Page 1 Service and Maintenance Manual Model H800AJ PVC 2001 31215043 November 4, 2019 - Rev A AS/NZS...
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Page 3 INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems oper- THIS MACHINE IS POWERED BY AN 84VDC (NOMINAL) ELECTRICAL SYSTEM ate at extremely high potentially dangerous pressures. Every THAT CAN RANGE UP TO 105VDC DURING NORMAL OPERATION, AND BY A effort should be made to relieve any system pressure prior to 48VAC (NOMINAL) ELECTRICAL MOTOR SYSTEM THAT CAN RANGE UP TO disconnecting or removing any portion of the system.
Page 4 INTRODUCTION MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION. • USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, R E P L A C E M E N T PA R T S O R CO M P O N E N T S M U S T B E IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
Page 5 INTRODUCTION REVISON LOG Original Issue A - November 4, 2019 31215043...
Page 6: Table Of Contents
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Damage .
Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.16 Swing Bearing ..................3-65 Turntable Bearing Mounting Bolt Condition Check .
Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Upright Monitoring System (UMS) ..............4-16 Re-Synchronizing Upright .
Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 4.17 Rotator Assembly ................. . 4-57 Theory of Operation.
Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Cylinder Removal And Installation ..............5-94 Main Boom Telescope Cylinder Removal .
Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Machine Personality Settings and Function Speeds..........6-29 Machine Orientation When Setting Function Speeds .
Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 7.13 Hybrid Electric Controller ................7-46 7.14 Resolver/Converter .
Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-4 2-1.
Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-55. Rotary Coupling Port Location (7 Port) ............. . 3-74 3-56.
Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-13. FFWR Method..................5-52 5-14.
Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-70. Cylinder Head Seal Installation ..............5-80 5-71.
Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-126. Hydraulic Schematic - Sheet 2 of 4 ..............5-135 5-127.
Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-35. 84V hybrid round connector on tank side ............7-34 7-36.
Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-92. Hybrid Harness - Sheet 1 of 3 ............... 7-125 7-93.
Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. Kubota D1305 ..................1-1 Hydraulic Oil .
Page 21 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-32 Flange Code (FL61 & FL62) - Metric Fasteners ............5-50 5-33 Symbols Used.
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Page 23 SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 TIRES Load Travel Speed 3.0 MPH (4.83 Km/hr.) Size Type Ply Rating Pressure Range Capacity (Unrestricted) 500 lb (227 Kg) 15-625 foam-filled 6.5 bar (94 psi) Gradeability 18-625 foam-filled 5.9 bar (86 psi) 18-625 foam-filled...
Page 24 SECTION 1 - SPECIFICATIONS 1.5 HYDRAULIC OIL Table 1-4. Mobil DTE 10 Excel 32 Specs Table 1-2. Hydraulic Oil ISO Viscosity Grade Hydraulic System Pour Point, Max -40°F (-54°C) S.A.E. Viscosity Operating Flash Point, Min. 330°F (250°C) Grade Temperature Range Viscosity +0°...
Page 25 SECTION 1 - SPECIFICATIONS 1.6 CRITICAL STABILITY WEIGHTS Table 1-7. Quintolubric 888-46 Density 0.92 @ 15°C (59°F) DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT Pour Point <-22°F (<-4°C) WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUN- Flash Point 572°F (300°C) TER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO...
Page 26 SECTION 1 - SPECIFICATIONS 3,4,5 MAE36790 Figure 1-1. Maintenance and Lubrication Diagram 31215043...
Page 27 SECTION 1 - SPECIFICATIONS 1.7 MAINTENANCE AND LUBRICATION 2. Wheel Drive Hub NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-9. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pres- sure type.
Page 28 SECTION 1 - SPECIFICATIONS 4. Fuel Filter/Water Separator 6. Radiator Lube Point(s) - Fill Cap Lube Point(s) - Replaceable Element Lube - Anti-Freeze Coolant (Fleet Charge A/F 50/50 or Interval - Drain water daily; Change every year or equivalent) 600hours of operation. Capacity - 6 qt.
