Not Included 10. Shaft Seal 19. Seal 28. O-Ring 2. Stator 11. Bearing 20. Seal 29. Rotor 3. Terminal Board 12. Washer 21. Cover 30. Retainer Clip 4. Nut 13. Speed Sensor 22. Screw 31.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 1. Drive Hub Assembly 2. Hub Seal 3. Motor Adapter Plate 4. Motor Seal 5. Drive Motor Assembly 6. Drive Brake Assembly 8. Drive Module 9. AC Drive Electrical Plate Figure 3-11. Drive Components 3-21 31215028...

  • Page 66: Oscillating Axle Lockout Test (If Equipped)

    SECTION 3 - CHASSIS & TURNTABLE 3.5 OSCILLATING AXLE LOCKOUT TEST (IF 3.6 OSCILLATION CYLINDER BLEEDING EQUIPPED) NOTE: The oscillating axle must be checked daily for proper oper- ation. Bleeding Procedure LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS Position the boom in the normal stowed transport posi- SUSPECTED.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 1001174527 C 1001174492 C 1001174528 C 1001174524 C 1001174525 C 1001173384 D Figure 3-12. Oscillating Axle - Sheet 1 of 2 3-24 31215028...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Weldment 6. Wear Pad 12. Bushing 1A. Steer Cylinder Mounting Block Assembly 7. Lockout Cam 13. Thrust Washer 2. Lockout Cylinder Assembly 8. Lockout Valve Assembly 14. Bolt 3. Bolt 9. Pin Keeper 15.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 1001180934-C MAF12470C 1. Spindle Assembly 6. Nut 11. Washer 2. Rotary Angle Sensor 7. Tie Rod 12. Rod End 3. Thrust Washer 8. Harness, Steering 13. Bolt 4. Shim 9. Steer Assebly 14. Keeper Pin 10.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 1001180935-C MAF12480C Figure 3-15. Axle Oscillation Lockout Valve (4WD) - Sheet 1 of 2 3-28 31215028...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 8. Drive Adapter Assembly 15. Cotter Pin 22. Locknut 2. Tie-Rod 9. Wheel Stud 16. Rotary Angle Sensor Switch 23. Spindle 3. Bolt 10. Thrust Washer 17. Capscrew 24. Shim 4. Washer 11.

  • Page 72: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll, Leak and Brake Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 1. Housing Assembly 1H. Thrust Washer 3D. Thrust Spacer 9. Sun Gear 19. Female Tube 1A. Output Shaft 1I. Retaining Ring 3E. Shaft Planet 10. Hydraulic Motor 20. Tubing 1B. Lip Seal 1J. Pipe Plug 3F.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Swing Motor Assembly - Sheet 1 of 2 3-32 31215028...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 101. Bolt 110. Drive Link 118. Housing 102. End Cover 112. Coupling Shaft 118A O-Ring 103. Commutator Seal 113. Bushing 121. Plug 104. Seal Ring 114. Thrust Washer 122. O-Ring 105. Commutator and Ring Assembly 115.

  • Page 76: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly Using a wrench, loosen jam nut on Elbow Fitting (17) and remove fitting from Motor Control Valve (31). NOTE: Refer to Figure 3-20., Motor Control Valve Using a wrench, remove Fitting (21) from Brake Housing. Remove Motor Control Valve (31) from Motor (10) by Place unit on bench with the motor end up.

  • Page 77: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly Remove Thrust Washer (11) from between Brake/ Motor Subassembly and Carrier. NOTE: Refer to Figure 3-21., Motor and Brake Remove one O-Ring Plug (13) from Motor (10) and one O-Ring Plug (13) from Brake Housing (6). With unit resting on bench with Motor (10) end up, Remove O-Ring Plug (4) from Brake Housing (6).
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE Remove Motor (10) from Brake Housing (6) by removing Remove Brake Piston (8-2) from Brake Housing (6) by four Bolts (15) incrementally until spring pressure is slowly pressurizing brake port in Brake Housing (6) with relieved.

