Oshkosh Corporation JLG E400AJP Service And Maintenance Manual
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Oshkosh Corporation JLG E400AJP Service And Maintenance Manual

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Service and Maintenance Manual
Models
E400AJP
E400A/AJPnarrow
M400AJP/AJPnarrow
SN 0300208530 to Present
PN - 3121717
November 30, 2018 - Rev D
AS/NZS

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  • Page 1 Service and Maintenance Manual Models E400AJP E400A/AJPnarrow M400AJP/AJPnarrow SN 0300208530 to Present PN - 3121717 November 30, 2018 - Rev D AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - January 06, 2017 Revised B - August 23, 2017 Revised C - June 29, 2018 - Revised Covers Revised D - November 30, 2018 3121717...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Inflation.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.10 Battery Charger ..................3-57 Operating Instructions .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Boom Cleanliness Guidelines ............... 4-9 Articulating Jib Boom.
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Hydraulic Cylinders ................5-54 Slave Cylinder (E400AN only) .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. LSS System ..................6-58 Diagnostic Menu .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Locations ................1-4 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-8. ORB-MPP Thread ................. . . 5-4 5-9.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-64. Wiper Seal Installation................5-81 5-65.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-119. Master Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN only) ........5-111 5-120.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-176. Hydraulic Schematic (SN 0300208530 through 0300233432) - Sheet 4 of 7 ......5-153 5-177.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-31. Turntable Harness - Sheet 2 of 3..............7-29 7-32.
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Capacities .
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-35 Cartridge Torque Values ................5-146 5-36 Coil Torque Values.
  • 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 Table 1-1. Operating Specifications Battery Recharge Time Table 1-1. Operating Specifications Charger 17 hours from ful l discharge Generator 6.2 hours Maximum Work Load (Capacity) ANSI Markets Maximum Main Relief Hydraulic Pressure 3400 psi (234 bar) Unrestricted: 500 lbs.

  • Page 21: Dimensional Data

    SECTION 1 - SPECIFICATIONS 1.4 DIMENSIONAL DATA 1.5 LUBRICATION SPECIFICATIONS Refer to Section 1.10, Maintenance and Lubrication, for spe- Table 1-4. Dimensional Data cific lubrication procedures. Machine Length (stowed) Hydraulic Oil E400An 18 ft. 1 in. (5.50 m) Table 1-5. Hydraulic Oil E/M400AJP;...

  • Page 22: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS 1.7 TORQUE SPECIFICATIONS Table 1-7. Mobil EAL H 32 Specs Table 1-9. Torque Requirements Type Synthetic Biodegradable Description Torque Value Interval Hours ISO Viscosity Grade Wheel Lugs 170 ft. lbs. Specific Gravity .950 (230 Nm) Pour Point, Max -59°F (-51°C) Swing Bearing 190 ft.

  • Page 23: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS 1.9 SERIAL NUMBER LOCATIONS Table 1-10. Major Component Weights For machine identification, a serial number plate is affixed to the left rear of frame, in front of left rear wheel. If the serial Component number plate is damaged or missing, the machine serial num- Platform and Support...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance and Lubrication Diagram 3121717...

  • Page 25: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.10 MAINTENANCE AND LUBRICATION 2. Swing Bearing/Worm Gear Teeth NOTE: The following numbers correspond to those in Figure 1-2., Maintenance and Lubrication Diagram. Table 1-11. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities;...
  • Page 26 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 4. Hydraulic Return Filter Lube Point(s) - Fill Cap Capacity -E400An- 4 Gal. (15.1 L);E/M400AJP & E/ M400AJPn-5 Gal.(19l) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Interval - Change after first 50 hrs.
  • Page 27 SECTION 1 - SPECIFICATIONS 5. Wheel Drive Hub 8. Boom Pivot Pins/Bushing Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At boom pivot pins/bushing replacement; Coat I.D. of bushings prior to installing pivot pins. 9.
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121717...
  • Page 29 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5) 1-10 3121717...
  • Page 30 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121717 1-11...
  • Page 31 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 4 of 5) 1-12 3121717...
  • Page 32 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 3121717 1-13...
  • Page 33 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 34: 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 35: Service And Guidelines

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

  • Page 36: Component Disassembly And Reassembly

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

  • Page 37: Lubrication

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

  • Page 38: Cylinder Drift

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

  • Page 39: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on Filament wound bearings. an external structure, or component, Pinned joints should be disassembled and inspected if the following occurs: Do the Following When Welding on JLG Equipment...
  • Page 40 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
  • Page 41 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Capacity Indicator Drive Brakes...
  • Page 42 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds...
  • Page 43 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 44 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 45: Chassis & Turntable

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

  • Page 46: Spindle

    SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Fol- way down. The unit should be checked again to assure it lowing the recommended sequence, tighten nuts per spins freely after the dust cap is installed. wheel torque chart.
  • Page 47 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle 2780241 C 1001180839 D Figure 3-1. Spindle Assembly 3121717...
  • Page 48 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 49: Tilt Module

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Torque Wheel Lugs to 170 ft.lbs. (230 Nm) DRIVE DRIVE BRAKE DRIVE MOTOR MOTOR ADAPTER Apply Pipe Sealant Loctite #567 Apply JLG Threadlocker PN 0100011 Torque to 165 ft. lbs. (224 Nm) TIRE AND WHEEL ASSEMBLY MAE38660 Figure 3-3.
  • Page 50 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 51: 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 52 SECTION 3 - CHASSIS & TURNTABLE OPTIONAL INVERTER RL-2 VOTE RL-1 RELAY IGNITION RELAY Figure 3-6. Relay 3121717...
  • Page 53 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 3-7. System Fuses 3121717...
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE FC-4 IGNITION RELAY FUSE Figure 3-8. Ignition Relay Fuses 3-10 3121717...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE IP 409 LEFT BRAKE POWER STUD IP 408 RIGHT BRAKE (10Amp) (10Amp) Figure 3-9. Drive Fuses 3121717 3-11...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 1001116232-A Figure 3-10. Drive Limit Switch 3-12 3121717...

  • Page 57: 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 58: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 11. 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, teeth will be integral to the Input Shaft (9).
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1F Ring Gear 9 Input Shaft 1G Housing 10 First Stage Sun Gear 4 Output Carrier Subassembly 11 Second Stage Sun Gear 5 Retaining Ring 18 O-ring 6 Cover Assembly 19 Flat Head Bolt 20 Retaining Ring 6G Retaining Ring Figure 3-12.

  • Page 60: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 4. 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 61 SECTION 3 - CHASSIS & TURNTABLE 4B Thrust Washer 4C Needle Bearing 4D Thrust Spacer 4F Planet Gear Figure 3-14. Planet Gear 3121717 3-17...

  • Page 62: 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. 4. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A).

  • Page 63: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-spindle Disassembly 6. 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. 7. Remove Seal (1B) from Hub (1G). NOTE: The Seal (1B) should NOT be reused when reassembling the 1.

  • Page 64: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A). 5. Use appropriate tool to remove O-Ring (6E) from inter- NOTE: Refer to Figure 3-17., Cover Assembly. nal groove in Cover (6A). 6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A). 1.

  • Page 65: 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. 1. Apply a liberal coat of grease to the bore of one Input 11.

  • Page 66: 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. 1. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during (4A).

  • Page 67: 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. 1.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Drive Hub - Sheet 1 of 2 3-24 3121717...
  • Page 69 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 1C Tapered Bearing Cone 1M Thrust Washer 4B Thrust Washer 6B Disengage Cap 11 Output Sun Gear...

  • Page 70: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE MOTOR 8. Remove the screws (22) from the retaining plate (23). 9. Remove the retaining plate (23) from the cover (21). Removal 10. Remove the cover (21) from the shield end (18). 1.

  • Page 71: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Installation NOTE: Refer to Figure 3-20., Drive Motor. NOTE: The drive motor weighs approximately 95 lbs. (43 kg). 1. Install the rotor (29) into the stator (2). 1. Use suitable lifting device to support the drive motor. 2.
  • Page 72 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 73: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING BEARING 2. 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 74: 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 1. 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 75: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3. If a difference greater than 0.057 in. (1.40 mm) is deter- 2. 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 4.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE k. Apply a light coating of JLG Threadlocker PN 0100019 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 3.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 3121717 3-33...
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 3-34 3121717...

  • Page 79: 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. 2. Measure and record total thickness of existing shim Checking Worm Gear End Play pack.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Figure 3-27. Swing Components 3-36 3121717...

  • Page 81: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING MOTOR Figure 3-28. 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. 3121717 3-37...
  • Page 82 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 83 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 84: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- 1. 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 85 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. Replace end cover as necessary.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove seal 8. 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 87 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 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 88 SECTION 3 - CHASSIS & TURNTABLE 12. 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. 13.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 15. Remove thrust bearing (15) and thrust washer (14). 18. 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.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the motor is com- 20. 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 91: 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 92 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing (18) 6. 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 93 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- 9. 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.
  • Page 94 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 of the alignment studs onto the housing (18). housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs and 18. 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 96 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 compo- nents into place with a final torque of 25-30 ft.