Page 29 SECTION 1 - SPECIFICATIONS 8. Hydraulic Return Filter 10. Hydraulic Tank Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Fill Cap or 300 hrs. thereafter or as indicated by Condition Indi- Capacity - 25 gallons (94.5 L) total capacity, 21 gallons cator.
Page 30 SECTION 1 - SPECIFICATIONS 1.8 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...
Page 31 SECTION 1 - SPECIFICATIONS 1.9 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
Page 32 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
Page 33 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
Page 34 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
Page 35 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
Page 36 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
Page 37 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
Page 38 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
Page 39 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...
Page 40 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
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Page 42 SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventive Maintenance Schedule for MAINTENANCE items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for General servicing and maintenance procedures.
Page 43 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 44 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 45 SECTION 2 - GENERAL Lubrication Hydraulic Oil Service applicable components with the amount, type, and 1. Refer to Section 1 for recommendations for viscosity grade of lubricant recommended in this manual, at the speci- ranges. fied intervals. When recommended lubricants are not avail- able, consult your local supplier for an equivalent that meets 2.
Page 46 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 47 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 Do the Following When Welding on JLG Equipment the following occurs:...
Page 48 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INSPECTION Pre-Delivery or Frequent Annual AREA Inspection Inspection (Quarterly) (Yearly) 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 49 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INSPECTION Pre-Delivery or Frequent Annual AREA Inspection Inspection (Quarterly) (Yearly) 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 Swing Brakes...
Page 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INSPECTION Pre-Delivery or Frequent Annual AREA Inspection Inspection (Quarterly) (Yearly) General Operators and Safety Manuals in Storage Box ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI and ANSI Export ONLY) Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible...
Page 51 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INSPECTION Pre-Delivery or Frequent Annual AREA Inspection Inspection (Quarterly) (Yearly) Footnotes: Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used Annually, no later than 13 months from the date of the prior inspection Performance Codes: 1 - Check for proper and secure installation...
Page 52 SECTION 2 - GENERAL NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE. 1001222023 B Figure 2-1.
Page 53 SECTION 2 - GENERAL 1001228397 B Fluid Base Properties Classification NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULTIN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM. MACHINE OPERATION TEMPERATURE BOUNDARIES CONTAINED IN THIS DOCUMENT APPLYTO THE...
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Page 55: Chassis & Turntable
SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE TIRES & WHEELS Wheel Replacement Tire Damage The rims installed on each product model have been designed for stability requirements which consist of track width and load capacity. Size changes such as rim width, center piece For polyurethane foam filled tires, JLG Industries, Inc.
Page 56: Powertrain Operating Modes
SECTION 3 - CHASSIS & TURNTABLE When the hydraulic pumps’ demand for power is less than Table 3-1. Wheel Torque Chart the full power available from the engine or the system is TORQUE SEQUENCE idling, depending on the State Of Charge (SOC) of the bat- 1st Stage 2nd Stage 3rd Stage...
Page 57: Idle Reduction Stop Start
SECTION 3 - CHASSIS & TURNTABLE Idle Reduction Stop Start There is an IRSS suspend override that can be triggered if the engine is starting after either of two progressive SOC% Idle Reduction Stop Start (IRSS) allows for the engine to thresholds are met.
Page 58: Drive Orientation System
SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE ORIENTATION SYSTEM 3.4 OSCILLATING AXLE SYSTEM The Drive Orientation System (DOS) is intended to indicate to The oscillating front axle is attached to the frame by a pivot the operator conditions that could make the direction of pin, which allows all four wheels to remain on the ground movement of the chassis different than the direction of move- when traveling on rough terrain.
Page 59: Lockout Cylinder Bleeding
SECTION 3 - CHASSIS & TURNTABLE 3.5 LOCKOUT CYLINDER BLEEDING 1. Start the engine. 2. Position the turntable to the normal stowed position. 3. Attach clear tubing to bleeder valve nipple. 4. Position a small bucket/bottle in front of the lockout cyl- inder bleeder valve and insert clear tubing.
