Oshkosh Corporation JLG E450A Service And Maintenance Manual
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Oshkosh Corporation JLG E450A Service And Maintenance Manual

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Service and Maintenance Manual
Model
E450A
E450AJ
M450A
M450AJ
P/N - 3121127
March 20, 2014

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  • Page 1 Service and Maintenance Manual Model E450A E450AJ M450A M450AJ P/N - 3121127 March 20, 2014...
  • 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 aerial FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN platform. It is of utmost importance that maintenance per- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON- sonnel pay strict attention to these warnings and precau- NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISON LOG Original Issue - August 15, 1999 Revised - April 5, 2001 Revised - May 25, 2004 Revised - July 30, 2007 Revised - January 24, 2008 Revised - January 26, 2009 Revised - November 27, 2012 Revised - April 26, 2013 Revised - October 23, 2013...

  • 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 ............2-3 Hydraulic System.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Positrac/Tilt module.............3-19 Swing Motor - S/N 0300135649 to Present.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. RBS Engine/Generator Controller ..........3-65 Warnings and Safety Precautions .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.13 Helac Rotary actuator ............4-13 Theory Of Operation .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ........6-1 Introduction .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Locations............1-5 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-1. Cylinder Barrel Support............5-4 5-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-12. DT/DTP Contact Installation ............7-27 7-13.
  • Page 14 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ............1-1 Capacities .
  • Page 15 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 16: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS OPERATING SPECIFICATIONS TIRES Table 1-1. Operating Specifications Table 1-3. Tire Specifications Maximum Work Load (Capacity) Size IN240/55-17.5 IN240/55-17.5 26x7x20 Unrestricted: 500 lb. (230 kg) Load Range 3.2 mph (5.2 kph) Travel Speed Ply Rating Maximum Travel Grade (Gradeablility Tire Pressure 90 psi (6.2 Bar)

  • Page 17: Drive System

    SECTION 1 - SPECIFICATIONS DRIVE SYSTEM FUNCTION SPEEDS Table 1-6. Drive System Table 1-9. Function Speeds Drive Motor 48 VDC, 12.5 H.P . @ 3200 rpm. continuous, Function Seconds rotation - reversible Main Lift Up 30-24 Drive Brake Spring-applied, hydraulically released Main Lift Down 29-23 Turntable Swing Right &...

  • Page 18: Pressure Settings

    SECTION 1 - SPECIFICATIONS 1.10 PRESSURE SETTINGS Table 1-11. Pressure Settings - S/N 0300062642 Present Table 1-10. Pressure Settings - Prior to S/N 0300062642 Circuit Circuit Main Control Valve Main Control Valve Lift Down Relief Lift Down Relief Tower Lift Down Relief (E/M450AJ) 1700 Prior to S/N 86022 Tower Lift Down Relief...

  • Page 19: Torque Specifications

    SECTION 1 - SPECIFICATIONS 1.11 TORQUE SPECIFICATIONS Table 1-14. Mobil DTE 11M Specs Table 1-12. Torque Requirements ISO Viscosity Grade Gravity API 31.9 Description Torque Value Interval Hours Wheel Lugs 170 ft. lbs. Pour Point, Max -40°F (-40°C) (230 Nm) Flash Point, Min.

  • Page 20: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS 1.14 CYLINDER SPECIFICATIONS SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF NOTE: All dimensions are given in inches (in.), with the met- SAFELY SUPPORTING WEIGHT. ric equivalent, millimeters (mm), given in parenthe- ses. 1.16 SERIAL NUMBER LOCATIONS Table 1-17.
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance & Lubrication Diagram – JLG Lift – 3121127...

  • Page 22: Operator Maintenance & Lubrication

    SECTION 1 - SPECIFICATIONS 1.17 OPERATOR MAINTENANCE & 2. Swing Bearing/Worm Gear Teeth LUBRICATION NOTE: The following numbers correspond to those in Fig- ure 1-2., Operator Maintenance & Lubrication Dia- gram. Table 1-19. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F.
  • Page 23 SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 6. Wheel Bearings Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 7.
  • Page 24 SECTION 1 - SPECIFICATIONS 9. Engine Lube Point(s) - Fill Cap Capacity - Refer to Engine Manual Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 3121127 –...
  • Page 25 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque Torque (Loctite® 242 or 271 Tensile (Loctite® 262 or Vibra- Size Bolt Dia Clamp Load Stress Area (Dry) Lubricated OR Vibra-TITE...
  • Page 26 SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque Tensile (Loctite® 242 or 271 (Loctite® 262 or Vibra- (Dry or Loctite® 263) Size Bolt Dia Clamp Load Stress Area OR Vibra-TITE 111 or TITE 131) K= 0.20...
  • Page 27 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load Torque Size Bolt Dia OR Vibra-TITE 111 or (Dry) K = .17 or Vibra-TITE 131) Stress Area See Note 4 140 OR Precoat 85®...
  • Page 28 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Torque Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load (Dry) Size Bolt Dia OR Vibra-TITE 111 or or Vibra-TITE 131) Stress Area See Note 4 K = .20 140 OR Precoat 85®...
  • Page 29 SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® Torque Tensile Clamp Torque (Loctite® 262 or 271 (Dry or Loctite® Size PITCH Stress Load (Lub) OR Vibra- OR Vibra- Area TITE 131) TITE 111 or 140) Sq mm [N.m]...
  • Page 30 SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque (Lub OR Loctite® Torque Torque Tensile (Dry or Loctite® Clamp or 271 (Loctite® 262 Size PITCH Stress Load Vibra-TITE 111 or Vibra-TITE...
  • Page 31 SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque (Lub OR Loctite® Torque Tensile (Loctite® 262 (Dry or Loctite® Clamp Load or 271 Size PITCH Stress OR Vibra-TITE See Note 4 OR Vibra-TITE Area 131)
  • Page 32 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 33: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventive Maintenance AND MAINTENANCE Schedule for items requiring inspection during the perfor- mance of these inspections. Reference the appropriate General areas of this manual for servicing and maintenance proce- dures.

  • Page 34: Service And Guidelines

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

  • Page 35: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring, as When disassembling or reassembling a component, com- well as their receptacles, when disconnecting or removing plete the procedural steps in sequence. Do not partially them from the unit.

  • Page 36: Hydraulic Oil

    SECTION 2 - GENERAL Lubrication Specifications fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles. Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, 3. Cloudy oils indicate a high moisture content which multi-purpose greases usually have the qualities which permits organic growth, resulting in oxidation or cor- meet a variety of single purpose grease requirements.