  • Page 97: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. 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 98: 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 99: 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 1. Open battery compartment cover to allow access to bat- ONLY. tery terminals and vent caps.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 3-56 3121717...

  • Page 101: 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 102: Maintenance Instructions

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Instructions Battery Charger Fault Codes If a fault occurred during charging, the red “Fault” LED will 1. For flooded lead-acid batteries, regularly check water flash with a code corresponding to the error. Refer to the levels of each battery cell after charging and add dis- table following for the flash codes and their removal.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-31. Battery Charger (E400AN/AJP/AJPN) 3121717 3-59...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 1. AC Voltage - Input Cable 2. Battery Charge Signal Cable 3. DC Power Cable to Batteries Figure 3-32. Battery Charger (M400AJP/AJPN) 3-60 3121717...
  • Page 105 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 106: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

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

  • Page 107: 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 108 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 109: 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 110: 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 111: 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 112: 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 113: 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 114: 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) Automatically: 1 Battery voltage above 54VDC and finish charging current below 30ADC 2 Low engine temperature (below 5°C) 2 Engine temperature above 8°C...

  • Page 115: 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 116: 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 117: 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 118: Supplementary Fuse For Apu

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SUPPLEMENTARY FUSE FOR APU 2. Find where the harness attaches to the rear cover of the generator and the connection point for the new inline The purpose of this section is to describe the procedure to fuse.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 4. Cut and remove the Wire Ties holding the Harness label to the harness. Next, remove the Wire Ties so that the cable sleeve can be moved, exposing the conductors of the harness. 6. Re-install the harness with the new fuse in place. 5.
  • Page 120 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 121: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 PLATFORM 4. Remove the bolts and locknuts securing the support to the rotator. Support Removal Figure 4-1. Location of Components Platform Support 5. Using a suitable brass drift and hammer, remove the rotator shaft, then remove the support from the rotator.

  • Page 122: Support Installation

    SECTION 4 - BOOM & PLATFORM Support Installation 5. Position the platform on the platform support and install the bolts securing the platform to the platform 1. Using a suitable lifting device, support the platform sup- support. port and position it on the rotator. NOTE: The platform support weighs approximately 77 lbs.
  • Page 123 SECTION 4 - BOOM & PLATFORM A,B,D NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Torque to 40 ft. lbs. (55 Nm) JLG Thread locker (#0100011) Torque to 250-270 ft. lbs. (339-366 Nm) Check torque every 150 hours of operation Figure 4-2.

  • Page 124: Rotator And Slave Cylinder Removal

    SECTION 4 - BOOM & PLATFORM 4.2 ROTATOR AND SLAVE CYLINDER REMOVAL Installation 1. Using a suitable lifting equipment, adequately support Removal main boom weight along entire length. 1. Using a suitable lifting equipment, adequately support 2. Supporting the slave cylinder, Using a suitable brass main boom weight along entire length.

  • Page 125: Main Boom Powertrack

    SECTION 4 - BOOM & PLATFORM 4.3 MAIN BOOM POWERTRACK Installation NOTE: The Main Boom weighs approximately 590lbs. (268kg). Removal 1. Using suitable lifting equipment, adequately support 1. Disconnect wiring harness connectors located in main Powertrack weight along entire length. upright.

  • Page 126: 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 127: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Inspection 1. Inspect boom pivot pin for wear, scoring or other dam- 1. 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 128: Installation

    SECTION 4 - BOOM & PLATFORM 11. Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring. 12. Align bolt holes at aft end of base boom section with telescope cylinder port block.

  • Page 129: Wear Pads

    SECTION 4 - BOOM & PLATFORM 4.5 WEAR PADS BOOM CLEANLINESS GUIDELINES 1. Shim up wear pads until snug to adjacent surface. The following are guidelines for internal boom cleanliness for 2. Replace wear pads when worn to thickness shown machines that are used in excessively dirty environments.
  • Page 130 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 131 SECTION 4 - BOOM & PLATFORM Figure 4-5. Jib/Platform Components and Attaching Hardware 3121717 4-11...

  • Page 132: Articulating Jib Boom

    SECTION 4 - BOOM & PLATFORM 4.8 ARTICULATING JIB BOOM Inspection 1. Inspect articulating fly boom pivot pin for wear, scoring, Removal tapering and ovality, or other damage. Replace pins as necessary. 1. For platform/support removal see platform/support removal diagram. See Section 4.1, Platform. 2.

  • Page 133: Boom Synchronizing Procedure

    SECTION 4 - BOOM & PLATFORM 3. Align articulating jib boom with attach hole in articulat- 4.9 BOOM SYNCHRONIZING PROCEDURE ing jib boom pivot weldment. Using a soft head mallet, install rotator support pin #4 into articulating jib boom NOTE: If the Lower Boom assembly does not fully lower: and secure with mounting hardware.

  • Page 134: 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- ing spline operating concept to convert linear piston motion 1.
  • Page 135 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 136 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 137: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 4. Install the end cap (4) removal tools provided with the Helac seal kit. 1. Remove the capscrews (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 138 SECTION 4 - BOOM & PLATFORM 7. Remove the stop tube if included. The stop tube is an 9. Prior to removing the shaft, (2), use a felt marker to available option to limit the rotation of the actuator. clearly indicate the timing marks between shaft and pis- ton.
  • Page 139 SECTION 4 - BOOM & PLATFORM 12. To remove the piston (3) use a rubber mallet and a plas- 15. Remove the wear guides (302) from the end cap (4) and tic mandrel so the piston is no damaged. shaft (2). 13.

  • Page 140: Inspection

    SECTION 4 - BOOM & PLATFORM 18. Remove the wiper seal (304.1) from its groove in the end Inspection 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 criti- cal areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.

  • Page 141: 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 circular 1. Gather all the components and tools into one location motion.
  • Page 142 SECTION 4 - BOOM & PLATFORM 6. Install the inner T-seal (200) into the piston (3) using a 8. Insert the piston (3) into the housing (1) as shown, until circular motion. Install the outer T-seal (202) by stretch- the outer piston seal (202) is touching inside the hous- ing it around the groove in a circular motion.
  • Page 143 SECTION 4 - BOOM & PLATFORM 10. Looking from the opposite end of the housing (1) you 13. Install 2 bolts in the threaded holes in the flange. Using a can see if your timing marks are lining up. When they do, bar, rotate the shaft in a clockwise direction until the tap the piston (3) in until the gear teeth mesh together.
  • Page 144 SECTION 4 - BOOM & PLATFORM 16. Install the O-ring (204) and backup ring (207) into the 19. 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 145: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Threadlocker PN 0100011 should be applied to the shank of the three bolts at the time of installation. Refer to Figure 4-9., Rotator Counterbalance Valve. 4. Torque the 1/4-inch bolts 110 to 120 in. lbs. (12.4 to 13.5 Nm).

  • Page 146: Greasing Thrust Washers

    SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on 6. 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 147: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 2. 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 148: Troubleshooting

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

  • Page 149: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.12 POWERTRACK MAINTENANCE 2. 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 150 SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together must be removed. Use a right-angle pneumatic die MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS grinder with a ¼” ball double cut bur attachment. TO PROTECT THEM.
  • Page 151 SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet out 6. 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 152: Installing A New Link

    SECTION 4 - BOOM & PLATFORM 7. Remove the link from the other section of the pow- Installing a New Link 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. 4-32 3121717...
  • Page 153 SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new link 3. After the new link is installed in the powertrack the and slide the peanut end of the track section into it. a round half-shears will not fit properly in the peanut cut- screwdriver may be necessary to do this.
  • Page 154 SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the new 6. Push pin through center hole then slide washer on pin. connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs.
  • Page 155 SECTION 4 - BOOM & PLATFORM 7. Install the snap ring in the groove on the pin. Repeat the NOTE: When installing snap rings make sure they are seated in pin installation steps for all center holes that have the pin groove and closed properly.
  • Page 156 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. 4-36 3121717...

  • Page 157: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM 10. Install a new 8-32 x 0.500 self threading screw on the Replacing Fixed End Brackets 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 158 SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. CLOSED SNAP RING 3. Take the new bracket and install bracket center pin and snap ring.

  • Page 159: 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. Repeat on other bracket if replacing it as well.
  • Page 160 SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and install NOTE: When installing snap rings make sure they are seated in snap rings. Repeat with other moving end if replacing as pin groove and closed properly. well.

  • Page 161: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.13 SKYGUARD Function Test SKYGUARD ONLY Operation Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2). When the SkyGuard sensor is activated, functions in use at From the Platform Control Console in an area free from obstruc- the time of actuation will reverse or cutout.

  • Page 162: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains OPEN while the Sky- Guard sensor is actively engaged, it is possible the sensor has If SkyGuard does not function when the sensor is engaged, failed and should be replaced immediately.
  • Page 163 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 164: Basic Hydraulic Information & Schematics

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

  • Page 165: Dip Method

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

  • Page 166: Hydraulic Connection Assembly And Torque Specification

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

  • Page 167: Straight Thread Types, Port Connections

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

  • Page 168: Assembly And Torque Specifications

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.

  • Page 169: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

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

  • Page 170: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

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

  • Page 171: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - 1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.
  • Page 172 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 173 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 174 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 5-11...