Page 60 SECTION 3 - CHASSIS & TURNTABLE 10, A 10, A 10, A 10, A 10, A 10, A A. Apply Medium Strength Threadlocking Compound 1001151037 C 1001154584 D 1. Oscillating Axle 4. Keeper Pin 7. Stop Plate 10. Bolt 2. Fixed Axle 5.
Page 61 SECTION 3 - CHASSIS & TURNTABLE 5, A 5, A 5, A A. Apply Medium Strength Threadlocking Compound 5, A 1001151034 F 1001151035 E 1. Drive Spindle 4. Kingpin 7. Composite Bearing 10. Keeper PIN 2. Steer Cylinder 5. Bolt 8.
Page 62: Oscillating Axle Lockout Test
SECTION 3 - CHASSIS & TURNTABLE 3.6 OSCILLATING AXLE LOCKOUT TEST 9. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel. 10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- is on top of block.
Page 63 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Lockout Cylinder 4. Drive Motor 2. Flow Drive Valve 5. Drive Hub 3. Swivel Figure 3-3. Chassis Component Location 31215043...
Page 64: Drive System
SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE SYSTEM The drive system consists of one variable displacement closed loop pump, four variable displacement piston motors, gear reduction hubs, and a traction control manifold that includes three flow dividers/combiners. Drive speed is varied by a combination of drive pump dis- placement, engine &...
Page 65 SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE HUB (TORQUE) Installation 1. Use suitable lifting device to support the drive hub Removal assembly. NOTE: Refer Figure 3-4., Drive Hub Removal and Installation. NOTE: The drive hub assembly motor weighs approximately 222 lb (100.7 kg).
Page 66: Drive Hub (Torque)
SECTION 3 - CHASSIS & TURNTABLE DRIVE HUB 5. Remove the motor from machine and place in a clean work area. Assembly/Disassembly 6. Clean the motor for dirt. Remove rust or corrosion from coupling shaft. For detail assembly/disassembly instruction, Refer to appropriate Drive Hub Manual.
Page 67: Removal
SECTION 3 - CHASSIS & TURNTABLE Description Shaft Seal Replacement The drive motors are low to medium power, two-position axial REMOVAL piston motors incorporating an integral servo piston. They are designed for operation in both open and closed circuit appli- 1.
Page 68: Loop Flushing Valve
SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve 2. Using a 1/4 in hex wrench remove plug (3). 3. Remove O-rings (4, 5, and 6). REMOVAL 4. Using pliers, remove centering springs (7, 8, and 9). 1. Using a 11/16 in internal hex wrench remove plug (1) 5.
Page 69: Troubleshooting
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-3. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.
Page 70: Disassembly
SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced.
Page 71 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 23. Endcap 26. Endcap 24. O-ring 27. O-ring Figure 3-11. Endcap 28. O-ring 29. Angle Stop 13. Using an 8 mm internal hex wrench, remove the end- 30. Servo Spring Capscrews (22).
Page 72 SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring (30) 20. Turn the housing over and remove the snap ring (32) from the housing. retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34).
Page 73 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-16. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer 23.
Page 74: Inspection
SECTION 3 - CHASSIS & TURNTABLE SLIPPERS Inspect the running surface of the slippers. Replace any piston RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES assemblies with scored or excessively rounded slipper edges. FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO Measure the slipper foot thickness.
Page 75 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Cylinder Block Measurements Measurement L25 mm (in.) L30 mm (in.) L35 mm (in.) K38 mm (in.) K45 mm (in.) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) Minimum Cylinder Block Height (A) Cylinder Block Surface Flatness 0.002 0.002...
Page 76: Assembly
SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate 1. Install new O-ring (1) and piston seal (2) to the servo pis- the bearings while feeling for uneven movement. Bearings ton (3). Install the piston seal over the O-ring. should spin smoothly and freely.
Page 77 SECTION 3 - CHASSIS & TURNTABLE 4. Turn the block over and install the retaining ring (8), hold-down pins (9), and ball guide (10) to the cylinder block. RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO 5.
