Oshkosh Corporation JLG E450AJ Service And Maintenance Manual
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Oshkosh Corporation JLG E450AJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
E450AJ
PVC 2001
31215013
November 26, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Model E450AJ PVC 2001 31215013 November 26, 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 (MEWP). It is of utmost importance that FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION maintenance personnel pay strict attention to these warnings COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A and precautions to avoid possible injury to themselves or oth-...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - November 26, 2019 31215013...

  • 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 Swing Motor ..................3-36 Preparation Before Disassembly .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM Platform ................... 4-1 Support Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lubricating O-Rings in the Hydraulic System ............5-1 Cup and Brush .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Pressure Setting Procedures ............... . 5-110 Main Relief .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Applying Silicone Dielectric Compound to Electrical Connections........7-4 Dielectric Grease Application .
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Locations ................1-3 1-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-16. Cylinder Head Removal ................5-54 5-17.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-73. Cylinder Barrel Support ................5-87 5-74.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-1. Hand Held Analyzer ................6-1 6-2.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-42. Chassis Steer/Brake Harness - Sheet 2 of 2 ............7-55 7-43.
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. Mobil DTE 10 Excel 15 Specs............... . 1-2 Mobil EAL 224H Specs.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Analyzer Abbreviations ................6-6 Machine Configuration Programming Information - Version P1.10 .
  • Page 19 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 20: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 TIRES Size IN240/55-17.5 IN240/55-17.5 26x7x20 Maximum Work Load (Capacity) Load Range ANSI Markets Ply Rating Unrestricted: 500 lb (227 kg) Tire Pressure 90 psi (6.2 Bar) 90 psi (6.2 Bar) Maximum Work Load (Capacity) CE &...

  • Page 21: Torque Specifications

    SECTION 1 - SPECIFICATIONS 1.5 TORQUE SPECIFICATIONS Table 1-1. Mobil DTE 10 Excel 15 Specs Description Torque Value Interval Hours ISO Viscosity Grade Wheel Lugs 170 ft. lbs. (230 Nm) Pour Point, Max -65°F (-54°C) Swing Bearing 190 ft. lbs. (260 Nm) 50/600* Flash Point, Min.

  • Page 22: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS 1.7 CRITICAL STABILITY WEIGHTS 1.9 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to Component the left rear of frame, in front of left rear wheel. If the serial number plate is damaged or missing, the machine serial num- Counterweight 3850 1746...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance & Lubrication Diagram 31215013...

  • Page 24: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.10 MAINTENANCE AND LUBRICATION Swing Bearing/Worm Gear Teeth NOTE: The following numbers correspond to those in Figure 1-2., Maintenance & Lubrication Diagram. Table 1-3. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities;...
  • Page 25 SECTION 1 - SPECIFICATIONS Hydraulic Tank Hydraulic Return Filter Lube Point(s) - Fill Cap Capacity - 4 Gal. (15.1 L) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently over- hauled, or after changing hydraulic oil, operate all sys- tems a minimum of two complete cycles and recheck oil level in reservoir.
  • Page 26 SECTION 1 - SPECIFICATIONS Wheel Bearing Engine Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation. Spindles/Bushing Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At Spindle/Bushing Replacement;...

  • Page 27: 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 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 28: 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 29: 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 30 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 31: 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 32 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 33: 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 34: 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 35: 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 36 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 37: 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 38: General

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

  • Page 39: 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 40: Component Disassembly And Assembly

    SECTION 2 - GENERAL Component Disassembly and Assembly Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring, as well When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble as their receptacles, when disconnecting or removing them or assemble one part, then start on another.

  • Page 41: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Hydraulic Oil Refer to Section 1 for recommendations for viscosity Hydraulic System ranges. The primary enemy of a hydraulic system is contamina- JLG recommends Premium Hydraulic Fluid, which has an tion. Contaminants enter the system by various means, SAE viscosity of 10W and a viscosity index of 168.