  • Page 175: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings 4. Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass 1. Inspect the flare for obvious visual squareness and con- while using the Double Wrench Method outlined in this centricity issues with the tube OD.
  • Page 176 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Turns From Thread Size ØA* ØB* [Ft-Lb] [N-m] Finger Tight Dash Size (TFFT)** (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 1/4 to 1/2 5/8-18...

  • Page 177: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
  • Page 178 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in) (mm)

  • Page 179: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
  • Page 180 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-9. DIN 24° Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...

  • Page 181: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2. Remove the locknut from the bulkhead assembly. 3.
  • Page 182 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12 Torque...
  • Page 183 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5...
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  • Page 185 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Tables 5-17, O-RING BOSS (ORB) while using the Double Fittings Wrench Method. 1. Inspect components to ensure that male and female NOTE: The table headings identify the straight thread O-ring port port threads are free of rust, splits, dirt, foreign matter, or and the type on the other side of the fitting.
  • Page 186 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb)
  • Page 187 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)
  • Page 188 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF)
  • Page 189 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)
  • Page 190 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque Thread Size ØA* Ft-Lb or (in-lb) [N-m] MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33)
  • Page 191 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-17. O-ring Boss (ORB) - Table 6 of 6 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque** Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in) (mm) 5/16-24 0.31 7.93...
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  • Page 193: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Metric Flat Face Port (MFF) - L Metric (MFF) Fittings Series and Table 5-21, Table 5-22, Table 5-23, Metric Flat Face Port (MFF) - S Series while using the Double 1.
  • Page 194 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 195 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 196 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
  • Page 197 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
  • Page 198 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 199 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...
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  • Page 201: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24, Metric Pipe Parallel O-ring Boss (MPP) while using the Port Assembly Stud Ends Double Wrench Method.
  • Page 202 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 203: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, British Standard Parallel Pipe Port (BSPP) Fittings (BSPP) - L Series and Table 5-28, Table 5-29, Table 5-30, British Standard Parallel Pipe Port (BSPP) - S Series while 1.
  • Page 204 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 FORM A** (SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 205 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-26. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37°...
  • Page 206 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-27. British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS BSPP...
  • Page 207 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 FORM A** (SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end BSPP Torque...
  • Page 208 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-29. British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 209 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end BSPP Torque...
  • Page 210 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 5-47...

  • Page 211: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See O-ring Installation (Replacement) for O-ring installa- tion instructions.
  • Page 212 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws Flange Size...
  • Page 213 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws CLASS 10.9 Screws...

  • Page 214: Double Wrench Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Double Wrench Method improper joint load and leads to leaks. For hose connections, the ‘layline’ printed on the hose is a good indicator of proper To prevent undesired hose or connector rotation, two hose installation.

  • Page 215: Ffwr And Tfft Methods

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: 1. Lubricate the o-ring with a light coat of hydraulic oil. 1.

  • Page 216: O-Ring Installation (Replacement)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads dur- ing replacement or installation.

  • Page 217: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.3 HYDRAULIC CYLINDERS 5. Using a spanner wrench, unscrew the cylinder head from the barrel. Slave Cylinder (E400AN only) 6. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.
  • Page 218 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft. lbs. (70 Nm) ** Torque gland to 221 ft. lbs (300 Nm) *** Torque to 22 ft. lbs. (30 Nm) **** Torque to 26 ft. lbs. (35 Nm) 1001140598 A 1.
  • Page 219 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 220 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 221 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 222: Slave Cylinder (E400Ajp/M400Ajp/E400Ajpn/M400Ajpn Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Slave Cylinder (E400AJP/M400AJP/E400AJPN/ 5. Using a spanner wrench, unscrew the cylinder head from the barrel. M400AJPN only) 6. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.
  • Page 223 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft. lbs. (70 Nm) ** Torque gland to 442 ft. lbs. (600 Nm) *** Torque to 7 ft. lbs. (10 Nm) **** Torque to 11 ft. lbs. (15 Nm) 1001140279 A 1.
  • Page 224 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 225 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 226 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. Install the new retain- diameter groove.

  • Page 227: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Jib Lift Cylinder 5. Using a spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY 6. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 228 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque to 52 ft. lbs. (70 Nm) ** Torque to 11 ft. lbs. (15 Nm) 1001140280 A 1. Barrel 6. Bushing 11. Retainer 16. O-ring 21. Piston Seal 2. Rod 7. Counterbalance Valve 12.
  • Page 229 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 230 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 231 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. Install the new retain- diameter groove.

  • Page 232: Lower Lift Cylinder (E400An Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lower Lift Cylinder (E400AN only) 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-46. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 233 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 234 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10** 6*** * Torque 100 in. lbs. (11 Nm) ** Torque 30-35 ft. lbs.(41-47 Nm) *** Torque 400 ft. lbs. (542 Nm) 1684453 D 1. Barrel 6. Locknut 10. Cartridge Valve 14. Piston Seal 18.
  • Page 235 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 16** 12*** * Torque 30-35 ft. lbs. (41-47 Nm) ** Torque 15 ft. lbs. (20 Nm) *** Torque 664 ft. lbs. (900 Nm) 1001228037-A MAE31570A 1. Barrel 5. Retainer 9. O-ring 13. Seal 17.
  • Page 236 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 237 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
  • Page 238 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 9. Thread piston onto rod until it abuts the spacer end. 14. With barrel clamped securely, and while adequately sup- porting the rod, insert the piston end into the barrel cyl- 10. Secure piston as mentioned below: inder.

  • Page 239: Lower Lift Cylinder (E400Ajp/M400Ajp/E400Ajpn/M400Ajpn Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lower Lift Cylinder (E400AJP/M400AJP/E400AJPN/ 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch M400AJPN only) for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-59. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 240 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 241 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque 100 in. lbs. (11 Nm) ** Torque 30-35 ft. lbs (41-47 Nm) *** Torque 400 ft. lbs. (542 Nm) 1684451 E 1. Barrel 5. Head 9. Cartridge Valve 13. O-ring 17.
  • Page 242 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 15*** 14** * Torque 30-35 ft. lbs. (41-47 Nm) ** Torque 398 ft. lbs. (539 Nm) *** Torque 11 ft. lbs. (15 Nm) 1001228035-B MAE31580B 1. Barrel 5. Wiper 9. Piston 13. Spacer 17.
  • Page 243 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 244 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
  • Page 245 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 12. Place new piston seal and wear rings in the outer piston 14. With barrel clamped securely, and while adequately sup- diameter groove. (A tube, with I.D. slightly larger than porting the rod, insert the piston end into the barrel cyl- the O.D.

  • Page 246: Mid Lift Cylinder(E400An Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Mid Lift Cylinder(E400AN only) 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-72. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 247 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 248 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10** 11** 6*** * Torque 100 in. lbs. (11 Nm) ** Torque 30-35 ft. lbs.(41-47 Nm) *** Torque 200 ft. lbs. (271 Nm) 1684454 B 1. Barrel 6. Locknut 10. Cartridge Valve 14.
  • Page 249 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque 30-35 ft. lbs. (41-47 Nm) 1001228038-A MAE31590A 1. Barrel 5. Retainer 9. O-ring 13. Seal 17. Cartridge Valve 21. Plug 2. Rod 6. Rod Seal 10. Backup Ring 14. O-ring 18.
  • Page 250 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 251 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
  • Page 252 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10. Install piston as mention below: 14. With barrel clamped securely, and while adequately sup- porting the rod, insert the piston end into the barrel cyl- a. Install the locknut and setscrew on the piston and inder.

  • Page 253: Mid Lift Cylinder (E400Ajp/M400Ajp/E400Ajpn/M400Ajpn Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Mid Lift Cylinder (E400AJP/M400AJP/E400AJPN/ 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch M400AJPN only) for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-85. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 254 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 255 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque 100 in. lbs. (11 Nm) ** Torque 30-35 ft. lbs (41-47 Nm) *** Torque 400 ft. lbs. (542 Nm) 1684452 D 1. Barrel 5. Head 9. Cartridge Valve 13. Wear Ring 17.
  • Page 256 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 17** 16*** 11 12 * Torque 30-35 ft. lbs. (41-47 Nm) ** Torque 105 ft. lbs. (142 Nm) *** Torque 574 ft. lbs. (778 Nm) 1001228036-C MAE31600C 1. Barrel 5. Wiper 9. Backup Ring 13.
  • Page 257 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 258 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
  • Page 259 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10. Install the locknut and setscrew on the piston and 14. With barrel clamped securely, and while adequately sup- attach the piston on the rod. porting the rod, insert the piston end into the barrel cyl- inder.