Page 78 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bear- 10. Verify swashplate and bearings are properly seated. ing onto shaft with lettering facing out. Lubricate bear- Install the cylinder kit (19) onto the shaft. Install with the ing rollers.
Page 79 SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the endcap. Install 15. Install the endcap (25) onto the housing with the end- the bearing with letters facing out. Press until bearing Capscrews (26). Check to ensure the endcap will prop- surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap sur- erly seat onto the housing without interference.
Page 80 SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 19. Install remaining plugs and fittings to the housing. Refer new shaft seal (27) with the cup side facing the motor. to the drawing below for wrench sizes and installation Press seal into housing until it bottoms out.
Page 81: Initial Start-Up Procedures
SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). Initial Start-up Procedures Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage incurred dur- ing shipping.
Page 82 SECTION 3 - CHASSIS & TURNTABLE 30 31 MAE37210 1. Journal Bearing 8. Slipper Retainer 15. Washer 22. O-Ring 29. Spring 2. Pin 9. Slipper Hold Pin 16. Retainer 23. Seat Spring 30. Seal Lip 3. Retaining Pin 10. Piston Assembly 17.
Page 83 SECTION 3 - CHASSIS & TURNTABLE 1001156136-B 1001157049-B 1001156798-A MAF24300 1. Swing Drive 4. Swing Bearing 7. Grease Line 2. Swing Motor 5. Outer Race Bearing Bolt 8. Bolt 3. Inner Race Bearing Bolt 6. Turntable Lock Pin 9. Jam Nut Figure 3-30.
Page 84: Swing Drive
SECTION 3 - CHASSIS & TURNTABLE 3.12 SWING DRIVE If a leak is detected in a seal, O-ring, or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 minutes. Roll, Leak And Brake Testing Brake Test Torque-Hub units should always be roll and leak tested before Prior to brake check remove Motor, Tubing and Elbow as per...
Page 85: Tightening And Torquing Bolts
SECTION 3 - CHASSIS & TURNTABLE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque. The following steps describe how to tighten and torque bolts or socket head Capscrews in a bolt circle.
Page 86: Motor Control Valve Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32). NOTE: Refer to Figure 3-31. 5. Remove O-ring Plugs (23) from Motor Control Valve (32). 1.
Page 87: Motor And Brake Disassembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 6. Lift Brake Piston Assembly (8A) out of the Brake Housing (6). If the Brake Piston assembly (8A) will not lift out, apply less than 50 psi air to the “brake port” to remove NOTE: Refer to Figure 3-32., Motor and Brake Brake Piston(8A).
Page 88: Main Drive Disassembly
SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly 15. Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Subassembly. NOTE: Refer to Figure 3-33., Main Drive Assembly 16. Remove Ring Gear (4) from Housing (1G). 17. Remove O-ring (5) from between Ring Gear (4) and 11.
Page 89: Hub-Shaft Disassembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 3. While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G). NOTE: Refer to Figure 3-34., Hub-Shaft NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by 1.
Page 90: Carrier Disassembly
SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E). NOTE: Refer to Figure 3-35., Carrier 3. Slide the Planet Gear (3F), the two Thrust Washers (3B) out of the Carrier (3A).
Page 91: Hub-Shaft Assembly
SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-35., Carrier NOTE: Refer to Figure 3-34., Hub-Shaft 1. Apply a liberal Coat of grease to the bore of Cluster Gear 1. Press Bearing Cup (1C) into Housing (1G) taking care to (3F).
Page 92: Main Drive Assembly
SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing. NOTE: Refer to Figure 3-33., Main Drive Assembly 9.
Page 93: Motor And Brake Assembly
SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly 12. The Unit should undergo brake test refer instruction on page 30. NOTE: Refer to Figure 3-32., Motor and Brake 13. Grease and install the O-Ring (26) into the Motor (31) pilot.
Page 94: Motor Control Valve Assembly
SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Assembly NOTE: Refer to Figure 3-31., Motor Control Valve 1. Install O-Rings (99) into counterbore on Motor Valve face. Assemble the Motor control Valve (32) onto the Motor (31) with Bolt (21) and Lock Washers (22). Torque Bolts (21) to 18-20 ft.