  • Page 42: 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 43: 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 44 SECTION 2 - GENERAL Table 2-3. 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 Platform Assembly...
  • Page 45 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Functions/Controls Platform Controls Return to Neutral/Off when Released Ground Controls Return to Neutral/Off when Released Function Control Locks, Guards, or Detents Footswitch (Shuts Off Function when Released) Emergency Stop Switches (Ground &...
  • Page 46 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications Function Test of All Systems 21, 22 Paint and Appearance Stamp Inspection Date on Frame...
  • Page 47 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 10 F(-12 C) TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
  • Page 48 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 49: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS Wheel Replacement The rims installed on each product model have been designed Tire Damage for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, For polyurethane foam filled tires, JLG Industries, Inc.

  • Page 50: Spindle

    SECTION 3 - CHASSIS & TURNTABLE The tightening of the nuts should be done in stages. Fol- Insert the dust cap and check to make sure the cotter pin is not going to interfere. Cap must be pressed all the lowing the recommended sequence, tighten nuts per wheel torque chart.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle 2780241 C 1001180839 D Figure 3-1. Spindle Assembly 31215013...
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE 1. Spindle 6. Battery 11. Drive Module (Left/Slave) 2. Steer Angle Sensor 7. Hydraulic Tank 12. Drive Hub 3. Steer Valve 8. Swing Bearing 13. Drive Motor 4. Motor/Pump 9. Swing Motor 14. Drive Brake 5.

  • Page 53: Tilt Module

    SECTION 3 - CHASSIS & TURNTABLE NOTE:TORQUE WHEEL LUGS TO 170 ft. lbs (230Nm) DRIVE DRIVE BRAKE DRIVE MOTOR Apply Pipe Sealant MOTOR Threadlocking Compound ADAPTER Apply Medium Strength Threadlocking Compound Torque to 165 ft. lbs (224 Nm) TIRE AND WHEEL ASSEMBLY MAE38660 Figure 3-3.

  • Page 54: Speed Sensor

    SECTION 3 - CHASSIS & TURNTABLE GROUND STUD RHT PWR MOD PUMP CONTACTOR LFT LFT PWR MOD B+ RHT PWR MOD B- CONTACTOR RHT LFT PWR MOD U LFT PWR MOD B- RHT PWR MOD B+ POWER STUD 48V TO 12V DC/DC LFT PWR MOD W RHT PWR MOD U CONVERTER...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE OPTIONAL INVERTER RL-2 VOTE RL-1 RELAY IGNITION RELAY Figure 3-5. Relay 31215013...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE FC-3 OPTION FUSE (5A) FC-1 48V B+ (20A) FC-601 DELTA Q (30A) FC-2 12V SYSTEM (15A) NOTE: CHARGER FUSE SHOULD BE IN PLACE. Figure 3-6. System Fuses 31215013...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE FC-4 IGNITION RELAY FUSE Figure 3-7. Ignition Relay Fuse 31215013...
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE IP 409 LEFT BRAKE POWER STUD IP 408 RIGHT BRAKE (10Amp) (10Amp) Figure 3-8. Drive Fuses 3-10 31215013...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1001116232-A Figure 3-9. Drive Limit Switch 3-11 31215013...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1. Steer Cylinder 7. Castle Nut 13. Hub 18. Castle Nut 2. Rod End 8. Thrust Washer 14. Lug Nut 19. Dust Cap 3. Nut 9. Lip Seal 15. Outer Bearing Cup 20. Cotter Pin 4.