  • Page 37: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING WELDING ON JLG EQUIPMENT REPAIR GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the Filament wound bearings. machine on an external structure, or component, 1.
  • Page 38 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Boom Assembly 1,2,4 1,2,4 Boom Weldments 1,2,9,12 1,2,9,12 Hose/Cable Carrier Installations Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings...
  • Page 39 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 40 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers...
  • Page 41 SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE F(49 C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE F(43 C) F(38 C) F(32 C) F(27 C) F(21 C) ENGINE F(16 C) SPECIFICATIONS F(10 C) F(4 C) F(-1 C) F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS F(-12 C) TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
  • Page 42 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 43: Section 3 - Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replace- Tire Inflation ment tire, ensure that all tires are inflated to the pressure The air pressure for pneumatic tires must be equal to...

  • Page 44: Spindle

    SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence: 5. Check the unit for end play by moving the hub up & down parallel along the centerline of the spindle. If you can feel excessive end play (over the 0.010" [0.25 mm] specification), recheck the nut to see what is causing the excessive end play.
  • Page 45 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 Figure 3-3. Spindle Assembly 3121127 – JLG Lift –...

  • Page 46: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB 15. Inspect the planetary stage assemblies as complete units. Thoroughly clean and check both the gearing PART NO. 2780236 and the bearings for damage and apply new oil. If the gears or bearings need replacing, they must be The final drive consists of two planetary stages with an replaced as complete sets.

  • Page 47: Disassembly Of Cover

    SECTION 3 - CHASSIS & TURNTABLE Disassembly of Cover Assembly of First Stage Planetary Assembly 1. Loosen and remove hex head bolts (53) to remove cover (51). 1. Pre-freeze planet pins (5) and install into planet car- 2. Remove shaft rod (56) and o-ring (54). rier (7).

  • Page 48: Final Assembly

    SECTION 3 - CHASSIS & TURNTABLE Final Assembly Maintenance Daily: - Check for oil leakage 1. Install thrust washer (29) in spindle (60). Weekly: - Check oil level 2. Install o-ring (19) into groove of support ring (6). 3. Install planet gears (1) onto planet pins which are Monthly: - Check mounting bolt torque part of spindle (60).
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE 1. Planet Gear 15. Retaining Ring 31. thru 32. (Not Used) 56. Shaft Rod 2. Planet Gear 16. Retaining Ring 33. O Ring 57. thru 58. (Not Used) 3. Sun Gear 17. Support Disc 34.

  • Page 50: Drive Brake - Mico

    SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover (21). Disassembly NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. This 1.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE NOTE: The speed sensor port in the cover (21) should be 180° from the brake release port in the pressure plate (3). 1. Capscrew 7. Piston 13. Rotor Disc 19. Retaining Ring 2. Washer 8.
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive Brake Diagnosis Corrective Problem Cause Explanation Action Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions system brake, holding torque will be reduced. in other hydraulic components.

  • Page 53: Speed Sensor Adjustment

    SECTION 3 - CHASSIS & TURNTABLE 3.5 SPEED SENSOR ADJUSTMENT Adjustment Procedure 1. Back off the locking nut and o-ring. 2. Thread the sensor in until it bottoms out (don’t use excessive force). 3. Back-off 1-2 turns and align the notch with the axis of the brake.
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE Figure 3-3. Speed Sensor Orientation 3-12 – JLG Lift – 3121127...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-13...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 3-14 – JLG Lift – 3121127...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-15...

  • Page 58: Speed Sensor Installation Verification

    SECTION 3 - CHASSIS & TURNTABLE Speed Sensor Installation Verification The motor controller averages the readings from the right 3. Power up the machine in platform mode and plug in and left speed sensors and therefore, it can be difficult to the Analyzer in the platform.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 18. while watching the analyzer display, select drive for- 22. After obtaining the display in step 10, operate the ward. Be ready to remove your foot from the foot- machine in both the forward and reverse directions. switch if the machine lunges forward.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 3-18 – JLG Lift – 3121127...

  • Page 61: Positrac/Tilt Module

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Torque Wheel Lugs to 170 ft. lbs. (230 Nm) DRIVE HUB DRIVE MOTOR DRIVE BRAKE Apply Loctite #242 Torque to 165 foot-pounds (224 Nm) TIRE AND WHEEL ASSEMBLY Figure 3-8. Drive Components 3.6 POSITRAC/TILT MODULE 5.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE Figure 3-9. Tilt Sensor Location 3-20 – JLG Lift – 3121127...

  • Page 63: Swing Motor - S/N 0300135649 To Present

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING MOTOR - S/N 0300135649 TO PRESENT Figure 3-10. 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.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 12. Coupling Shaft 17. Backup Ring 22. Not Used 8C. Stator Vane 2. End Cover 7. Manifold 13. Inner Bushing 18. Housing 23. Not Used 8D. Stator Half 3. Seal Ring 8.

  • Page 66: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its 1. Place the motor in a soft jawed vice, with coupling components read this entire section. It provides impor- shaft (12) pointed down and the vise jaws clamping tant information on parts and procedures you will need firmly on the sides of the housing (18) mounting...
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 5. 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.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove 8. Remove manifold (7) and inspect for cracks surface seal ring from commutator, using an air hose to blow scoring, brinelling or spalling. Replace manifold if air into ring groove until seal ring is lifted out and dis- any of these conditions exist.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 9. Remove rotor set (8) and wearplate (9), together to 10. Place rotor set (8) and wear plate (9) on a flat sur- retain the rotor set in its assembled form, maintain- face and center rotor in stator such that two rotor ing the same rotor vane to stator contact surfaces.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 12. Check exposed portion of coupling shaft (12) to be keyway. Replace coupling shaft if any of these con- sure you have removed all signs of rust and corro- ditions exist. sion which might prevent its withdrawal through the seal and bearing.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 15. Remove thrust bearing (15) and thrust washer (14). 18. Inspect housing (18) assembly for cracks, the Inspect for wear, brinelling, corrosion and a full com- machined surfaces for nicks, burrs, brinelling or cor- plement of retained rollers.