  • Page 260: Upper Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Upper Lift Cylinder 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch DISASSEMBLY for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-98. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 261 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 262 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque 100 in. lbs. (11 Nm) ** Torque 30-35 ft. lbs. (41-47 Nm) *** Torque 200 ft. lbs. (271 Nm) 1684061 G 1683945 G 1. Barrel 5. Head 9. Cartridge Valve 13.
  • Page 263 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10** 9*** * Torque 30-35 ft. lbs. (41-47 Nm) ** Torque 4 ft. lbs. (5 Nm) *** Torque 199 ft. lbs. (270 Nm) 1001228016-A MAE31620A 1. Barrel 5. Head 9. Nut 13. Cartridge Valve 17.
  • Page 264 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10*** 8**** * Torque 30-35 ft. lbs. (41-47 Nm) ** Torque 199 ft. lbs. (270 Nm) *** Torque 4 ft. lbs. (5 Nm) **** Torque 7 ft. lbs. (9 Nm) 1001228018-A MAE31630A 1.
  • Page 265 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 266 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install the new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
  • Page 267 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 10. Install the locknut and setscrew on the piston and 14. With barrel clamped securely, and while adequately sup- attach the piston on the rod. porting the rod, insert the piston end into the barrel cyl- inder.

  • Page 268: Master Cylinder (E400An Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder (E400AN only) 4. Using a spanner wrench, unscrew the cylinder head from the barrel. DISASSEMBLY 5. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, SURFACE IN A DIRT FREE WORK AREA.
  • Page 269 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque gland to 221 ft. lbs. (300 Nm) 1001140597 A 1. Barrel 5. Wear Ring 9. Spacer 13. Rod Wiper 2. Rod 6. Piston Seal 10. O-ring 14. O-ring 3. Head 7.
  • Page 270 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 271 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 272 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 273: Master Cylinder (E400Ajp/M400Ajp/E400Ajpn/M400Ajpn Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Master Cylinder (E400AJP/M400AJP/E400AJPN/ 4. Using a spanner wrench, unscrew the cylinder head from the barrel. M400AJPN only) 5. Attach a suitable pulling device to the cylinder rod end. DISASSEMBLY EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON.
  • Page 274 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque gland to 443 ft. lbs. (600 Nm) 1001140278 A 1. Barrel 5. Bushing 9. O-ring 13. O-ring 2. Rod 6. O-ring 10. Rod Seal 14. Wear Ring 3. Head 7. Retaining Ring 11.
  • Page 275 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 276 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 277 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Place new piston seal and wear rings in the outer piston cable cylinder head gland groove. Install a new retaining diameter groove.

  • Page 278: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Cylinder 4. Using a hook spanner, loosen and remove spanner nut from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1.
  • Page 279 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS * Torque rod to 200-250 ft. lbs. (271-339 Nm) 1683591 D 1. Wiper 6. Backup Ring 10. Tube 14. O-ring 2. Spanner Nut 7. O-ring 11. Piston 15. O-ring 3. Retaining Ring 8.
  • Page 280 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 281 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder guide gland groove. Install the new NOTE: Prior to cylinder assembly, ensure that the proper cylinder retaining ring into the applicable cylinder guide gland seal kit is used.
  • Page 282 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 12. Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, the O.D. of the piston is recommended to install the HEAD, AND PISTON.

  • Page 283: Telescope Cylinder (E400An Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder (E400AN only) 5. Mark cylinder head and barrel with a center punch for easy realignment. Unscrew the cylinder cap from the barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 284 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001151497 B 1. Barrel 6. Counterbalance Valve 11. Locknut 16. O-ring 21. Fitting 2. Rod 7. Bolt 12. Wear Ring 17. Backup Ring 22. Cap Fitting 3. Piston 8. Plug 13. Cap Seal 18.
  • Page 285 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 8. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as 1. Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 286 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTE: Install pin into the composite bearing dry. Lubrication is ASSEMBLY not required with nickel plated pins and bearings. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 287 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 11. Place new cap seal and wear rings in the outer piston cable cylinder head gland groove. diameter groove. (A tube, with I.D. slightly larger than the O.D.

  • Page 288: Telescope Cylinder (E400Ajp/M400Ajp/E400Ajpn/M400Ajpn Only)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Telescope Cylinder (E400AJP/M400AJP/E400AJPN/ 5. Remove cylinder head as mention below: a. Mark cylinder head and barrel with a center punch M400AJPN only) for easy realignment. Unscrew the cylinder cap from the barrel. Refer Figure 5-149. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 289 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 7. With the barrel clamped securely, apply pressure to the 8. Using suitable protection, clamp the cylinder rod in a rod pulling device and carefully withdraw the complete vise or similar holding fixture as close to the piston as rod assembly from the cylinder barrel.
  • Page 290 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1683911 D 1. Barrel 7. Bolt 13. Cap Seal 18. Wiper Seal 23. Fitting 2. Rod 8. Plug 14. O-ring 19. Fitting 24. Fitting 3. Piston 9. Setscrew 15. Wear Ring 20. Fitting 25.
  • Page 291 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 11** *Torque 30-35 ft. lbs. (41-48 Nm) **Torque 225 ft. lbs. (305 Nm) 1001228015-A MAE32000A 1. Barrel 5. Spacer 9. Setscrew 13. Cap Seal 17. Backup Ring 21. Fitting 25. Bolt 2. Rod 6.
  • Page 292 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS CLEANING AND INSPECTION NOTE: Install pin into the composite bearing dry. Lubrication is not required with nickel plated pins and bearings. 1. Clean all parts thoroughly in an approved cleaning sol- vent. 2.
  • Page 293 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 294 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 11. Place new cap seal and wear rings in the outer piston 13. With barrel clamped securely, and while adequately sup- diameter groove. (A tube, with I.D. slightly larger than porting the rod, insert the piston end into the barrel cyl- the O.D.
  • Page 295 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-157. Components Boom 5-132 3121717...

  • Page 296: Cylinder Removal And Installation

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

  • Page 297: Mid Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Mid Boom Lift Cylinder Removal Mid Boom Lift Cylinder Installation NOTE: The Upright weighs approximately 92 lbs. (42kg) and Main NOTE: Coat I.D. of bushings with specified lubricant prior to Boom weighs approximately 450lbs. (204kg). installing pins.

  • Page 298: Lower Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Lower Boom Lift Cylinder Removal Lower Boom Lift Cylinder Installation NOTE: The Lower Lift Cylinder weighs approximately NOTE: Coat I.D. of bushings with specified lubricant prior to 130lbs. (59kg). installing pins. 1. Place machine on flat and level surface. Place the Main NOTE: The Lower Lift Cylinder weighs approximately Boom in a horizontal position.

  • Page 299: Main Boom Telescope Cylinder Removal

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Removal 10. Using another lifting device, support the rod end of the cylinder and remove the cylinder from the boom assem- bly. 1. Place machine on flat and level surface, with Main Boom in the horizontal position.

  • Page 300: Pressure Setting Procedures

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 5.5 MID AND LOWER LIFT CYLINDER BLEEDING 5.6 PRESSURE SETTING PROCEDURES PROCEDURE NOTE: Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the NOTE: Bleeding procedure should only be necessary if rebuilding machine until hydraulic system has warmed to normal or replacing lift cylinder.

  • Page 301: Platform Level Up Relief

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Platform Level Up Relief Platform Level Down Relief 1. Install the pressure gauge at the "B2" port on the back of 1. Install the pressure gauge at the "B1" port on the back of the Main Control Valve, activate and bottom out Plat- the Main Control Valve, activate and bottom out Plat- form Level Up.