Page 95 SECTION 3 - CHASSIS & TURNTABLE 1A. Output Shaft 1G. Housing 2. Internal Gear 5A. O-Ring 12. Bolt 1B. Lip Seal 1H. Tanged Washer 3. Carrier Assembly 6. Brake Housing 13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4. Ring Gear 8.
Page 96 SECTION 3 - CHASSIS & TURNTABLE 35. Tube 108. Rotor Set 117. Backup Washer 6. Brake Housing 8L. Spring 8A. Piston 21. Thrust Washer 101. Bolt 109. Wear Plate 118. Housing 8D. 0-Ring 22. Lock washer 102. End Cover 110. Drive Link 119.
Page 97 SECTION 3 - CHASSIS & TURNTABLE MAF23980 Figure 3-38. Bearing Cone Press Tool (T144566) MAF23990 Figure 3-39. Bearing Cone Pressing Tool (T145741) 31215043 3-43...
Page 98 SECTION 3 - CHASSIS & TURNTABLE MAF24000 Figure 3-40. Bearing Cup Pressing Tool (T149013) MAF24010 Figure 3-41. Locknut Wrench Tool (T151047) 3-44 31215043...
Page 99 SECTION 3 - CHASSIS & TURNTABLE MAF24020 Figure 3-42. Bearing Cup Pressing Tool (T155291) MAF24030 Figure 3-43. Seal Press Tool (T175741) 31215043 3-45...
Page 100 SECTION 3 - CHASSIS & TURNTABLE MAF24040 Figure 3-44. Swing Drive Test Plate (T187845) MAF24050 Figure 3-45. Leak Test Adapter Plate (T201476) 3-46 31215043...
Page 101: Swing Motor
SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING MOTOR Disassembly and inspection 1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
Page 102 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8. Rotor Set 12. Coupling Shaft 18A. O-Ring 2. End Cover 8A. Rotor 13. Bearing/Bushing, Inner 19. Bearing/Bushing, Outer 3. Seal Ring-Commutator 8B. Stator or Stator Vane 14. Thrust Washer 20. Dirt & Water Seal 4.
Page 103 SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve com- inspection of end cover, commutator, manifold, and rotor ponents, remove the two previously loosened plugs set. (21). 7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.
Page 104 SECTION 3 - CHASSIS & TURNTABLE 9. Remove manifold (7) and inspect for cracks surface scor- NOTE: The rotor set (8) components may become disassembled ing, brinelling or spalling. Replace manifold if any of during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pen- these conditions exist.
Page 105 SECTION 3 - CHASSIS & TURNTABLE NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets 14. Check exposed portion of coupling shaft (12) to be sure of seven vanes (8C & 8E) as shown in the alternate con- you have removed all signs of rust and corrosion which struction TG rotor set assembly view, check the rotor lobe might prevent its withdrawal through the seal and bear-...
Page 106 SECTION 3 - CHASSIS & TURNTABLE NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 19. Remove housing (18) from vise, invert it and remove and 0.020 inches (0.51 mm) diametrically, replace coupling discard seal shaft. 20. A blind hole bearing or seal puller is required. NOTE: A slight “polish”...
Page 107 SECTION 3 - CHASSIS & TURNTABLE 22. If the housing (18) assembly has passed inspection to NOTE: The depth or location of bearing/bushing (13) in relation to this point, inspect the housing bearings/bushings (19) the housing wear plate surface and the depth or location and (13) and if they are captured in the housing cavity of bearing/bushing (19) in relation to the beginning of the two thrust washers (14) and thrust bearing (15).
Page 108: Assembly
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
Page 109 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).
Page 110 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the ORIGINAL DESIGN LARGE FRAME, TF & TG TORQMOTORS™ THAT DO NOT HAVE mounting flange. BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
Page 111 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- tant grease has been applied to the lower (outer) hous- ing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings.