  • Page 72: Assembly

    SECTION 3 - CHASSIS & TURNTABLE replaced. If the housing has passed this inspection 20. If the bearings, bushing or thrust washers must be the disassembly of the motor is completed. replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from hous- ing (18) without damaging the housing.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE (19) THE BEARING/BUSHING DEPTHS SPECIFIED MUST BE COULD CAUSE INJURY OR DEATH.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing 6. Assemble thrust washer (14) then thrust bearing (15) (18) outer bearing counterbore. The dirt and water that was removed from the motor. seal (20) must be pressed in until its’...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion 9. Apply a small amount of clean grease to a new seal resistant grease has been applied to the lower ring (4) and insert it into the housing (18) seal ring (outer) housing bearing/bushing (19).
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: It may be necessary to turn one alignment stud out alignment studs onto the housing (18). of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs 18. Assemble a new seal ring (3) flat side up, into com- and drive link (10) and onto the rotor set. Be sure the mutator (5) and assemble commutator over the end correct manifold surface is against the rotor set.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 20. 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 components into place with a final torque of 25-30 ft.

  • Page 79: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes, or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the fol- lowing procedures.

  • Page 80: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE Two Piece Stator Construction 8. Assemble six vanes, or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor set (8) that cannot be readily assem- 9. Grasp the output end of coupling shaft (12) bled by hand and has a two piece stator can be assem- with locking pliers or other appropriate turning bled by the following procedures.

  • Page 81: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING BEARING 2. Check the turntable to bearing. Attach bolts as fol- lows: Turntable Bearing Mounting Bolt Condition a. Elevate the fully retracted boom to 70 degrees (full elevation). Check b. At the positions indicated on Figure 3-12. try and insert the 0.0015"...

  • Page 82: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance fully extended and Mid/Lower Boom stowed, (See Figure 3-13.), using a magnetic base dial indicator, 1. With the boom positioned over the side of the measure and record the distance between the swing machine, the Upper Boom horizontal with telescope bearing and turntable.

  • Page 83: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3. If a difference greater than 0.057 in. (1.40 mm) is 2. Installation. determined, the swing bearing should be replaced. a. Install bearing to rotation box with two cap- 4. If a difference less than 0.057 in. (1.40 mm) is deter- screws, so that fill plug of bearing is as close to mined, and any of the following conditions exist, the gear as bolt pattern will allow.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE ft. lbs. (175 Nm). Then following the same sequence, tighten the bolts to 190 ft. lbs (260 IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT Nm). WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT m. Remove the lifting equipment. BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD n.

  • Page 85: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Adjusting End Play Install with Loctite - 190 ft. lbs. (260 Nm). 1. Remove end plate. Checking Worm Gear End Play 2. Measure and record total thickness of existing shim pack.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Figure 3-16. Swing Components 3-44 – JLG Lift – 3121127...

  • Page 87: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.9 BATTERY MAINTENANCE AND Optional On Board Generator CHARGING Battery Maintenance, Quarterly EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VEN- TILATED AREA ONLY. 1. Open battery compartment cover to allow access to battery terminals and vent caps.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 3-46 – JLG Lift – 3121127...

  • Page 89: Battery Charging (On Board Charger)

    SECTION 3 - CHASSIS & TURNTABLE 2. To charge the batteries, connect the charger to a NOTE: The engine will automatically shut down under the 115 volt source with a 15 amp minimum capacity. following conditions: 3. The Charger will shut off automatically when the bat- High Engine Oil Temperature teries are fully charged.

  • Page 90: Battery Charger (S/N 0300059350 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY CHARGER (S/N 0300059350 4. If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. TO PRESENT) Maintenance Instructions 1. For flooded lead-acid batteries, regularly check LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN water levels of each battery cell after charging and GAS DURING NORMAL OPERATION.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 3. DC Power Cable to Batteries 2. Charger Interlock Cable 4. LED Indicator Cable Figure 3-19. Battery Charger ((S/N 0300059350 to Present) 3121127 – JLG Lift – 3-49...
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is Indicates the battery failed to charge within the allowed not connected or that the AC voltage is too low. It could time.

  • Page 93: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    SECTION 3 - CHASSIS & TURNTABLE Excessive Battery Watering Requirements or [5 Flashes] - Over Temperature 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 94: Checking/Changing The Battery Charger Algorithm

    SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger 3. Remove the AC power from the charger and recon- nect the charger’s positive connector to the battery. Algorithm It is recommended to check a newly changed algo- rithm by repeating the above steps 1 and 3. The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Table 3-4.

  • Page 95: Generator (Prior To S/N 88539)

    SECTION 3 - CHASSIS & TURNTABLE 3.11 GENERATOR (PRIOR TO S/N 88539) • Start Control Relay The start control relay energizes the solenoid of the NOTE: Throughout the Generator section, the abbreviations engine starter and the pull coil of the engine fuel solenoid. RBS and CTS are used.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Generator Components 3-54 – JLG Lift – 3121127...

  • Page 97: Timing Sequences

    SECTION 3 - CHASSIS & TURNTABLE Timing Sequences 6. Time Delay Bypass (TDBP) • RBS Prestart Sequence Once the engine starts, TDBP must elapse before low oil pressure and underspeed shutdowns are 1. Time Delay Engine Start (TDES) activated. This allows the engine to come up to nor- mal operating conditions before enabling these TDES is the period which the RBS waits to verify that shutdowns are monitored.

  • Page 98: To Connect The Jlg Control System Analyzer To The Generator

    SECTION 3 - CHASSIS & TURNTABLE To Connect the JLG Control System Analyzer Alarms and Fault Flash Codes to the Generator In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. The JLG Control System Analyzer can be used to monitor generator settings and conditions.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-57...

  • Page 100: Output Current And Voltage Settings

    SECTION 3 - CHASSIS & TURNTABLE • Overspeed • Loss Of Voltage Sense If the engine speed exceeds the overspeed limit, the If the voltage measured at the alternator output is less engine will stop immediately and an overspeed alarm will than half of the system nominal voltage, the RBS will stop be indicated.

  • Page 101: Priming The Fuel Line

    SECTION 3 - CHASSIS & TURNTABLE Priming the Fuel Line 5. Clean up any spilled fuel and try to start the genera- tor engine. The following procedure is for re-priming the fuel line on 6. If the engine still doesn’t start, remove the steel line the generator engine in the event fuel system components from the fuel injector pump.