  • Page 61: Drive Hub

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

  • Page 62: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly Remove the First Stage Sun Gear (10) if applicable. NOTE: On units with ratios greater than 36:1 numerically, there NOTE: Refer to Figure 3-11., Main Assembly - Sheet 1 of 2 and Fig- will not be a separate First Stage Sun Gear (10), as the gear ure 3-12., Main Assembly - Sheet 2 of 2.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 1F. Ring Gear 9. Input Shaft 1G. Housing 11. Second Stage Sun Gear 4. Output Carrier Subassembly 18. O-ring 5. Retaining Ring 19. Flat Head Bolt 20. Retaining Ring Figure 3-12. Main Assembly - Sheet 2 of 2 3-15 31215013...

  • Page 64: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly Slide the Planet Gear Sub-assembly (4) out of the Output Carrier (4A) being careful to not drop the Needle Bear- ings (4C) in the process. NOTE: Refer to Figure 3-13., Output Carrier and Figure 3-14., Planet Gear.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 4B. Thrust Washer 4C. Needle Bearing 4D. Thrust Spacer 4F. Planet Gear Figure 3-14. Planet Gear 3-17 31215013...

  • Page 66: Input Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly NOTE: The Roll Pins (4G} should not be reused when reassembling the unit. NOTE: Refer to Figure 3-15., Input Carrier. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A). Using a 1/8”...

  • Page 67: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-spindle Disassembly If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end. NOTE: Refer to Figure 3-16., Hub Spindle. Remove Seal (1B) from Hub (1G). NOTE: The Seal (1B) should NOT be reused when reassembling the Place unit on bench with Spindle (1A) end down.

  • Page 68: Cover Disassembly

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

  • Page 69: Input Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Assembly Output Planet Gear Assembly NOTE: Refer to Figure 3-15., Input Carrier. NOTE: Refer to Figure 3-14., Planet Gear. Apply a liberal coat of grease to the bore of one Input Apply a liberal coat of grease to the bore of one Output Planet Gear (3F).

  • Page 70: Output Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Assembly Hub-spindle Assembly NOTE: Refer to Figure 3-13., Output Carrier NOTE: Refer to Figure 3-16., Hub Spindle NOTE: Spray a light film of oil on all component parts during Place Thrust Washer (4H) into counterbore of Carrier (4A).

  • Page 71: Cover Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Assembly Main Assembly NOTE: Refer to Figure 3-17., Cover Assembly. NOTE: Refer to Figure 3-11., Main Assembly - Sheet 1 of 2 and Fig- ure 3-12., Main Assembly - Sheet 2 of 2. Grease O-Ring (6E) and insert into internal groove in Cover (6A).
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Drive Hub - Sheet 1 of 2 3-24 31215013...
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 1A Spindle 1K Retaining Ring 3F Planet Gear 5 Retaining Ring 9 Input Shaft 1B Lip Seal 1L Spring 4A Output Carrier 6A Cover 10 Input Sun Gear 4B Thrust Washer 6B Disengage Cap 11 Output Sun Gear 1C Tapered Bearing Cone 1M Thrust Washer...

  • Page 74: Drive Motor

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

  • Page 75: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Installation NOTE: Refer to Figure 3-20., Drive Motor. NOTE: The drive motor weighs approximately 95 lb (43 kg). Install the rotor (29) into the stator (2). Use suitable lifting device to support the drive motor. Install the gear key (32) on to the rotor shaft.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE 1. Not Included 10. Shaft Seal 19. Seal 28. O-Ring 2. Stator 11. Bearing 20. Seal 29. Rotor 3. Terminal Board 12. Washer 21. Cover 30. Retainer Clip 4. Nut 13. Sensor 22. Screw 31.

  • Page 77: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING BEARING Check the turntable to bearing. Attach bolts as follows: a. Elevate the fully retracted boom to 70 degrees (full Turntable Bearing Mounting Bolt Condition Check elevation). b. At the positions indicated on Figure 3-21. try and insert the 0.0015"...

  • Page 78: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance extended and Mid/Lower Boom stowed, (See Figure 3- 22.), using a magnetic base dial indicator, measure and With the boom positioned over the side of the machine, record the distance between the swing bearing and the Upper Boom horizontal with telescope fully turntable.