  • Page 79: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Remove O-ring (5) from between Ring Gear (2) and Housing Subassembly. NOTE: Refer to Figure 3-23., Main Assembly Remove four Dowel Pins (14) from Housing Subassem- bly. With the unit resting on the Output Shaft (Pinion) (1A), remove the Carrier Subassembly.

  • Page 80: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-shaft Disassembly NOTE: The Lip Seal (1B) may or may not be pressed out of the Housing (1G) by the Bearing Cone (1D) during this step. NOTE: Refer to Figure 3-24., Hub Shaft Remove the Bearing Cone (1D) from the Housing (1G). Invert the Housing (1G) and remove the Lip Seal (1B) if Using retaining ring pliers, remove Retaining Ring (1I) not already removed when Output Shaft (1A)was...

  • Page 81: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A). NOTE: Refer to Figure 3-25., Carrier Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F). Using a 1/4"...

  • Page 82: Hub-Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Sub-Assembly Carrier Sub-Assembly NOTE: Refer to Figure 3-24., Hub Shaft NOTE: Refer to Figure 3-25., Carrier Press Bearing Cup (1E) into Motor end of Housing (1G) Apply a liberal coat of grease to the bore of Planet Gear using an appropriate pressing tool.

  • Page 83: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly prevent them from being “shaved” when Piston (8-2) is installed into Brake Housing (6). NOTE: Refer to Figure 3-23., Main Assembly Apply grease sparingly to Piston (8-2) O.D. and the cylin- der bore of Brake Housing (6). Insert Piston (8- 2) into With the Housing-Shaft Subassembly resting on the cylinder of Brake Housing (6), be sure not to cut the O Shaft (1A) install one Dowel Pin (14) into each of the four...

  • Page 84: Motor Control Valve Assembly

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

  • Page 85: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE Tighten the Setscrew (3) until the pinion is completely Lower the boom to horizontal and fully extend the boom. snug against the shim and bearing and then back off the setscrew. Swing the turntable over the side. Torque the setscrew to 50 ft.lbs.

  • Page 86: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank. With the boom positioned over the side of the machine, Swing the turntable 90 degrees, and check some the Boom horizontal with telescope fully extended, selected bolts at the new position.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE FRAME REF. 0270752 C 1001175087 B 1. Swing Motor Assembly 7. Shoulder Screw 13. Bulkhead Fitting 19. Clamp Bar 2. Turntable Stop 8. Washer 14. Adapter Fitting 20. Hose 3. Chain 9. Nut 15. Hose 21.

  • Page 88: Replacement Of Swing Bearing

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

  • Page 89: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Drive Installation Following the torque sequence shown in Figure 3- 28., Swing Bearing Torque Sequence tighten the bolts to an initial torque of 130 ft. lbs. (175 Nm). Then following the Coat the threads of the socket head bolts securing the same sequence, tighten the bolts to 190 ft.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE MAF15150 3-48 31215028...
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE MAF15160 3-49 31215028...

  • Page 92: Battery Maintenance And Charging

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

  • Page 93: Removing The Battery Box

    SECTION 3 - CHASSIS & TURNTABLE Removing the Battery Box NOTE: The battery box and batteries complete weigh approxi- mately 668 pounds (303 kg). To remove the battery box, perform the following steps. Using a forklift, lift the battery box up enough to clear Pull the pull ring to disconnect the batteries at the bat- the notch on the battery box rails and remove the bat- tery disconnect beside the box.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE BATTERY BOX BATTERY BOX BATTERY BOX RAIL BATTERY CHARGER ATTACHMENT BOLT BATTERY BOX BATTERY DISCONNECT BATTERY DISCONNECT FORK POCKET AGM BATTERY STANDARD AND UL SPECS BATTERY MAF12540 Figure 3-35. Batteries and Battery Charger 3-52 31215028...