  • Page 102: Generator (S/N 88539 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.12 GENERATOR (S/N 88539 TO PRESENT) 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 103 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 104: Start Battery

    SECTION 3 - CHASSIS & TURNTABLE Start Battery Start Control Relay The RBS requires a 12V lead-acid start battery (not sup- plied 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 105: Fuel Control Relay

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

  • Page 106: 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 107: Alternator Output Current Sensor

    SECTION 3 - CHASSIS & TURNTABLE RBS Engine/Generator Controller engine. The signal is also used in determining if the air glow plug should be energized. The control system enclosure houses the RBS engine/ The engine oil temperature sensor is connected to the generator controller, which performs all control tasks engine/generator controller at pins J2-8 and J2-19.

  • Page 108: Warnings And Safety Precautions

    SECTION 3 - CHASSIS & TURNTABLE Warnings and Safety Precautions System Settings CALL TO START SETTINGS Low battery voltage call to start level 48.0 VDC THE RBS MAY START WITHOUT WARNING. Low battery voltage remove call to start level 54.0 VDC Low temperature call to start level 5°C Low temperature remove call to start level...

  • Page 109: 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 Automati- 1 Battery voltage above 48VDC) cally: 54VDC and finish charging cur-...

  • Page 110: 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 3-10. RBS Alarms and Flash Codes Flash Code Problem RBS Condition Below 7psi...

  • Page 111: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-11. Troubleshooting Flash Code Problem Solution Unit Off / Disabled (engine will not Check position of selector switch. crank) 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 112: Apu Engine Start Battery Boosting

    SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Troubleshooting Flash Code Problem Solution Engine Starting System fault Check engine start battery charging system for current output. Check for failed engine start battery. Loss Of Voltage Sense APU Engine Start Battery Boosting Always connect the POSITIVE (+) of the booster battery DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID to the POSITIVE (+) of the APU start battery, and the...

  • Page 113: Supplementary Fuse For Apu

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SUPPLEMENTARY FUSE FOR APU 2. Find where the harness attaches to the rear cover of the generator and the connection point for the new The purpose of this section is to describe the procedure to inline fuse.
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE conductors of the harness. 6. Re-install the harness with the new fuse in place. 7. Reconnect the lift and APU start battery. The APU is now ready for use. 5. Cut wire 106 going to the Engine/Generator Control- ler after the existing connection point and install the conductors that lead to the new inline fuse holder.
  • Page 115 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 116: Section 4 - Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE e. Remove hardware securing the master cylinder pin #2. Using a suitable brass drift and hammer, remove pin #2 from the base boom. Removal f. Remove hardware securing the base boom pin 1.

  • Page 117: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 4. Remove hardware securing telescope cylinder #1 to the fly boom section, then remove pin from fly. 1. Inspect boom pivot pin for wear, scoring or other 5. Remove hardware securing telescope cylinder to damage, and for tapering or ovality.

  • Page 118: Installation

    SECTION 4 - BOOM & PLATFORM Installation 6. Using suitable lifting equipment, slide fly boom sec- tion out to gain access to telescope cylinder attach 1. Using suitable lifting equipment, position boom pin hole. assembly on upright so that boom pivot holes in 7.

  • Page 119: Upper (Main) Boom Lift Cylinder

    SECTION 4 - BOOM & PLATFORM 4.2 UPPER (MAIN) BOOM LIFT CYLINDER 4. With function speed switch at its slowest setting, extend the cylinder rod until attach pin hole aligns with those in boom. Using a suitable drift, drive the Removal cylinder rod attach pin #1 through the aligned 1.

  • Page 120: Installation

    SECTION 4 - BOOM & PLATFORM Installation 3. Remove the hardware securing the cylinder rod attach pin #5 to the boom. Using an appropriate brass drift, drive out the cylinder rod attach pin #5. NOTE: Coat I.D. of bushings with specified lubricant prior to installing pins.

  • Page 121: Upper Boom Telescope Cylinder

    SECTION 4 - BOOM & PLATFORM 4.5 UPPER BOOM TELESCOPE CYLINDER 9. Using another lifting device, support the rod end of the cylinder and remove the cylinder from the boom assembly. Removal 10. Carefully lift the cylinder clear of the boom assembly 1.

  • Page 122: Mid And Lower Lift Cylinder Bleeding Procedure

    SECTION 4 - BOOM & PLATFORM 4.6 MID AND LOWER LIFT CYLINDER 4.7 WEAR PADS BLEEDING PROCEDURE 1. Shim up wear pads until snug to adjacent surface. 2. Replace wear pads when worn to thickness shown NOTE: Bleeding procedure should only be necessary if below.

  • Page 123: Boom Limit Switches

    SECTION 4 - BOOM & PLATFORM 4.8 BOOM LIMIT SWITCHES Refer to Figure 4-8., Boom Limit Switches for adjustments to be made to the two Boom Limit Switches which bolt in place on the upright. NOTE: If any rotator bolts are replaced, all bolts A,B,D on the rotator should be retorqued.
  • Page 124 SECTION 4 - BOOM & PLATFORM Figure 4-8. Boom Limit Switches 3121127 – JLG Lift –...
  • Page 125 SECTION 4 - BOOM & PLATFORM Figure 4-9. Platform Components and Attaching Hardware (M450A & E450A) 4-10 – JLG Lift – 3121127...

  • Page 126: Articulating Jib Boom

    SECTION 4 - BOOM & PLATFORM 4.9 ARTICULATING JIB BOOM Inspection Removal NOTE: When inspecting pins and bearings refer to Section 2, Pins and Composite Bearing Repair Guidelines. 1. For platform/support removal see platform/support removal diagram. See Section 4.1, Boom Mainte- 1.

  • Page 127: Load Sensing System

    SECTION 4 - BOOM & PLATFORM 3. Align bottom tubes with attach holes in rotator sup- 16. Adjust P1 until the load = 100%. port. Using a soft head mallet, install rotator support 17. Remove weight from the basket. pin #5 into articulating jib boom and secure with mounting hardware.

  • Page 128: Helac Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.13 HELAC ROTARY ACTUATOR Tools Required for Assembly/Disassembly there Upon assembly and disassembly of the actuator Theory Of Operation are basic tools required. The tools and their The rotary actuator is a simple mechanism that uses the intended functions are as follows: sliding spline operating concept to convert linear piston 1.
  • Page 129 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 130 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 131: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 4. Install the end cap (4) removal tools provided with the Helac seal kit. 1. Remove the cap screws (113) over end cap lock pins (109). 5. Using a metal bar, or something similar, un-screw the end cap (4) by turning it counter clock-wise.
  • Page 132 SECTION 4 - BOOM & PLATFORM 7. Remove the stop tube if included. The stop tube is 9. Prior to removing the shaft, (2), use a felt marker to an available option to limit the rotation of the actua- clearly indicate the timing marks between shaft and tor.
  • Page 133 SECTION 4 - BOOM & PLATFORM 12. To remove the piston (3) use a rubber mallet and a 15. Remove the wear guides (302) from the end cap (4) plastic mandrel so the piston is no damaged. and shaft (2). 13.