  • Page 302: Steer Relief

    SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Steer Relief 4. Adjust the releveling pressure relief to the value given in Figure 5-167., Main Valve Pressure Adjustment. Turning 1. With pressure gauge at “G” port on steer/brake valve, clockwise increases the pressure and turning counter- activate and bottom out Steer Left or Right.
  • Page 303 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS JIB VALVE RELEVELING VALVE MAIN CONTROL VALVE HYBRID JIB VALAVE STEER VALVE MAE32480 Figure 5-163. Hydraulic Component Location 5-140 3121717...
  • Page 304 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS STEER RELIEF Figure 5-164. Steer Valve Pressure Adjustment 3121717 5-141...
  • Page 305 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS STEER RELIEF Figure 5-165. Steer Valve Component 5-142 3121717...
  • Page 306 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2, B 1, A 1001177364-G MAE32360G Table 5-34. Coil Torque Values Table 5-33. Cartridge Torque Values Ft. Lbs. Ft. Lbs. 35-40 47-54 10-12 13-16 25-30 34-41 Figure 5-166. Steer Valve Torque Specification 3121717 5-143...
  • Page 307 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS RELEVELING VALVE RELEVELING RELIEF ADJUST TO 2200 psi (151.7 Bar) UPPER LIFT DOWN RELIEF ADJUST TO 800 psi (55.15 Bar) LOWER LIFT DOWN RELIEF ADJUST TO 2600 psi (179.26 Bar) TELESCOPE RELIEF ADJUST TO 3000 psi (206.84 Bar) PLATFORM LEVEL RELIEF...
  • Page 308 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 5-168. Main Valve Components 3121717 5-145...
  • Page 309 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 2, A 1, B 1, B 1, C 1, A 1, A 2, A 1001180554-F 1, B MAE32320F Table 5-36. Coil Torque Values Table 5-35. Cartridge Torque Values Ft. Lbs. Ft. Lbs. 10-12 13-16 7-10...
  • Page 310 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001097777-B MAE32330B Table 5-37. Cartridge Torque Values Ft. Lbs. Figure 5-170. Releveling Valve Torque Specification 3121717 5-147...
  • Page 311 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1, A 1001097505-C MAE32340C Table 5-38. Cartridge Torque Values Table 5-39. Coil Torque Values Ft. Lbs. Ft. Lbs. Figure 5-171. Jib Valve Torque Specification (SN 0300208530 through 0300233432) 5-148 3121717...
  • Page 312 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001216921-B MAE32350B Table 5-40. Cartridge Torque Values Ft. Lbs. Figure 5-172. Jib Valve Torque Specification (SN 0300233433 to Present) 3121717 5-149...
  • Page 313 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 314 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT LOWER LIFT LOWER LIFT DOWN...
  • Page 315 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY JIB VALVE ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 316 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS JIB CYL BORE 2.5" 4.908 SO IN.= ROD 1.5" 1.77 SQ IN. ANNULUS 3.14 STROKE 22.842" RATIO 1.5 : 1 MAIN VALVE ASSY JIB VALVE E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75"...
  • Page 317 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 318 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SIDE SWING MAIN VALVE ASSY E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN JIB VALVE ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5"...
  • Page 319 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS COMPONENT LIST 1. PROPORTIONAL FLOW REGULATOR, PRESSURE COMPENSATED, PV70-3001B-0-N-12DW 2. 2-POS, 2-WAY POPPET VALVE, NORMALLY OPEN, SV08-21-0-N-12DW (BYPASS UNLOADING) 3. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (LOWER LIFT) 4. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (UPPER LIFT) 5.
  • Page 320 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 5-157...
  • Page 321 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 322 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5" 1.76 SQ IN ANNULUS 5.305 SQ IN UPPER LIFT LOWER LIFT LOWER LIFT DOWN...
  • Page 323 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR JIB VALVE .015 .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 324 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS JIB CYL BORE 2.5" 4.908 SO IN.= ROD 1.5" 1.77 SQ IN. ANNULUS 3.14 STROKE 22.842" RATIO 1.5 : 1 MAIN VALVE ASSY JIB VALVE E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.75"...
  • Page 325 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS E450A, E400A NARROW PLATFORM SLAVE CYL BORE: 2" 3.14 SQ IN ROD 1" .785 SQ IN ANNULUS 2.35 SQ IN ROTATOR MAIN VALVE ASSY ROTATOR .015 JIB VALVE .015 UPPER LIFT E450A, E400A NARROW MASTER CYLINDER BORE: 2"...
  • Page 326 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SIDE SWING MAIN VALVE ASSY E400A NARROW UPPER LIFT CYL BORE:3" 7.065 SQ IN JIB VALVE ROD 1.75" 2.405 SQ IN ANNULUS 4.660 SQ IN E450A UPPER LIFT CYL BORE:3" 7.065 SQ IN ROD 1.5"...
  • Page 327 SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS COMPONENT LIST 1. PROPORTIONAL FLOW REGULATOR, PRESSURE COMPENSATED, PV70-3001B-0-N-12DW 2. 2-POS, 2-WAY POPPET VALVE, NORMALLY OPEN, SV08-21-0-N-12DW (BYPASS UNLOADING) 3. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (LOWER LIFT) 4. 3-POS, 4-WAY VALVE, SV10-4722E-0-N-12DW, (UPPER LIFT) 5.
  • Page 328 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 329: Jlg Control System

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

  • Page 330: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer The top level menus are as follows: HELP Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the DIAGNOSTICS platform box or at the power module and connect the SYSTEM TEST...

  • Page 331: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: Press ENTER to select the ACCESS LEVEL menu. DRIVE BOOM Using the UP or DOWN arrow keys, enter the first SYSTEM digit of the password, 3.

  • Page 332: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer Once you have gained access to level 1, and a personality item When a machine digit item is selected, press the UP is selected, press the UP or DOWN arrow keys to DOWN...

  • Page 333: Level Vehicle Description

    SECTION 6 - JLG CONTROL SYSTEM There is a setting that JLG strongly recommends that you do Table 6-1. Analyzer Abbreviations not change. This setting is so noted below: ABBREVIATION MEANING ELEVATION CUTBACK ACCEL ACCELERATE ACTIVE ANALOG DIGITAL CONVERTER COUNT CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
  • Page 334 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND SHORT CIRCUIT GREEN SELECTOR GROUND MODULE SERIAL NUMBER HOURS SPEED HARDWARE STOW STOWED HWFS HARDWARE FAILSAFE STOWD STOWED IN or CURRENT SWITCH or SOFTWARE JOYSTICK TELE...
  • Page 335 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 336 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number TILT: 5 DEGREES+CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also disallows the tower lift up, drive, telescope ANSI USA, out and lift up.
  • Page 337 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number LOAD SYSTEM: NO: No load sensor installed. * Only visible under certain WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps(5 sec ON, 2 sec OFF). market selections.
  • Page 338 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number CHARGER INTERLOCK: DRIVE ONLY: Drive function is disabled when battery charger is plugged in. CUTOUT ALL: Drive and bottom function is disabled when battery charger is plugged in. PLAT LVL OVR CUT: NO: Platform level functions above elevation.
  • Page 339 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings E400 E400 Display Units Model Number Market Alert Beacon Batteries Temp Cutout Wheel Drive Tilt Charger Interlock Plat Lvl Ovr Cut Ground Alarm BOLD TEXT indicates the default setting.
  • Page 340 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Settings Table 6-4. Machine Configuration Programming Settings E400n E400n Display Units Model Number Market Alert Beacon Batteries Temp Cutout Wheel Drive Tilt Charger Interlock Plat Lvl Ovr Cut Ground Alarm BOLD TEXT indicates the default setting.

  • Page 341: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Function Speed Table 6-5. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5s to 5.0s 2.0s DECELeration 0.3s to 5.0s...
  • Page 342 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS BOOM LIFT ACCELeration 0.1 to 5.0s 2.5s DECELeration 0.1 to 5.0s 2.5s MINimum UP speed 1 to 15% MAXimum UP speed 36 to 80% CREEP maximum UP speed 16 to 35% MINimum DOWN speed 1 to 15%...
  • Page 343 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS CREEP maximum DOWN speed 16 to 35% JIB SWING ACCELeration 0.1 to 5.0s 2.0s DECELeration 0.1 to 5.0s 1.0s MlNimum LEFT speed 1 to 15% MAXimum LEFT speed 41 to 75% CREEP Maximum LEFT speed 16 to 40%...
  • Page 344 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS Telescope OUT 61 to 100% Jib UP 41 to 80% Jib DOWN 41 to 80% Jib SWING 41 to 75% Platform LEVEL 36 to 80% Platform ROTATE 25 to 50% ALARM/HORN Volume HORN...
  • Page 345 SECTION 6 - JLG CONTROL SYSTEM ANAL YZER MENU STRUCTURE HELP : (001) MENU : HELP : PRESS ENTER SYSTEM OK LOG : *(XXXXX) X : XXXXXXXXXXXXXX DIAGNOSTICS : MENU : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS DRIVE/STEER BOOM FUNCTIONS SYSTEM...
  • Page 346 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : TRACTION VOLTAGE/CUR OPER CONTROLS OPTIONS PLATFORM LOAD SYSTEM INPUTS CAN STATISTICS RIGHT MOTOR BATTERY SOC JOYSTICK DRIVE H&T LIGHTS SW PLATFORM LOAD XXXHz XXX%...
  • Page 347 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : CAN STATISTICS DEBUG UGM I/O CALIBRATION DATA DATALOG VERSIONS PLATFORM LOAD CAN1 STATISTICS DEBUG DIAG UGM TILT X DATALOG TIME DATALOG CYCLES RX/SEC: XXXXX DIGITAL INPUTS XXXX COUNTS...
  • Page 348 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : OPERATOR ACCESS MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES DRIVE STEER SWING TOWER LIFT LIFT TELESCOPE DRIVE MAX SPEED STEER SWING TOWER LIFT LIFT TELESCOPE ACCEL X.X SEC...
  • Page 349 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : PERSONALITIES MENU: MODEL MARKET BATTERIES TILT GROUND ALARM MACHINE SETUP E400 ANSI USA 310AH FLOOD 5 DEGREES JIB SWING SKYGUARD SOFTTOUCH H & T LIGHTS LOAD SYSTEM FUNCTION CUTOUT DISPLAY UNITS ALERT BEACON TEMP CUTOUT IMPERIAL...
  • Page 350 SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN PERFORMING Main lift: Main Lift in stowed position Tower Lift in stowed position, Telescope Retracted. Main Lift Up, record time. Main TEST Lift Down, record time. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode;...