  • Page 95: Battery Charger

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

  • Page 96: 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 table levels of each battery cell after charging and add dis- following for the flash codes and their removal.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 1. Battery Charger Assembly 2. AC Voltage - Input Cable 3. Battery Charge Signal Cable 4. DC Power Cable to Batteries Figure 3-36. Battery Charger 3-55 31215028...
  • Page 98 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 99: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

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

  • Page 100: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.11 GENERATOR Dynamo and Dynamo Voltage Regulator NOTE: Throughout the Generator section, the abbreviation RBS is used. RBS stands for Rotary Battery System, which is the generator system. The engine-driven generator is designed to produce a DC output directly without the need of a separate rectifier.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 1. Glow Plug Relay 8. Temperature Sensor 2. Fuel Control Relay 9. Voltage Regulator 3. Start Control Relay 10. Alternator 4. Fuel Solenoid 11. Starter 5. Fuel Pump 12. Starter Solenoid 6. Low Oil Pressure Switch 13.

  • Page 102: Start Battery

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

  • Page 103: Fuel Control Relay

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

  • Page 104: Fuel Pump

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

  • Page 105: Alternator Output Current Sensor

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

  • Page 106: Warnings And Safety Precautions

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

  • Page 107: Rbs Start

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

  • Page 108: Rbs Alarms And Flash Codes

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

  • Page 109: Troubleshooting

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

  • Page 110: Apu Engine Start Battery Boosting

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

  • Page 111: Supplementary Fuse For Apu

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SUPPLEMENTARY FUSE FOR APU where the harness attaches to the rear cover of the gen- erator and the connection point for the new inline fuse. The purpose of this section is to describe the procedure to add a supplementary fuse for the Engine Generator Con- troller for the APU.
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. Re-install the harness with the new fuse in place. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the con- ductors that lead to the new inline fuse holder.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Counterweight 3-71 31215028...
  • Page 114 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 115: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM Support Removal Platform Valve Removal Tag and disconnect the hydraulic lines from the plat- form control valve. Use suitable container to retain any ROTATOR BOLTS residual hydraulic fluid. Cap hydraulic lines and ports. PLATFORM Using a suitable device, support the platform support.

  • Page 116: Support Installation

    SECTION 4 - BOOM & PLATFORM Support Installation Remove the bolts and locknuts securing the support to the rotator. Using a suitable lifting device, support the platform sup- port and position it on the rotator. NOTE: The platform support weighs approximately 125 lb (56.8 kg).

  • Page 117: Platform Valve Installation

    SECTION 4 - BOOM & PLATFORM Position the platform on the platform support and Install cover onto the platform support securing the hardware. install the bolts securing the platform to the platform support.Torque the bolts to 71.5 ft. lbs. (97 Nm). MAF18780 Remove tag and reconnect the hydraulic lines to the MAF18800...
  • Page 118 SECTION 4 - BOOM & PLATFORM A, B, D NOTE: If any rotator bolts are replaced, replace all bolts on the rotator and torque them. 1001219342-D MAF18990D C, D Torque to 40 ft.lbs. (55 Nm) Medium Strength Threadlocking Compound Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 71.5 ft.

  • Page 119: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM 4.2 BOOM MAINTENANCE Removal NOTE: The main boom assembly weighs approximately 1993 lb (904 kg). Raise the boom to horizontal and make sure that it is adequately supported with a lifting device or blocking. Tag and disconnect the electrical leads at the platform and the platform valve.
  • Page 120 SECTION 4 - BOOM & PLATFORM UPRIGHT LIFT CYLINDER POWER MASTER TRACK CYLINDER MAIN BOOM BOOM LINK TOWER LINK TOWER BOOM UPPER WEAR PADS BOOM FLY SECTION BOOM BASE SECTION TELE CYLINDER LOWER WEAR PADS Figure 4-3. Boom Assembly - Sheet 1 of 3 31215028...
  • Page 121 SECTION 4 - BOOM & PLATFORM BOOM BASE SECTION WEAR PADS BOOM FLY SECTION TELE CYLINDER POWER TRACK BOOM BASE SECTION BOOM FLY SECTION BOOM SLAVE REST CYLINDER TOWER BOOM TOWER PLATFORM LINK ROTATOR Figure 4-4. Boom Assembly - Sheet 2 of 3 31215028...
  • Page 122 SECTION 4 - BOOM & PLATFORM BOOM PIVOT WITH JIB UPPER SLAVE JIB LINK CYLINDER CYLINDER LOWER ROTATOR JIB LINK COVER PLATE BOOM WITH SIDE SWING ROTATOR UPPER JIB LINK SLAVE CYLINDER CYLINDER PIVOT COVER PLATE ROTATOR LOWER JIB LINK Figure 4-5.