  • Page 134: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.

  • Page 135: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a 1. Gather all the components and tools into one loca- circular motion.
  • Page 136 SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using 8. Insert the piston (3) into the housing (1) as shown, a circular motion. Install the outer T-seal (202) by until the outer piston seal (202) is touching inside stretching it around the groove in a circular motion.
  • Page 137 SECTION 4 - BOOM & PLATFORM 10. Looking from the opposite end of the housing (1) 13. Install 2 bolts in the threaded holes in the flange. you can see if your timing marks are lining up. When Using a bar, rotate the shaft in a clockwise direction they do, tap the piston (3) in until the gear teeth until the wear guides are seated inside the housing mesh together.
  • Page 138 SECTION 4 - BOOM & PLATFORM 16. Install the O-ring (204) and back-up ring (207) into 19. Place the lock pins (109) provided in the Helac seal the inner seal groove on the end cap (4). kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.

  • Page 139: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Testing the Actuator Refer to Figure 4-14., Rotator Counterbalance Valve. If the equipment is available, the actuator should be tested on a hydraulic test bench. The breakaway pressure — the 1. Make sure the surface of the actuator is clean, free pressure at which the shaft begins to rotate —...
  • Page 140 SECTION 4 - BOOM & PLATFORM Figure 4-14. Rotator Counterbalance Valve 3121127 – JLG Lift – 4-25...

  • Page 141: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the After installation of the actuator on the equipment, it is two bleed nipples.

  • Page 142: Troubleshooting

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

  • Page 143: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.14 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the powertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be differ- ent.
  • Page 144 SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together 4. insert the tool into the rolled over end of the rivet as must be removed. Use a right-angle pneumatic die shown. Grind out the middle of the rivet until the grinder with a ¼”...
  • Page 145 SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet 6. Using a flat head screwdriver between the links, out by using a center punch with a hammer. twist 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 146: Installing A New Link

    SECTION 4 - BOOM & PLATFORM Installing a New Link 7. Remove the link from the other section of the pow- ertrack using a screwdriver. 1. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section. 3121127 –...
  • Page 147 SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new 3. After the new link is installed in the powertrack the link and slide the peanut end of the track section round half-shears will not fit properly in the peanut into it.
  • Page 148 SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the 6. Push pin thru center hole then slide washer on pin. new connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs.
  • Page 149 SECTION 4 - BOOM & PLATFORM 7. Install the snap ring in the groove on the pin. Repeat NOTE: When installing snap rings make sure they are the pin installation steps for all center holes that seated in pin groove and closed properly. have the rivets removed.
  • Page 150 SECTION 4 - BOOM & PLATFORM NOTE: Maximum tightening torque is 18-20 in-lbs. 9. Pull up on the other end of the round bar and slide the new poly roller onto the bar. 3121127 – JLG Lift – 4-35...

  • Page 151: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Fixed End Brackets 10. Install a new 8-32 x 0.500 self threading screw on the other side. 1. 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 152 SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap NOTE: When installing snap rings make sure they are Ring. seated in pin groove and closed properly. CLOSED SNAP RING 3. Take the new bracket and install bracket center pin and snap ring.

  • Page 153: Replacing Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets 2. Take new bracket and install center pin with snap ring. 1. Remove existing pins and center rivet. Remove the rivet the same way as shown in the link removal instructions.
  • Page 154 SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and NOTE: When installing snap rings make sure they are install snap rings. Repeat with other moving end if seated in pin groove and closed properly. replacing as well.
  • Page 155 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 156: Section 5 - Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com- pletely saturated.

  • Page 157: Dip Method

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

  • Page 158: Cylinders - Theory Of Operation

    SECTION 5 - HYDRAULICS 5.2 CYLINDERS - THEORY OF OPERATION check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made. Double Acting Cylinder (Upper Boom Lift, Mid Boom Lift, Lower Boom Lift, Tele- Cylinders With Single Counterbalance scope, Slave, Master, Rotator, and Steer) Valve...

  • Page 159: Cylinders With Dual Counterbalance Valve

    SECTION 5 - HYDRAULICS Cylinders With Dual Counterbalance Valve 5.4 CYLINDER REPAIR (Lower Lift, Mid Lift, Telescope, and Slave Cylinders) NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION Disassembly ONLY.

  • Page 160: Cleaning And Inspection

    SECTION 5 - HYDRAULICS the cylinder head retainer cap screws, and remove 10. Loosen and remove the cap screw(s), if applicable, cap screws from cylinder barrel. which attach the tapered bushing to the piston. 11. Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing.