  • Page 351: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM Test Notes 6.4 FUNCTION SPEED Table 6-6. Function Speeds Stop watch should be started with the function move- ment, not with actuation of joystick and switch. Function Speed (In Seconds) Drive speeds should be set to the values below regard- Main Lift Up 24-30 less of the tire size.
  • Page 352 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONTROL MODULE Figure 6-7. Control Module Location - Sheet 1 of 2 6-24 3121717...
  • Page 353 SECTION 6 - JLG CONTROL SYSTEM GENERATOR CONTROL MODULE GROUND CONTROL MODULE Figure 6-8. Control Module Location - Sheet 2 of 2 3121717 6-25...
  • Page 354 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-9. Analyzer Connecting Points 6-26 3121717...
  • Page 355 SECTION 6 - JLG CONTROL SYSTEM 1001192212 D Figure 6-10. Power Module - LH 3121717 6-27...
  • Page 356 SECTION 6 - JLG CONTROL SYSTEM 1001178339 E Figure 6-11. Power Module - RH 6-28 3121717...
  • Page 357 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type UNUSED DIGITAL OUTPUT ALERT BEACON POWER DIGITAL OUTPUT UNUSED DIGITAL OUTPUT ALERT BEACON GROUND GROUND INPUT UNUSED GROUND INPUT UNUSED DIGITAL OUTPUT UNUSED DIGITAL OUTPUT UNUSED (GROUND) GROUND INPUT UNUSED (GROUND) GROUND INPUT UNUSED...
  • Page 358 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type PLATFORM EMS DIGITAL INPUT PLATFORM MODE DIGITAL INPUT GROUND MODE DIGITAL INPUT UPPER BOOM ELEVATION SWITCH ANALOG INPUT UNUSED VOLTAGE OUTPUT CAN1 TERMINATOR TERM LOWER BOOM ELEVATION SWITCH ANALOG INPUT UNUSED ANALOG INPUT UNUSED (GROUND)
  • Page 359 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type MODULE GROUND / GROUND FROM BATTERY GROUND OUTPUT MODULE POWER / GROUND EMS VBAT INPUT (Black) GROUND TO PLATFORM MODULE GROUND INPUT POWER TO PLATFORM MODULE / GROUND EMS OUT TO PLATFORM VBAT OUTPUT Connector...
  • Page 360 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION UNALLOCATED (JIB RT) DIGITAL INPUT UNALLOCATED (JIB LT) DIGITAL INPUT UNUSED (BATTERY VOLTAGE) BATTERY VOLTAGE DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT UNALLOCATED (BASKET STOW SWITCH) DIGITAL INPUT CHASSIS TILTED INDICATOR LAMP OUTPUT FUNCTION ENABLE INDICATOR LAMP OUTPUT...
  • Page 361 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION LIFT / SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE LIFT CENTER TAP ANALOG INPUT LIFT SIGNAL ANALOG INPUT SWING SIGNAL ANALOG INPUT NATURAL SWING CENTER TAP ANALOG INPUT UNUSED ANALOG INPUT LIFT / SWING JOYSTICK RETURN GROUND UNUSED GROUND...

  • Page 362: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Machine Setup Descriptions Help Descriptions and Fault Flash Codes MODEL NUMBER... Displays/adjusts machine model NOTE: all Table 6-8. JLG Control System Flash Codes personalities reset to default when model number is altered Code Description TILT...
  • Page 363 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. 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 364 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. 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 365 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. 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 simultane- ous drive &...
  • Page 366 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Help Descriptions and Fault Flash Codes Flash code 4/2 indicates that the controller is over temperature. CONTROLLER TOO HOT - PLEASE WAIT The controller heatsink temperature reached 75 degrees. The controller is shut down until it cools to below 70 degrees.
  • Page 367 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Help Descriptions and Fault Flash Codes Flash code 7/7 indicates problems with a motor. CAPACITOR BANK FAULT - CHECK POWER CIRCUITS The capacitor bank is not charging. This is probably due to a power wiring error causing illegal current drain; it could also be due to a very low battery supply.
  • Page 368 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. 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 perma- nently tripped.

  • Page 369: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure arrow keys move between items in the same level. The In the following structure descriptions, an intended item is or DOWN arrow keys alter a value if allowed. z selected by pressing ENTER ;...
  • Page 370 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLAT LVL DEMAND UP/DOWN XXX%/CREEP Direction and percentage of input command (or CREEP if applicable) from Function Speed Pot or Ground% PLAT LVL OUTPUT UP/DOWN XXX%...
  • Page 371 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) SYSTEM INPUTS BOOM ELEV SW OPEN/CLOSED State of Boom Elevation Switch #1 TOWER ELEV SW OPEN/CLOSED State of Boom Elevation Switch #2...
  • Page 372 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) VOLTAGE/CUR BATTERY SOC XXX%/DISCHARGED/DEEP DISCHARGED UGM calculated battery State-of-Charge; display percentage unless Discharged or Deeply Discharged BATTERY VOLTAGE XX.XXV...
  • Page 373 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) JIB LIFT UP SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input [MACHINE SETUP ' Jib = YES] JIB LIFT DN SW OPEN/CLOSED...
  • Page 374 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. DIAGNOSTICS - Menu Descriptions Diagnostics Submenu Parameter Parameter Value (Displayed on Analyzer (Displayed on (Displayed on Description Line) Analyzer 1 Line) Analyzer 2 Line) PLATFORM LOAD PLATFORM LOAD STATE: OK/OVER LOAD LSS Status (DISPLAY ONLY IF MACHINE PLATFORM LOAD ACTUAL: XXX.XKG...

  • Page 375: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM System Self Test operator to close the lower lift up switch. When the con- troller sees that the lower lift up switch has been closed, The system self test is utilized to locate typical problems. See it will move on to the next input, lower lift down LLD.
  • Page 376 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run while running certain “critical” checks are made. CHECK GROUND/ PLATFORM SELECT The analyzer must be connected to the active control station to run the system test CHECK CAN WIRING The system test cannot run unless the CAN Bus is operating properly BATTERY VOLTAGE TOO LOW...
  • Page 377 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer PLATFORM RT VALVE SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay) PLATFORM LEVEL UP SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay) PLATFORM LEVEL DOWN SHORT TO BATTERY or OPEN-CIRCUIT or SHORT TO GROUND (or advance test after short delay)
  • Page 378 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP TELE IN OPEN or CLOSED (advanced test after switch toggles) CL TELE OUT OPEN or CLOSED (advanced test after switch toggles) OP TELE OUT OPEN or CLOSED (advanced test after switch toggles) CL DRIVE ORIENT...
  • Page 379 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer OP JIB DOWN OPEN or CLOSED (advanced test after switch toggles) CL JIB SWING LEFT OPEN or CLOSED (advanced test after switch toggles) OP JIB SWING LEFT OPEN or CLOSED (advanced test after switch toggles) CL JIB SWING RIGHT...

  • Page 380: Calibrating Steer

    SECTION 6 - JLG CONTROL SYSTEM 6.5 CALIBRATING STEER 8. Use the arrow keys to reach STEER SENSOR. The screen will read: When calibrating steering, each individual wheel must be cali- brated in order to make the tire and wheel parallel with the frame.
  • Page 381 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 14. Hit Enter. The screen will read: 15. The display will read Left Steer Maximum value. 11. Activate the steer control until the tire and wheel are straight in relationship with the chassis, then leave off 16.

  • Page 382: Calibrating Tilt Sensor

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

  • Page 383: Calibrating Load Sensing

    SECTION 6 - JLG CONTROL SYSTEM 12. When prompted, swing turntable 180° to opposite end 6.7 CALIBRATING LOAD SENSING of chassis. NOTE: Calibration sub-menu LOAD SENSING is visible only if MACHINE SET-UP sub-menu LOAD SYSTEM is selected to 1. Position the Platform/Ground select switch to the Plat- form position.
  • Page 384 SECTION 6 - JLG CONTROL SYSTEM 8. Use the arrow keys to reach LOAD SENSING. The screen 10. Hit Enter. The screen will read: will read: 11. Hit Enter. The screen will read: 9. Hit Enter. The screen will read: 6-56 3121717...
  • Page 385 SECTION 6 - JLG CONTROL SYSTEM 12. Hit Enter. The screen will read: 14. Hit Enter. The screen will read: 13. Hit Enter. The screen will read: 15. After few seconds, the screen will read: 16. Hit ESC twice to go back to CALIBRATIONS. 3121717 6-57...

  • Page 386: Lss System

    SECTION 6 - JLG CONTROL SYSTEM 6.8 LSS SYSTEM The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR: ture.

  • Page 387: Diagnostic Menu

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

  • Page 388: Calibration Procedure

    SECTION 6 - JLG CONTROL SYSTEM Calibration Procedure 5. Press the ENTER key to view the menu. Upon entry 1. Remove everything from the platform, except perma- to the Calibration Menu, the JLG Control System will link nently fixed JLG Accessories, to allow the Load Sensing to the Analyzer and the screen will read: System to record its’...
  • Page 389 SECTION 6 - JLG CONTROL SYSTEM NOTE: Accessory weight will reset to 0 lbs. each time the machine is re-calibrated and will need to be re-entered. NOTE: Pressing the ESC key after starting calibration and before calibration is complete will display the CAL FAILED NOTE: The Accessory weight will be temporarily stored in the Con- message.
  • Page 390 SECTION 6 - JLG CONTROL SYSTEM 9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg).
  • Page 391 SECTION 6 - JLG CONTROL SYSTEM 12. Use the analyzer keys to select N for no or Y for yes. Press Table 6-16. Pipe Rack Capacity Reductions PLATFORM OVRLD ENTER . The control system will default to an esti- Capacity PLATFORM OVRLD RESTRICT mate of unrestricted capacity, which can be adjusted if...
  • Page 392 SECTION 6 - JLG CONTROL SYSTEM 14. Press ENTER . If calibration is successful, the screen will read: 6-64 3121717...