  • Page 123: Installation

    SECTION 4 - BOOM & PLATFORM Connect the hydraulic lines running to the master cylin- der as tagged during removal. Connect the hydraulic lines running to the telescope cyl- inder as tagged during removal. MASTER CYLINDER Install the covers on the side of the upright to conceal PIVOT PIN the pivot pins.
  • Page 124 SECTION 4 - BOOM & PLATFORM Figure 4-6. Boom Limit Switch Adjustment 4-10 31215028...
  • Page 125 SECTION 4 - BOOM & PLATFORM SWITCH TO ACTIVATE WHEN BOOM IS EXTENDED 18±1” (46±2.5 CM) Figure 4-7. Transport Limit Switch (CE Only) 4-11 31215028...

  • Page 126: Platform Rotator

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

  • Page 127: Tools Required For Assembly/Disassembly

    SECTION 4 - BOOM & PLATFORM Tools Required for Assembly/Disassembly there are Upon assembly and disassembly of the actuator basic tools required. The tools and their intended func- tions are as follows: Flashlight- helps examine timing marks, component fail- ure and overall condition. Felt Marker- match mark the timing marks and outline troubled areas.
  • Page 128 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 129 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2. Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing 3. Piston Sleeve 106.1. Port Plug 204.

  • Page 130: 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 counterclockwise. Using a 1/8”...
  • Page 131 SECTION 4 - BOOM & PLATFORM Remove the end cap (4) and set aside for later inspec- Every actuator has timing marks for proper engage- tion. ment. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actuator. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and pis- ton.
  • Page 132 SECTION 4 - BOOM & PLATFORM Remove the shaft (2). It may be necessary to strike the At the point when the piston gear teeth come out of threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis- ton and housing with a marker as shown.
  • Page 133 SECTION 4 - BOOM & PLATFORM To remove the main pressure seals (205), it is easiest to Remove the piston O.D. seal (202). cut them using a sharp razor blade being careful not to damage the seal groove. Remove the piston I.D. seal (200). You may now proceed to the inspection process.

  • Page 134: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection Inspect the wear guide condition and measure thick- ness (not less than 0.123” or 3.12 mm). 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 135 SECTION 4 - BOOM & PLATFORM Install the thrust washer (304) onto shaft (2) and end cap Using a seal tool install the main pressure seal (205) onto (4). shaft (2) and end cap (4). Use the seal tool in a circular motion.
  • Page 136 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 137 SECTION 4 - BOOM & PLATFORM Looking from the opposite end of the housing (1) you Looking from the view shown, use the existing timing can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the tap the piston (3) in until the gear teeth mesh together.
  • Page 138 SECTION 4 - BOOM & PLATFORM Coat the threads on the end of the shaft with anti-seize Tighten the end cap (4). In most cases the original holes grease to prevent galling. for the lock pins will line up. Place the lock pins (109) provided in the Helac seal kit in Install the O-ring (204) and backup ring (207) into the the holes with the dimple side up.