  • Page 161: Assembly

    SECTION 5 - HYDRAULICS 6. Inspect piston surface for damage and scoring and 16. Inspect the oil ports for blockage or the presence of for distortion. Dress piston surface or replace piston dirt or other foreign material. Repair as necessary. as necessary.
  • Page 162 SECTION 5 - HYDRAULICS wear ring into the applicable cylinder head gland 7. If applicable, correctly place new seals and guide groove. lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D.of the pis- ton is recommended to install the solid seal.) NOTE: The backup rings for the solid seal have a radius on one side.
  • Page 163 SECTION 5 - HYDRAULICS 11. Assemble the tapered bushing loosely into the pis- b. Tap each space once; this means the tapered ton and insert JLG capscrews (not vendor cap- bushing is tapped 3 times as there are 3 spaces screws) through the drilled holes in the bushing and between the capscrews.
  • Page 164 SECTION 5 - HYDRAULICS 17. Position the cylinder barrel in a suitable holding fix- Table 5-1.Cylinder Head and Tapered Bushing Torque ture. Specifications Head Torque Value Tapered Bushing Description (Wet) Torque Value (Wet) EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL- Jib Cylinder 30 ft.
  • Page 165 SECTION 5 - HYDRAULICS 3*,4*,24 Prior to S/N 0300106518 1683779-E 1. Loctite #242 7. Bearing 13. O-ring Plug 19. Wear Ring 25. Seal 2. Loctite #222 8. Bushing 14. Piston 20. Wear Ring 26. Bolt 3. Primer #7471 9. Cylinder Head 15.
  • Page 166 SECTION 5 - HYDRAULICS 1. Barrel 7. Tube Spacer 13. O-ring 19. Loctite #242 2. Cylinder Rod 8. Holding Valve 14. O-ring 20. Loctite #222 3. Retainer 9. Setscrew 15. Wear Ring 21. Pipe Sealant 4. Piston 10. Pipe Plug 16.
  • Page 167 SECTION 5 - HYDRAULICS 1. Loctite #242 7. Cylinder Rod 13. Wear Ring 19. Backup Ring 2. Primer #7471 8. Barrel 14. Backup Ring 20. Seal 3. Socket Head Bolt 9. Washer Ring 15. O-ring 21. Valve Cartridge 4. Tapered Bushing 10.
  • Page 168 SECTION 5 - HYDRAULICS E/M 450AJ E/M 450 A 1683711-A 1683826-A 1683939-B 1. Barrel 7. Tube Spacer 13. Wear Ring 19. Not Used 2. Cylinder Rod 8. Holding Valve 14. O-ring 20. Loctite #242 3. Retainer 9. Holding Valve 15. Wear Ring 21.
  • Page 169 SECTION 5 - HYDRAULICS E/M 450AJ E/M 450A 1683713-A 1683825-A 1683942-C 1684057-B 1. Barrel 6. Hex Nut 11. Plug 16. Not Used 21. Loctite #242 2. Cylinder Rod 7. Washer 12. Setscrew 17. O-ring 22. Loctite #222 3. Retainer 8. Spacer 13.
  • Page 170 SECTION 5 - HYDRAULICS 1683708-B 1683813-A 1683945-C 1684061-C 1. Barrel 6. Hex Nut 11. Setscrew 16. Wear Ring 21. Locking Primer 2. Cylinder Rod 7. Tube Spacer 12. Setscrew 17. O-ring 22. Loctite #222 3. End Cap 8. Not Used 13.
  • Page 171 SECTION 5 - HYDRAULICS 1. Barrel 6. Hex Nut 11. O-ring 16. Locking Primer 2. Cylinder Rod 7. Tube Spacer 12. O-ring 17. Loctite #242 3. Retainer 8. Setscrew 13. Wear Ring 18. Loctite #222 4. Piston 9. T-Seal 14. Rod Seal 5.
  • Page 172 SECTION 5 - HYDRAULICS 1. Loctite #242 6. Piston 11. Not Used 16. O-ring 21. Bolt 2. Locking Primer 7. Washer 12. Lock Ring 17. Wiper 3. Bolt 8. Head 13. Wear Ring 18. Seal 4. Tapered Bushing 9. Barrel 14.
  • Page 173 SECTION 5 - HYDRAULICS 1. Wiper 6. Backup Ring 11. Piston 16. Rod 2. Spanner Nut 7. O-ring 12. Wear Ring 17. Rod 3. Retaining Ring 8. Guide 13. Seal 4. Lip Seal 9. Barrel 14. O-ring 5. Wear Ring 10.
  • Page 174 SECTION 5 - HYDRAULICS 7. Bolt 13. Cap Seal 19. Loctite #242 25. Fitting 1. Barrel 2. Rod 8. Plug 14. O-Ring 20. Not Used 26. Cap 3. Piston 9. Setscrew 15. Wear Ring 21. Fitting 27. Lockwasher 4. Head 10.

  • Page 175: Pressure Setting Procedures

    SECTION 5 - HYDRAULICS 5.5 PRESSURE SETTING PROCEDURES Platform Level Up Relief Cold temperatures have a significant impact on pressure 1. On machines prior to S/N 0300062642, install the readings.JLG Industries Inc. recommends operating the pressure gauge at the “G” port on Main Control machine until hydraulic system has warmed to normal valve, activate and bottom out Platform Level Up.