  • Page 79: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE If a difference greater than 0.057 in. (1.40 mm) is deter- Installation. mined, the swing bearing should be replaced. a. Install bearing to rotation box with two capscrews, so that fill plug of bearing is as close to gear as bolt If a difference less than 0.057 in.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE k. Apply a light coating of High Strength Threadlock- ing Compound to the new bearing bolts and install IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED through the turntable and inner race of bearing. FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING l.
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE 3-33 31215013...

  • Page 82: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Value Adjusting End Play Install with JLG Threadlocker - 190 ft. lbs. (260 Nm). Remove end plate. Measure and record total thickness of existing shim Checking Worm Gear End Play pack. NOTE: JLG Industries requires that a annual inspection be per- Determine thickness of shim pack required to obtain formed on the worm gear end play.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Figure 3-26. Swing Components 3-35 31215013...

  • Page 84: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING MOTOR Figure 3-27. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY. 3-36 31215013...
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufac- turers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used 2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used 3. Seal Ring 8.

  • Page 87: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- Place the motor in a soft jawed vice, with coupling shaft nents read this entire section. It provides important infor- (12) pointed down and the vise jaws clamping firmly on mation on parts and procedures you will need to know to the sides of the housing (18) mounting flange or port...
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE Remove commutator (5) and seal ring (3) Remove seal Remove manifold (7) and inspect for cracks surface scor- ring from commutator, using an air hose to blow air into ing, brinelling or spalling. Replace manifold if any of ring groove until seal ring is lifted out and discard seal these conditions exist.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE Remove rotor set (8) and wearplate (9), together to Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 retain the rotor set in its assembled form, maintaining degrees apart) and a roller vane centerline are on the the same rotor vane to stator contact surfaces.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bear- ing. Crocus cloth or fine emery paper may be used. Remove coupling shaft (12), by pushing on the output end of shaft.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Remove thrust bearing (15) and thrust washer (14). Inspect housing (18) assembly for cracks, the machined Inspect for wear, brinelling, corrosion and a full comple- surfaces for nicks, burrs, brinelling or corrosion. Remove ment of retained rollers. burrs that can be removed without changing dimen- sional characteristics.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the motor is com- If the bearings, bushing or thrust washers must be pleted. replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) with- out damaging the housing.

  • Page 94: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square Replace all seals and seal rings with new ones each time with the press base and the bearing/ bushing is not cocked you reassemble the motor unit.
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Press a new dirt and water seal (20) into the housing (18) Assemble thrust washer (14) then thrust bearing (15) outer bearing counterbore. The dirt and water seal (20) that was removed from the motor. must be pressed in until its’...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Be sure that a generous amount of clean corrosion resis- Apply a small amount of clean grease to a new seal ring tant grease has been applied to the lower (outer) hous- (4) and insert it into the housing (18) seal ring groove. ing bearing/bushing (19).
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE NOTE: It may be necessary to turn one alignment stud out of the Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE Assemble the manifold (7) over the alignment studs and Assemble a new seal ring (3) flat side up, into commuta- drive link (10) and onto the rotor set. Be sure the correct tor (5) and assemble commutator over the end of drive manifold surface is against the rotor set.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other compo- nents into place with a final torque of 25-30 ft.

  • Page 100: One Piece Stator Construction

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

  • Page 101: Two Piece Stator Construction

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

  • Page 102: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.9 BATTERY MAINTENANCE AND CHARGING Optional On Board Generator Battery Maintenance, Quarterly EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA Open battery compartment cover to allow access to bat- ONLY. tery terminals and vent caps. WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COV- WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CON- ERS PLATES.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 3-55 31215013...

  • Page 104: 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 BATTERIES. AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3-WIRE 12 AWG CORD.