  • Page 139: Greasing Thrust Washers

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

  • Page 140: Jib Rotator

    SECTION 4 - BOOM & PLATFORM 4.4 JIB ROTATOR Disassembly Remove all hydraulic fittings Drain the oil from both Operating Principle sides of the piston through the pressure ports. Place the actuator horizontally on a clean work bench Helac’s helical hydraulic rotary actuators use our sliding spline with ample room to place the internal parts as they are technology which converts linear piston motion into powerful removed.
  • Page 141 SECTION 4 - BOOM & PLATFORM Before the shaft and piston gearing are completely dis- engaged, note the orientation between the spline teeth: small punch marks on the face of the piston and the root of a spline tooth on the shaft gearing indicate timing as seen below A cons id era ble amou nt of torque may be required to...
  • Page 142 SECTION 4 - BOOM & PLATFORM 1. Housing 111. Grease Fitting 205. Bearing Seal 2. Shaft 112. Grease Relief Valve 206. Exclusion Seal 3. Piston Sleeve 400. Stop Tube 301. Piston Bearing 4. End Cap 200. Rod Seal 302. Shaft Bearing 5.
  • Page 143 SECTION 4 - BOOM & PLATFORM DRILL 17/64 DIAMETER THRU 1.00 BREAK EDGES, BOTH SIDES 4-PLACES EQUALLY SPACED .050 x 45° ON A 2.780 BOLT CIRCLE TYPICAL 3.330 2.20 DRILL & TAP 3/8-16 UNC THRU 2 PLACES EQUALLY SPACED ON A 2.780 BOLT CIRCLE Figure 4-12.

  • Page 144: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection Lightly coat the thrust washers (304) with grease and install them on the shaft (02) and end cap (04) prior to seal installation. Inspect all parts for wear, damage, cracks, etc. Lightly coat all sealing and working surfaces with a good HOUSING grade of hydraulic oil.
  • Page 145 SECTION 4 - BOOM & PLATFORM Apply a generous amount of anti-seize to the splines at the end of the shaft. Locate the correct position of the locknut to align its bolt circle with that of the end cap. If the bolt circles do not align, unthread the end cap no more than a half a pitch of the shaft splines.

  • Page 146: 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. Refer to Figure 4-13., Rotator Counterbalance Valve. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4 to 13.5 Nm).

  • Page 147: Testing The Actuator

    SECTION 4 - BOOM & PLATFORM Testing the Actuator If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the pres- sure at which the shaft begins to rotate — should be approxi- mately 400 psi (28 bar).
  • Page 148 SECTION 4 - BOOM & PLATFORM Table 4-1. Troubleshooting Problem Cause Solution 126. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.

  • Page 149: Skyguard

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

  • Page 150: 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 151: Bolt-On External Fall Arrest

    SECTION 4 - BOOM & PLATFORM BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The Bolt-On External Fall Arrest system is designed to provide GAP SHOWING: a lanyard attach point while allowing the operator to access GAP SHOWING: INCORRECT INCORRECT...
  • Page 152 SECTION 4 - BOOM & PLATFORM Attach the fall arrest cable to the right hand bracket Use the two jam nuts to prevent the cable from rotating Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel- shown below.
  • Page 153 SECTION 4 - BOOM & PLATFORM 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 4-15. Bolt-On External Fall Arrest System 4-39 31215028...
  • Page 154 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 155: 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 156: 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 157: Cylinder Removal And Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.2 CYLINDER REMOVAL AND INSTALLATION EC600SJP, H600SJP EC600SJ, H600SJ MAF19230 1. Main Boom 3. Master Cylinder 5. Slave Cylinder 7. Main Telescope Cylinder 9. Steer Cylinder 2. Upright Level 4. Main Lift Cylinder 6.

  • Page 158: Main Boom Telescope Cylinder Removal

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

  • Page 159: Main Boom Telescope Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Installation Install four bolts, two blocks and shims to attach tele- scope cylinder barrel ens support to boom assembly. Attach hydraulic power supply to telescope cylinder ports. Using suitable supports or lifting devices at each end of cylinder, extend rod so cylinder pin holes are same dis- tance apart as boom pin attach holes.

  • Page 160: Main Boom Lift Cylinder Removal

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

  • Page 161: Main Boom Lift Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Lift Cylinder Installation Use auxiliary power to extend cylinder rod until attach pin hole aligns with hole in the boom. NOTE: The main boom weighs approximately 1816 lb (824 kg). Use a suitable drift to drive cylinder rod attach pin through aligned holes, take care to align the grooved Support platform end of the main boom with suitable...