  • Page 176: Platform Level Down Relief

    SECTION 5 - HYDRAULICS Platform Level Down Relief Steer Relief 1. With pressure gauge at “G” port on steer/brake 1. On machines prior to S/N 0300062642, install the valve, activate and bottom out Steer Left or Right. pressure gauge at the “G” port on Main Control valve, activate and bottom out Platform Level Down.
  • Page 177 SECTION 5 - HYDRAULICS Table 5-4. Pressure Settings - Prior to S/N 0300062642 Table 5-5. Pressure Settings - S/N 0300062642 Present Circuit Circuit Main Control Valve Main Control Valve Lift Down Relief Lift Down Relief Tower Lift Down Relief 1700 Tower Lift Down Relief (E/M450AJ) 1700 Prior to S/N 86022...
  • Page 178 SECTION 5 - HYDRAULICS MAIN RELIEF STEER RELIEF CHECK PRESSURE CARTRIDGE SWITCH GAUGE PORT BRAKE RELEASE CARTRIDGE STEER CARTRIDGE SHUTTLE CARTRIDGE PROPORTIONAL HYDRAULIC (FLOW CONTROL) FILTER CARTRIDGE Figure 5-25. Brake/Steer Valve Components 3121127 – JLG Lift – 5-23...
  • Page 179 SECTION 5 - HYDRAULICS Figure 5-26. Main Valve Components Prior to S/N 62642 5-24 – JLG Lift – 3121127...
  • Page 180 SECTION 5 - HYDRAULICS EMERGENCY DESCENT EMERGENCY DESCENT VALVE HAND PUMP UPPER LIFT DOWN RELIEF LOWER LIFT DOWN RELIEF GAUGE PORT TELESCOPE RELIEF RELEVELING VALVE PLATFORM LEVEL RELIEF (BACKWARD) RELEVELING RELIEF PLATFORM LEVEL RELIEF (FORWARD) Figure 5-27. Main Valve Components S/N 62642 to Present 3121127 –...
  • Page 181 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 182 SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Figure 6-1. Control Module Location Introduction IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
  • Page 183 SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer The JLG designed Control System is a 48 volt based motor control unit installed on the boom lift. 1. Connect the four pin end of the cable supplied with The JLG Control System has reduced the need for the analyzer, to the motor controller module located exposed terminal strips, diodes and trimpots and provides...
  • Page 184 SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected HELP menu. In some cases, such as DRIVE, the next level is the DIAGNOSTICS parameter or information to be changed.
  • Page 185 SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- Analyzer word was entered correctly: Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: MENU:...
  • Page 186 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: When a machine digit item is selected, press the UP or ELEVATION CUTBACK DOWN arrow keys to adjust its value, for example: CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- FORMANCE OF YOUR MACHINE.
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM PIN 1 BATTERY B+ TP CONTACTOR PANEL PIN 1 PIN 1 PUMP PT. A TO CONTACTOR MOTOR PANEL Figure 6-2. Power Controller - Sheet 1 of 4 – JLG Lift – 3121127...
  • Page 188 SECTION 6 - JLG CONTROL SYSTEM Figure 6-3. Power Controller - Sheet 2 of 4 3121127 – JLG Lift –...
  • Page 189 SECTION 6 - JLG CONTROL SYSTEM PIN 1 CONT MAIN CONTACTOR DIGITAL OUTPUT DRIVE FORWARD DIGITAL OUTPUT DRIVE REVERSE DIGITAL OUTPUT NOT CONNECTED GROUND INPUT GROUND GROUND INPUT NOT CONNECTED GROUND INPUT SPEED ENCODER POWER +12V OUTPUT SPEED ENCODER SIGNAL DIGITAL INPUT SPEED ENCODER GROUND...
  • Page 190 SECTION 6 - JLG CONTROL SYSTEM PIN 1 4WD FORWARD 4WD FWD DIGITAL OUTPUT NOT CONNECTED DIGITAL OUTPUT 4WD FWDB 4WD FORWARD B DIGITAL OUTPUT ST RT STEER RIGHT DIGITAL OUTPUT ST LF STEER LEFT DIGITAL OUTPUT ST PROP STEER PROPORTIONAL DIGITAL OUTPUT 4WD REVERSE...
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM Machine Personality Settings NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5s to 5.0s DECELeration 0.1s to 2.0s MINimum speed 0 to 25%...
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS SWING ACCELeration 0.5 to 5.0s DECELeration 0.0 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed 0 to 100% MINimum RIGHT speed 0 to 50% MAXimum RIGHT speed...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0 DECELeration 0.1 to 3.0 MINimum UP speed 0 to 50% MAXimum UP speed 0 to 100% MINimum DOWN speed 0 to 50% MAXimum DOWN speed 0 to 100% MINimum RIGHT speed...
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM 2. TILT SWITCH Table 6-2. Machine Setup Descriptions When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting MODEL NUMBER... Displays/adjusts machine model NOTE: all personalities reset to default 1=5 degree - reduces the maximum speed of all when model number is altered platform functions to creep when tilted and...
  • Page 195 SECTION 6 - JLG CONTROL SYSTEM 3= Motion Alarm - Sounds when any function is Not available at password level 2 ENTER confirms that active (Option) vehicle is currently level, and zeroes the tilt sensor mea- surements 7. PLATFORM ALARM Help Descriptions and Fault Flash Codes 0= Sounds continuously when above elevation and tilted only.
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected. EVERYTHING OK The "normal"...
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/2 indicates problems with drive & steer selection. DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range, or the wiper is wire-off. DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FWS Drive was selected before and during footswitch closure.
  • Page 198 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/5 indicates that a function is prevented due to a cutout. BOOM PREVENTED - DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive &...
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 3/3 indicates that a contactor coil is short-circuited. OVERLOADED VALVE SUPPLY-CHECK WIRING. There is a high current draw from the valve supply when no valve is energized; this is probably due to a wir- ing error at the ground module.
  • Page 200 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 6/6 indicates problems with the CANbus. 48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data, and the protection circuit which supplies the platform and ground modules has tripped.
  • Page 201 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 9/9 indicates problems with the controller. POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off. POWER MODULE FAILURE: HWFS CODE 2 The hardware failsafe tests did not complete because traction point A is not safe, or the hardware failsafe is permanently tripped.
  • Page 202 SECTION 6 - JLG CONTROL SYSTEM 3121127 – JLG Lift – 6-21...
  • Page 203 SECTION 6 - JLG CONTROL SYSTEM 6-22 – JLG Lift – 3121127...
  • Page 204 SECTION 6 - JLG CONTROL SYSTEM 3121127 – JLG Lift – 6-23...
  • Page 205 SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow In the following structure descriptions, an intended item is keys alter a value if allowed selected by pressing ENTER;...
  • Page 206 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. DIAGNOSTICS - Menu Descriptions TILT . . . Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direction (pitch) The second value indicates tilt in the left/ right direction (roll) DATALOG MAX.TEMP .
  • Page 207 SECTION 6 - JLG CONTROL SYSTEM System Self Test switch. When the controller sees that the lower lift up switch has been closed, it will move on to the next The system self test is utilized to locate typical problems. input, lower lift down LLD.
  • Page 208 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages RUNNING Initial display when system test is run; certain "critical" checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BAD POWER WIRING The capacitor bank is not charged or pump point A is low or traction point A is high or low.
  • Page 209 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open-and short- circuit valve coils. The valves are tested in the order: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L, SWING R, SWING REST, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, TELE I, TELE O, BYPASS, STEER L, STEER R, STEER PROP, BRAKE NOTE: in platform mode, the footswitch must be closed.
  • Page 210 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its "normal" position; function switches should be open, cutout switches should be closed, joysticks should be in neutral. In platform mode, inputs are tested in the order: UL U, UL D, UL JOY., SWING L, SWING R, SWING JOY., LEVEL U, LEVEL D, PUMP POT., ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY., STEER L, STEER R,...
  • Page 211 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends. If ENTER is pressed, each operator input is prompted for in turn. In platform mode, operator inputs are tested in the order: UL U, UL D, SWING L, SWING R, LEVEL U, LEVEL D, PUMP POT, CREEP, ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV, STEER L, STEER R, POSITRAC...
  • Page 212 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code EVERYTHING OK The "normal" help message in platform mode GROUND MODE OK The "normal" help message in ground mode 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX"...
  • Page 213 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 2252 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY Input was CLOSED during startup SELECTED 2253 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED Input was CLOSED during startup 2254 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY Input was CLOSED during startup...
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 2514 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configured to not allow simultaneous drive & boom opera- tion.