  • Page 105: Maintenance Instructions

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Instructions Battery Charger Fault Codes If a fault occurred during charging, the red "Fault" LED will For flooded lead-acid batteries, regularly check water flash with a code corresponding to the error. Refer to the levels of each battery cell after charging and add dis- table following for the flash codes and their removal.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-30. Battery Charger 3-58 31215013...
  • Page 107 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 108: 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 109: 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 110 SECTION 3 - CHASSIS & TURNTABLE 1. Glow Plug Relay 4. Temperature Sensor 2. Fuel Control Relay 5. Voltage Regulator 3. Start Control Relay 6. Alternator 4. Fuel Solenoid 7. Starter 5. Fuel Pump 8. Starter Solenoid 6. Low Oil Pressure Switch 9.

  • Page 111: 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 112: 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 113: 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 114: Alternator Output Current Sensor

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

  • Page 115: Warnings And Safety Precautions

    SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Controller Interface Pin Assignments System Settings FUNCTION CALL TO START SETTINGS + Output voltage Low battery voltage call to start level 48.0 VDC Speed sensing + 5V Low battery voltage remove call to start level 54.0 VDC Output current sense Low temperature call to start level...

  • Page 116: 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 117: 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 3-6. RBS Alarms and Flash Codes Flash Code Problem RBS Condition Below 7psi...

  • Page 118: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-7. 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 119: 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 120: 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 121 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 122 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 123: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM PLATFORM Remove the bolts and washer securing the platform support cover to the platform support. Remove plat- form support cover. Support Removal MAF17790 Remove the bolts and locknuts securing the support to MAF17720 the rotator.

  • Page 124: Support Installation

    SECTION 4 - BOOM & PLATFORM Using a suitable brass drift and hammer, remove the Apply Medium Strength Threadlocking Compound to rotator shaft, then remove the support from the rotator. the bolts and locknuts securing the support to the rota- tor and install the bolts and locknuts.
  • Page 125 SECTION 4 - BOOM & PLATFORM Position the platform on the platform support and install the bolts securing the platform to the platform support. Connect the electrical cables to the platform control console. A, B, D NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued.

  • Page 126: Rotator And Platform Level Cylinder Removal

    SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR AND PLATFORM LEVEL CYLINDER Installation REMOVAL Using a suitable lifting equipment, adequately support main boom weight along entire length. Removal Supporting the slave cylinder, Using a suitable brass drift and hammer, Install pin to the fly boom. Using a suitable lifting equipment, adequately support main boom weight along entire length.

  • Page 127: Main Boom Powertrack

    SECTION 4 - BOOM & PLATFORM 4.3 MAIN BOOM POWERTRACK Installation NOTE: The Main Boom weighs approximately 590 lb (268kg). Removal Disconnect wiring harness connectors located in main Using suitable lifting equipment, adequately support upright. Powertrack weight along entire length. With powertrack supported and using all applicable safety precautions, Install bolts #3 securing rail to the HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-...

  • Page 128: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM 4.4 BOOM MAINTENANCE Removal a. Remove hardware securing the cover plate on the side of the base boom section and remove hose clamps. Disconnect wiring harness from ground control harness connector. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

  • Page 129: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Inspection Inspect boom pivot pin for wear, scoring or other dam- Loosen jam nuts on aft end of fly boom wear pad adjust- age, and for tapering or ovality. Replace pin as neces- ment and loosen adjustments.

  • Page 130: Installation

    SECTION 4 - BOOM & PLATFORM Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring. Align bolt holes at aft end of base boom section with telescope cylinder port block.

  • Page 131: Wear Pads

    SECTION 4 - BOOM & PLATFORM 4.5 WEAR PADS BOOM CLEANLINESS GUIDELINES Shim up wear pads until snug to adjacent surface. The following are guidelines for internal boom cleanliness for Replace wear pads when worn to thickness shown machines that are used in excessively dirty environments. below.
  • Page 132 SECTION 4 - BOOM & PLATFORM THE FOLLOWING ANGLES ARE USED TO SET THE UPPER LIMIT SWITCH IF IT IS AN AJ MODEL THE JIB IS TO BE COMPLETELY LOWERED MAKE SURE THE LOWER BOOM IS COMPLETELY LOWERED ALL ANGLES ARE TAKEN FROM THE MIDDLE OF THE UPPER BOOM 0˚...