  • Page 162: Master Cylinder Removal

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

  • Page 163: Master Cylinder Installation

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

  • Page 164: Slave Cylinder Removal

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

  • Page 165: Slave Cylinder Installation

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder Installation Use a suitable drift to drive cylinder rod attach pin through aligned holes in slave cylinder and rotator. Secure rod end attach pin with screw. NOTE: The main boom weighs approximately 1816 lb (824 kg). Using a suitable lifting device, properly secure the plat- form to prevent the platform from tilting backward or forward during removal of the slave cylinder.

  • Page 166: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.3 HYDRAULIC CYLINDERS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder Axle Lockout Cylinder seal kit is used. See your JLG Parts Manual. DISASSEMBLY NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 167 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 22-24 ft.lbs. (30-33 Nm) ** Torque to 22 ft.lbs. (30 Nm) 1001163580 E 1. Rod 4. Cartridge Valve 7. Wiper Seal 2. O-ring Plug 5. Barrel 8. Rod Seal 3.

  • Page 168: Slave Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
  • Page 169 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 443 ft.lbs. (600 Nm) ** Torque to 42 ft.lbs. (70 Nm) *** Torque to 11 ft.lbs. (15 Nm) 1001140596 A 1. Barrel 6. Wear Ring 11. Backup Ring 16. O-ring 21.
  • Page 170 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION Using suitable protection, clamp the cylinder rod in a vise or holding fixture as close to the piston as possible. Clean all parts thoroughly in an approved cleaning sol- Remove the retainer from rod end.
  • Page 171 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Lubrication is not required with nickel plated pins and ASSEMBLY bearings. Install pin into the composite bearing dry. NOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 172 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new retain- WEAR PISTON WEAR ing ring into the applicable cylinder head gland groove. RING SEAL RING...

  • Page 173: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Jib Lift Cylinder Using a pin-face spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
  • Page 174 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft.lbs. (70 Nm) ** Torque to 11 ft.lbs. (15 Nm) ** *Torque to 369 ft.lbs. (500 Nm) 1001140282 A 1. Barrel 6. Bushing 11. Retainer 16. O-ring 21. Piston Seal 2.
  • Page 175 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 176 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 177 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than cable cylinder head gland groove.

  • Page 178: Main Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Lift Cylinder Unscrew cylinder head with hook spanner wrench. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
  • Page 179 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 13** 22 19**** 21*** 24 20***** * Torque to 892 ft.lbs. (1209 Nm) ** Torque to 1164 ft.lbs. (1578 Nm) *** Torque to 20 ft.lbs. (27.1 Nm) ****Torque to 30 - 35 ft.lbs. (41 - 48 Nm) *****Torque to 50 - 55 ft.lbs.

  • Page 180: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a Inspect rod and barrel bearings for signs of excessive wear or damage. Replace as necessary. vise or similar holding fixture as close to the piston as possible.

  • Page 181: Assembly

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head groove. Install a new bearing into the applicable inside diameter of the cylinder head groove. IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER CYLINDER OPERATION.
  • Page 182 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Place new piston seal in the outer piston diameter Stake the machined area of the cylinder barrel end so groove. (A tube, with I.D. slightly larger than the O.D. of that it locks the cylinder head in place and it does not the piston is recommended to install the solid seal).

  • Page 183: Master Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder Using a hook spanner wrench, loosen the setscrew and remove setscrew from the cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SPANNER NUT SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.
  • Page 184 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1683866 D 1. Lock Nut 6. O-ring 11. Bushing 15. Guide 2. O-ring 7. Wiper Seal 12. O-ring 16. Seal 3. Wear Ring 8. Barrel 13. Backup Ring 4. Piston 9. Bushing 14.
  • Page 185 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 186 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 187 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Place new piston seal, wear rings and o-ring in the outer cable cylinder head gland groove. and inner piston diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 188: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Cylinder Using a pin-face spanner wrench, unscrew the cylinder head from both ends of the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.

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