  • Page 393: Testing & Evaluation

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

  • Page 394: Troubleshooting

    SECTION 6 - JLG CONTROL SYSTEM Troubleshooting The following tables are furnished to provide possible resolu- tions for common difficulties. Difficulties are classified as Gen- eral, Calibration, Measurement Performance, and Host System Functionality. Table 6-17. LSS Troubleshooting Chart Difficulty Possible Resolution Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.

  • Page 395: Resetting The Msso System

    SECTION 6 - JLG CONTROL SYSTEM 6.9 RESETTING THE MSSO SYSTEM 9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read: 1. Use the following procedure to reset the MSSO system. 2. Position the Platform/Ground select switch to the desired position.
  • Page 396 SECTION 6 - JLG CONTROL SYSTEM 12. Press Enter . The screen will read: 13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu. 6-68 3121717...
  • Page 397 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution EVERYTHING OK The UGM determines that platform station (EVERYT- Occurrence of active DTC ING OK) OR ground station (GROUND MODE OK) is selected and no system faults exist, including Power Module check;...
  • Page 398 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution TORQUE CUTBACK - EXCESSIVE TILT UGM detects that the machine is ascending an incli- The UGM detects that the grade in direction of nation of greater than or equal to: travel is more than 3 degrees less than the 19 degrees for a period of greater than 1 second.
  • Page 399 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution L/S JOY. CENTER TAP BAD The PM detects that the Lift or Swing center tap volt- The PM detects that the lift/swing center tap age is not between 3.31 volts and 3.75 volts and voltage is between 3.31 and 3.75 volts and no reports the fault to the UGM...
  • Page 400 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution FUNCTION PROBLEM - SOFT TOUCH / SKYGUARD [(MACHINE SETUPSKYGUARD = YES) or (MACHINE The Soft Touch / SkyGuard Override switch OVERRIDE PERMANENTLY SELECTED SETUP...
  • Page 401 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution AMBIENT TEMPERATURE SENSOR - OUT OF System is in platform mode; Ambient Temperature sensor reading > -50 °C ; RANGE HIGH MACHINE SETUP ->...
  • Page 402 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution FUNCTION PREVENTED – TILTED & ABOVE ELE- Machine is in Platform mode At least one of the trigger conditions is not met; VATION Machine is Above Elevation and Tilted then non-Creep function speed permitted after...
  • Page 403 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution PLATFORM LEVEL DOWN VALVE - SHORT TO The UGM detects a short to ground at the platform Power cycle GROUND level down output PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT The UGM detects an open circuit at the platform level...
  • Page 404 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution SWING LEFT VALVE - SHORT TO GROUND The UGM detects a short to ground at the Swing Left Power cycle output TELESCOPE OUT VALVE - SHORT TO BATTERY The UGM detects a short to 12V battery at this output...
  • Page 405 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution STEER PRIORITY BYPASS VALVE - OPEN CIRCUIT The UGM detects an OC at steer priority bypass output UGM no longer detects OC; Speed restriction removed after CntIni.
  • Page 406 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution LSS BATTERY VOLTAGE TOO HIGH MACHINE SETUP -> LOAD SYSTEM ≠ NO; The UGM Not all of the trigger conditions are met; determines that LSS error bit is set for supply voltage motion restrictions removed after controls ini- too high (>...
  • Page 407 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT BRAKE SUPPLY VOLTAGE – OUT OF Associated Power Module determines that a low park- Power cycle RANGE LOW ing brake supply voltage condition exists.
  • Page 408 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT MOTOR STALLED The UGM or Power Module(s) detects that the motor is UGM and Left Power Module shall clear the stalled during active traction.
  • Page 409 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR RIGHT MOTOR - OPEN CIRCUIT When motor output is active, the Power Module Power cycle detects that a motor phase is disconnected/open dur- ing active traction CHASSIS TILT SENSOR NOT CALIBRATED UGM determines that tilt sensor,...
  • Page 410 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution STEER SENSOR - DECOUPLED The UGM observes the Master Traction Module UGM determines steer angle within allowed reported steer raw voltage 0.3V < signal < 0.5V (Con- range;...
  • Page 411 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution GROUND MODULE CONSTANT DATA UPDATE The UGM detects one of the following conditions A different application code or constant data REQUIRED when software type is ‘P’...
  • Page 412 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR LEFT MODULE - RAM FAILURE Applicable Power Module determines that a RAM Power cycle checksum error has occurred REAR LEFT MODULE - INTERNAL ERROR Applicable Power Module determines at Startup that Power cycle the current gain is incorrect and may cause incorrect...
  • Page 413 SECTION 6 - JLG CONTROL SYSTEM Table 6-18. Diagnostic Trouble Codes DTC Cat DTC Num DTC Text Fault Description Solution REAR RIGHT MODULE - INTERNAL ERROR Applicable Power Module determines at Startup that Power cycle there is a problem with overvoltage/undervoltage detection REAR RIGHT MODULE - CAPACITOR BANK FAULT The power capacitor bank of the Power Module is not...
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  • Page 415: Basic Electrical Information & Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERAL Polarity Getting a negative Voltage or current reading when expecting This section contains basic electrical information and sche- a positive reading frequently means the leads are reversed. matics to be used for locating and correcting most of the oper- Check what reading is expected, the location of the signal and ating problems which may develop.

  • Page 416: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement Figure 7-2. Resistance Measurement • Some meters require a separate button press to enable • First test meter and leads by touching leads together. audible continuity testing.

  • Page 417: Current Measurement

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

  • Page 418: Automatic Switches

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

  • Page 419: Installation Of Dielectric Grease

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS When applied to electrical connections, dielectric grease helps Deutsch HD, DT, DTM, DRC Series to prevent corrosion of electrical contacts and improper con- The Deutsch connector system is commonly used for harsh ductivity between contacts from moisture intrusion.

  • Page 420: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AMP Mate-N-Lok This connector system is widely used inside enclosures for general-purpose interconnect. Follow the installation instruc- tions. Figure 7-6. Use of Seal Plugs DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions.
  • Page 421 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity. and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric mistakenly applied to this connector system, the low-force grease and create electrical contact.

  • Page 422: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as-shipped, Applying Silicone Dielectric Compound to AMP position (See Figure 7-7.). Proceed as follows: Connectors Silicone Dielectric Compound must be used on the AMP con- nections for the following reasons: •...
  • Page 423 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 424: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 6.
  • Page 425 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13. Connector Installation 3121717 7-11...

  • Page 426: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 5. Remove wedgelock using needle nose pliers or a hook 1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 427: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp 11. With rear insert toward you, snap appropriate size barrel.