  • Page 133: Articulating Jib Boom

    SECTION 4 - BOOM & PLATFORM 4.8 ARTICULATING JIB BOOM Inspection NOTE: When inspecting pins and bearings refer to “Pins and Com- Removal posite Bearing Repair Guidelines” on page 6. For platform/support removal see platform/support Inspect articulating fly boom pivot pin for wear, scoring, removal diagram.

  • Page 134: Boom Synchronizing Procedure

    SECTION 4 - BOOM & PLATFORM 4.9 BOOM SYNCHRONIZING PROCEDURE Align bottom tubes with attach holes in rotator support. Using a soft head mallet, install rotator support pin #5 into articulating jib boom and secure with mounting NOTE: If the Lower Boom assembly does not fully lower: hardware.

  • Page 135: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.11 ROTARY ACTUATOR Tools Required for Assembly/Disassembly there are Upon assembly and disassembly of the actuator Theory Of Operation basic tools required. The tools and their intended func- tions are as follows: The rotary actuator is a simple mechanism that uses the slid- Flashlight- helps examine timing marks, component ing spline operating concept to convert linear piston motion failure and overall condition.
  • Page 136 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 137 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 138: 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 counter clock-wise. Using a 1/8”...
  • Page 139 SECTION 4 - BOOM & PLATFORM Remove the stop tube if included. The stop tube is an Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and pis- available option to limit the rotation of the actuator. ton.
  • Page 140 SECTION 4 - BOOM & PLATFORM To remove the piston (3) use a rubber mallet and a plas- Remove the wear guides (302) from the end cap (4) and tic mandrel so the piston is no damaged. shaft (2). At the point when the piston gear teeth come out of To remove the main pressure seals (205), it is easiest to engagement with the housing gear teeth, mark the pis- cut them using a sharp razor blade being careful not to...

  • Page 141: Inspection

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

  • Page 142: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular Gather all the components and tools into one location motion.
  • Page 143 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 the outer piston seal (202) is touching inside the hous- circular motion. Install the outer T-seal (202) by stretch- ing bore.
  • Page 144 SECTION 4 - BOOM & PLATFORM Looking from the opposite end of the housing (1) you Install 2 bolts in the threaded holes in the flange. Using a bar, rotate the shaft in a clockwise direction until the can see if your timing marks are lining up. When they do, wear guides are seated inside the housing bore.
  • Page 145 SECTION 4 - BOOM & PLATFORM Install the O-ring (204) and backup ring (207) into the Place the lock pins (109) provided in the Helac seal kit in inner seal groove on the end cap (4). the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.

  • Page 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 4-8., Rotator Counterbalance Valve. Torque the 1/4-inch bolts 110 to 120 in. lbs. (12.4 to 13.5 Nm).

  • Page 147: Greasing Thrust Washers

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

  • Page 148: Installation And Bleeding

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

  • Page 149: 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.

  • Page 150: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.12 POWERTRACK MAINTENANCE Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the pow- ertrack. Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be different.
  • Page 151 SECTION 4 - BOOM & PLATFORM To remove a link, the rivets holding the links together insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled must be removed. Use a right-angle pneumatic die over part of the rivet falls off.
  • Page 152 SECTION 4 - BOOM & PLATFORM After grinding it may be necessary to help the rivet out Using a flat head screwdriver between the links, twist by using a center punch with a hammer. the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.
  • Page 153 SECTION 4 - BOOM & PLATFORM Installing a New Link Remove the link from the other section of the pow- ertrack using a screwdriver. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section. 4-31 31215013...

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