  • Page 215 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 33364 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized. This maybe due to an open circuit traction motor or power wiring error 33369 REVERSE CONTACTOR COIL - OPEN CIRCUIT...
  • Page 216 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code STALLED PUMP MOTOR OR POWER WIRING ERROR The power module pump MOSFET protection circuit is active, This is due to a massive current drain and could be a stalled pump motor or a power wiring error OPEN CIRCUIT PUMP MOTOR WIRING Pump point A is collapsing when the pump MOSFETs are pulsed,...
  • Page 217 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Fault Codes Flash Fault Message Description Code 99133 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardware failsafe the contactor drive failsafe did not trip within the allowed test time 99134 POWER MODULE FAILURE - HWFS CODE 16 Hardware failsafe tests failed because the hardware failsafe the...
  • Page 218 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 219 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS SECTION 7. BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.1 GENERAL It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has This section contains basic troubleshooting information been made to ensure that all likely problems in these and basic electrical information to be used for locating...
  • Page 220 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Automatic leveling inoperative. Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on Clean, repair, or replace line or fitting.
  • Page 221 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered. Check wiring/Run System Test. Personalities not set correctly Check settings. 3121127 – JLG Lift –...
  • Page 222 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature build- Flush system and change oil using recom- mended viscosity Moisture in oil.
  • Page 223 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Restricted or broken supply line on valve bank or Clean or replace line. hydraulic pump. Directional valve not functioning properly. Repair or replace valve. Lift cylinder not functioning properly.
  • Page 224 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function Speed and Drive Speed does not operate below horizontal. Damaged wiring on level limit switch. Repair or replace wiring/Run System Test Creep Switch Open.
  • Page 225 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom extends and retracts erratically. Hydraulic system oil low. Replenish oil as necessary. Wear pads worn. Replace pads as required. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
  • Page 226 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom swings erratically in either direction. Hydraulic system oil low. Replenish oil as necessary. Lack of lubricant on swing gear or speed reducer Lubricate as required.
  • Page 227 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-3. Turntable Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVE. Valve Spool Sticking. Dirt in oil causing excessive temperature built- Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the Loosen valve and check mounting.Repair as unit.
  • Page 228 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY GENERATOR. Engine will not start. Enable switch is open. Actuate switch. Fuses open. Determine and correct cause; replace fuse. Ground EMS is open. Pull out EMS to activate.
  • Page 229 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY FRONT FRAME AXLE AREA. One or both wheels will not steer. Steering link or tie rod broken or attaching hard- Replace steering link, tie rod or hardware as nec- ware missing.
  • Page 230 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Joystick not functioning properly. Replace joystick/Run System Test. Charger plugged in. Check help message. Drive prevented. Check help message. Brake(s) not releasing. Determine cause and repair or replace.
  • Page 231 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Valve not functioning properly. Repair or replace valve. Hydraulic pump not functioning properly. Repair or replace pump. Personality Settings Incorrect. Adjust settings.
  • Page 232 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Brake Drags or runs hot. Low actuation pressure. Place pressure gauge in bleed port & check pres- sure with system on. Bearing failure.
  • Page 233 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEMS - GENERAL. Hydraulic pump noisy. Air entering system through broken line or fitting. Repair or replace line or fitting. (Suction Side.) Air bubbles in oil.
  • Page 234 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function sluggish during operation. (System pressure too low.) Main relief valve set too low. Reset valve as required. Pump section not delivering sufficient oil. Repair or replace pump section or pump.
  • Page 235 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS. No power to platform controls. 15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary.
  • Page 236 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hourmeter inoperative. Damaged wiring in hourmeter circuit. Repair or replace wiring. Inoperative hourmeter. Replace hourmeter. Platform alarm circuit. Platform alarm inoperative. Check platform alarm/Run System Test.
  • Page 237 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.3 MULTIMETER BASICS nal and the lead on the other port goes to the positive side of the signal. A wide variety of multimeters or Volt Ohm Meters (VOM) Scale can be used for troubleshooting your equipment. This section shows diagrams of a common, digital VOM con- M = Mega = 1,000,000 * (Displayed Number) figured for several different circuit measurements.
  • Page 238 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Resistance Measurement • Use firm contact with meter leads Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to Figure 7-2. Resistance Measurement enable audible continuity testing •...
  • Page 239 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Current Measurement b. Change the switch position. c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short.
  • Page 240 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Automatic Switches • LSS Modules connections, • Deutz EMR 2 ECM connection. If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the Silicone Dielectric Compound must be used on all electri- switch to test it.
  • Page 241 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as- Applying Silicone Dielectric Compound to shipped, position (See Figure 7-5.). Proceed as follows: AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: •...
  • Page 242 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
  • Page 243 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ- INGS.
  • Page 244 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-11. Connector Installation 7-26 – JLG Lift – 3121127...
  • Page 245 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 7.7 DEUTSCH CONNECTORS NOTE: The receptacle is shown - use the same procedure for plug. DT/DTP Series Assembly DT/DTP Series Disassembly Figure 7-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the con- Figure 7-13.
  • Page 246 SECTION 7 - BASIC TROUBLESHOOTING, 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 1. Grasp contact about 25mm behind the contact 1. With rear insert toward you, snap appropriate size crimp barrel.
  • Page 247 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-18. Electrical Components Installation - Sheet 1 7-30 – JLG Lift – 3121127...
  • Page 248 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-19. Electrical Components Installation - Sheet 2 3121127 – JLG Lift – 7-31...
  • Page 249 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-20. Electrical Schematic - Sheet 1 of 6 7-32 – JLG Lift – 3121127...
  • Page 250 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227E Figure 7-21. Electrical Schematic - Sheet 2 of 6 3121127 – JLG Lift – 7-33...
  • Page 251 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-22. Electrical Schematic - Sheet 3 of 6 7-34 – JLG Lift – 3121127...
  • Page 252 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227E Figure 7-23. Electrical Schematic - Sheet 4 of 6 3121127 – JLG Lift – 7-35...
  • Page 253 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-24. Electrical Schematic - Sheet 5 of 6 7-36 – JLG Lift – 3121127...
  • Page 254 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 E Figure 7-25. Electrical Schematic - Sheet 6 of 6 3121127 – JLG Lift – 7-37...
  • Page 255 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-26. Hydraulic Schematic - M450A/E450A - Sheet 1 of 2 7-38 – JLG Lift – 3121127...
  • Page 256 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505E Figure 7-27. Hydraulic Schematic - M450A/E450A - Sheet 2 of 2 3121127 – JLG Lift – 7-39...
  • Page 257 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-28. Hydraulic Schematic - M450AJ/E450AJ - Sheet 1 of 2 7-40 – JLG Lift – 3121127...
  • Page 258 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505E Figure 7-29. Hydraulic Schematic - M450AJ/E450AJ - Sheet 2 of 2 3121127 – JLG Lift – 7-41...
  • Page 259 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-30. Hydraulic Schematic Component List 7-42 – JLG Lift – 3121127...
  • Page 261 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.
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