  • Page 428: Wiring Harness Connector Labels

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.7 WIRING HARNESS CONNECTOR LABELS Table 7-1. Wiring Harness Connector Labels Connector Labels Components Category Label Connectors between harnesses are identified by the prefix "X" Audible Alarms and a sequentially assigned number. An optional suffix (letters Horns &...
  • Page 429 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Table 7-1. Wiring Harness Connector Labels Components Category Label Other Switches Disconnect Foot HVAC Park brake Pump pot Push Shifter Turn signal Relay 5 Pin 4 Pin Contactor Power module Rocker Switch Sensor Angle Fuel...
  • Page 430 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-16 3121717...
  • Page 431 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21. Platform Console Harness - Sheet 2 of 4 3121717 7-17...
  • Page 432 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Platform Console Harness - Sheet 3 of 4 7-18 3121717...
  • Page 433 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-23. Platform Console Harness - Sheet 4 of 4 3121717 7-19...
  • Page 434 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-20 3121717...
  • Page 435 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 7-21...
  • Page 436 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-22 3121717...
  • Page 437 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS T391 Figure 7-26. Load Sensing System Harness - Sheet 2 of 2 3121717 7-23...
  • Page 438 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-24 3121717...
  • Page 439 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Main Valve Harness - Sheet 2 of 3 3121717 7-25...
  • Page 440 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-29. Main Valve Harness - Sheet 3 of 3 7-26 3121717...
  • Page 441 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 7-27...
  • Page 442 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-28 3121717...
  • Page 443 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-31. Turntable Harness - Sheet 2 of 3 3121717 7-29...
  • Page 444 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Turntable Harness - Sheet 3 of 3 7-30 3121717...
  • Page 445 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 7-31...
  • Page 446 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-32 3121717...
  • Page 447 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34. Ground Control Panel Harness - Sheet 2 of 3 3121717 7-33...
  • Page 448 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-35. Ground Control Panel Harness - Sheet 3 of 3 7-34 3121717...
  • Page 449 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 7-35...
  • Page 450 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-36 3121717...
  • Page 451 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-37. Chassis Traction Harness - Sheet 2 of 4 3121717 7-37...
  • Page 452 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-38. Chassis Traction Harness - Sheet 3 of 4 7-38 3121717...
  • Page 453 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-39. Chassis Traction Harness - Sheet 4 of 4 3121717 7-39...
  • Page 454 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-40 3121717...
  • Page 455 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This Page Left Blank Intentionally 3121717 7-41...
  • Page 456 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-42 3121717...
  • Page 457 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-42. Chassis Steer/Brake Harness - Sheet 2 of 2 3121717 7-43...
  • Page 458 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-44 3121717...
  • Page 459 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-44. Chassis Head /Tail Light Harness - Sheet 2 of 2 3121717 7-45...
  • Page 460 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-46 3121717...
  • Page 461 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121717 7-47...
  • Page 462 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-48 3121717...
  • Page 463 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X617 Figure 7-48. Generator IGN Harness - Sheet 2 of 2 3121717 7-49...
  • Page 464 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-50 3121717...
  • Page 465 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X506 Figure 7-50. SkyGuard Harness Sheet - 2 of 2 3121717 7-51...
  • Page 466 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-52 3121717...
  • Page 467 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X7B-12 Figure 7-52. Soft Touch Harness - Sheet 2 of 2 3121717 7-53...
  • Page 468 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-54 3121717...
  • Page 469 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. Figure 7-54. Console Harness with SkyGuard and 1 Cell LSS - Sheet 2 of 4 3121717 7-55...
  • Page 470 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-55. Console Harness with SkyGuard and 1 Cell LSS - Sheet 3 of 4 7-56 3121717...
  • Page 471 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-56. Console Harness with SkyGuard and 1 Cell LSS - Sheet 4 of 4 3121717 7-57...
  • Page 472 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-58 3121717...
  • Page 473 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS SHEET 2: PLATFORM CONSOLE CONSOLE HARNESS PLATFORM BEACON SHEET 3: PLATFORM AND BOOM COMPONENTS SHEET 4: TURNTABLE, AND UGM WIRING MAIN VALVE HARNESS TURNTABLE HARNESS SHEET 5: GROUND CONTROL WIRING GROUND PANEL HARNESS SHEET 6: CHASSIS WIRING TRACTION HARNESS...
  • Page 474 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW305 WHT 120-1 TORQUE/SPEED MODE YEL 5-14-1 WHT 120-2 AWDA MAN SW06 YEL 5-14-1 WHT 29-0 TWR LFT UP WHT 29-30 TWR LFT DN YEL 5-14-2 SW09 WHT 13-0 MAIN TELE IN YEL 5-14-2 WHT 14-0 MAIN TELE OUT YEL 5-14-3...
  • Page 475 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS WHT 124-2 SKYG INPUT#2 WHT 124-5 SOFTT YEL 3-8 PLAT IGN 12AWG BLK 1-5 PLAT GND 12AWG WHT 1-551 JUMPER 15 POS WHT 131-1 FOOT SWITCH WHT 3-16 FOOTSWITCH MATE-N-LOK GRN 131-2 FOOT PEDAL FC-7 S830 BLK 14AWG...
  • Page 476 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS LSS MODULE (OPTIONAL) *LOCATED UNDER CONSOLE BOX* GENERIC FOOT SWITCH TO SHEET 2 15 POS MATE-N-LOK IN CONSOLE T394 WHT 1-28 LSS GND T395 WHT 3-20 LSS PWR TO SHEET 2 T391 15 POS YEL TP CAN CABLE MATE-N-LOK...
  • Page 477 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS X50A RED 12AWG BLK 12AWG SHIELD BLK 18AWG RED 18AWG TO TURNTABLE BLU 18AWG HARNESS ORG 18AWG YEL 18AWG TO SHEET 4 BRN 18AWG BLU/BLK 18AWG BLK/WHT 12AWG ORG 12AWG YEL/BLK 18AWG RED/BLK 18AWG ORN/BLK 18AWG ALL WIRES ARE 18AWG UNLESS OTHERWISE NOTED...
  • Page 478 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ANALYZER PORT HV13 BLK 4-13-2 RTN WHT 13-0-3 TELE IN BLK 4-13 RTN HV14 BLK 4-13-1 RTN WHT 14-0-3 TELE OUT HV21 WHT 38-5-1 CURNT FBACK BLK 300-2 ALERT GND WHT 21-0-1 SWG LFT WHT 300-1 ALERT PWR HV22 WHT 38-5-2 CURNT FBACK...
  • Page 479 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS TO MDI Sheet_5-[2,D] Sheet_5-[2,D] MS423-3 YEL CAN1 HI GRN CAN1 LO MS423-2 YEL CAN1 HI GRN CAN1 LO MS423-1 X4-A GRN CAN1 LO YEL CAN1 HI BLK 4-0-1 INSTR GND 12GXL YEL 5-10-1-1 SWITCHED PWR 12GXL WHT 8-3 GENSET ENABLE SW Sheet_8-[6,G] BLK PLAT GND 12GXL...
  • Page 480 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GENSET LED LT START PLATFORM ROTATE PLATFORM LEVEL SIDESWING JIB LIFT MAIN LIFT TOWER LIFT CO66-J4 WHT 26-0-1 PLAT LVL DN WHT 25-0-1 PLAT LVL UP WHT 23-0-1 PLAT ROT LFT WHT 24-0-1 PLAT ROT RHT WHT 27-0-1 JIB UP WHT 28-0-1 JIB DN WHT 32-0-1 SIDE SWG LFT...
  • Page 481 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SIDESWING JIB LIFT MAIN LIFT TOWER LIFT SWING TELESCOPE ENABLE GD139 WHT METER PWR BLK METER GND GRN CAN1 LO YEL CAN1 HI WHT 5-11-1 IGN PLAT SW100-1 YEL 2-26 IGN SW100-B YEL 5-10-6 IGN GMODE KEY SWITCH SW100-3...
  • Page 482 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CHASSIS TO TURNTABLE HARNESS TO TURNTABLE HARNESS YEL CAN2 HI SHLD 85-1 SHIELD YEL CAN2 HI S551 Sheet_4-[8,B] GRN 84-1 CAN2 LOW GRN CAN2 LO Sheet_4-[8,B] MS-4 YEL 83-1 CAN2 HIGH YEL CAN2 HI GRN CAN2 LO S552 Sheet_4-[8,B]...
  • Page 483 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ATTACHED TO RIGHT CONTROLLER MOUNTING PLATE X600 STEER SENSOR ZAPI #1 RIGHT (MASTER) CO4-J1-RL RED BRAKE1-IN-2 SHIELD 18/3 CABLE X599A RED EPDM 4 AWG WHT 200 RT BRK WHT 201-1 STR SNR RED 18/3 CABLE RED BRAKE1-IN IP408...
  • Page 484 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CONNECTS TO TH2-2 ON SHEET 6 A4 RED GENERATOR B+ 4EPDM X637 BLK GENERATOR B- 4EPDM CONNECTS TO TH3-1 ON SHEET 6 D1 X638 EC363B- EC363B+ UA103 UA131 48VDC UA108 DYNAMO GENERATOR ENGINE SCHEMATIC VR110 UA112 X705...
  • Page 485 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS EC363B+ X658 48VDC PLUGS IN TO X617 PAGE 8 H8 EC104 SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOID MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP. ENGINE OIL TEMP SPEED SENSING INPUT RS232 +12V CONN-2...
  • Page 486 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERIC GENERIC RR LT FR LT WHT 88-2 LIGHTING TO SHEET 4 A3 X596B RL266 WHT 88-2 LIGHTING WHT 1-22-5 GND WHT 3-12-4 LIGHT 16AWG BLK 5-1 FUSE 12AWG WHT 3-12-2 LIGHT 16AWG S267 WHT 3-12 LIGHT PWR 12AWG WHT 3-12-1 LIGHT 16AWG...
  • Page 487 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERIC X617 FR LT WHT 8-6 WHT 8-7 PLUGS IN TO X658 WHT 8-8 GEN DISTRESS PWR PAGE 7 G7 WHT 8-5 GEN DISTRESS GND WHT 8-4-2 IGN 48VOLT CONNECTS TO X598A S620 WHT 8-4-1 IGN 48VOLT WHT 8-4-2 IGN 48VOLT...
  • Page 488 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SW305 WHT 120-1 TORQUE/SPEED MODE YEL 5-14-1 WHT 120-2 AWDA MAN SW06 YEL 5-14-1 WHT 29-0 TWR LFT UP WHT 29-30 TWR LFT DN WHT 5-14-2 SW09 WHT 13-0 MAIN TELE IN WHT 3-8 PLAT IGN 12AWG WHT 5-14-2 WHT 1-5 PLAT GND 12AWG...
  • Page 489 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FC-8 BLK 14AWG BLK 14AWG WHT 3-18-1 SKYG PWR 5A SKYG FUSE WHT 1-36 SKYG GND SHEET 10 WHT 3-18-2 SOFTT SENSE 20AWG WHT 124-1 SKYG INPUT#1 20AWG WHT 124-2 SKYG INPUT#2 20AWG WHT 124-5 SOFTT 20AWG WHT 124-5-1 SOFTT OUT 20AWG WHT 3-8 PLAT IGN 12AWG...
  • Page 490 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HARNESS,GEN 2 PLAT INTERFACE HARNESS,GEN 2 PLAT INTERFACE PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR PLTFM SNSR RELAY #1 RELAY #1 RELAY #2 RELAY #2 S191 S191 S192 S192 WHT P2 WHT P2 WHT P6...
  • Page 491 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 492 3121717...

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