Page 112 SECTION 3 - CHASSIS & TURNTABLE 10. Install drive link (10) the long splined end down into the 12. Apply a small amount of clean grease to a new seal ring coupling shaft (12) and engage the drive link splines (4) and assemble it into the seal ring groove on the wear into mesh with the coupling shaft splines.
Page 113 SECTION 3 - CHASSIS & TURNTABLE 14. Apply clean grease to a new seal ring (4) and assemble it 16. Apply grease to a new seal ring (4) and insert it in the in the seal ring groove in the rotor set contact side of seal ring groove exposed on the manifold.
Page 114 SECTION 3 - CHASSIS & TURNTABLE 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 bolt end cover bolt hole relationship to housing port bosses.
Page 115 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts bolts after the other bolts are in place.
Page 116: One Piece Stator Construction
SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.
Page 117: Swing Hub Installation
SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING HUB INSTALLATION 4. Remove turntable lock pin. 5. Apply High Strength Threadlocking Compound and pre- Ensure mounting plate and mounting location of the base torque swing drive mounting bolts to 30 ft. lbs. (40 Nm). plate are clean and painted with a uniform coating of mini- mum thickness (no runs, drips, etc.).
Page 118: Swing Drive Lubrication
SECTION 3 - CHASSIS & TURNTABLE 9. Torque mounting bolts to 340 ft. lbs. (460 Nm). 3.15 SWING HUB REMOVAL 1. Disconnect all wiring harness terminals connected to the swing motor. 2. Gently loosen the set screw. Do not remove. 3.
Page 119: Swing Bearing
SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING BEARING Turntable Bearing Mounting Bolt Condition Check 2. Check the turntable to bearing Attach bolts as follows: a. Elevate the fully retracted main boom to full eleva- tion. b. At the position indicated on Figure 3-47. try to insert THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON A MOBILE the 0.0015 in.
Page 120 SECTION 3 - CHASSIS & TURNTABLE Figure 3-47. Swing Bearing Tolerance Boom Placement (Sheet 1 of 2) 3-66 31215043...
Page 121 SECTION 3 - CHASSIS & TURNTABLE 31215043 3-67...
Page 122: Wear Tolerance
SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Swing Bearing Tolerance Measuring Point Figure 3-49. Swing Bolt Feeler Gauge Check Swing Bearing Replacement Wear Tolerance REMOVAL 1. From the underside of the machine, at rear center, with the main boom fully elevated and fully retracted, and 1.
Page 123: Swing Bearing Torque Values
SECTION 3 - CHASSIS & TURNTABLE 8. Carefully place the turntable on a suitably supported 7. Clean any residue off the new bearing bolts, then apply trestle. a light coating of High Strength Threadlocking Com- pound and install the bolts and washers through the 9.
Page 124 SECTION 3 - CHASSIS & TURNTABLE 3-70 31215043...
Page 125: Chassis Tilt Indicator System
SECTION 3 - CHASSIS & TURNTABLE FRONT NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-52. Swing Bearing Torque Sequence 3.17 CHASSIS TILT INDICATOR SYSTEM The control system responds to indicated angle readings 0.25 degree smaller than the required angles to account for calibra- The Chassis Tilt Indicator System measures the turntable angle tion and sensor variation.
Page 126: Rotary Coupling
SECTION 3 - CHASSIS & TURNTABLE 3.18 ROTARY COUPLING 7. Assemble lip seals (2) in direction shown in Figure 3-53., Rotary Coupling Seal Installation. Use the following procedure to install the seal kit. 8. Reassemble O-ring (4). 1. If not already removed, remove the axle oscillation valve 9.
Page 127 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 6. Thrust Ring 2. Seal 7. Snap Ring 3. Housing 8. Valve Block (Axle Oscillation) 4. O-ring 9. O-ring 5. Seal 10. Proximity Switch Figure 3-54. Rotary Coupling Cutaway 31215043 3-73...
Page 128 SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. Rotary Coupling Port Location (7 Port) 3-74 31215043...
Page 129 SECTION 3 - CHASSIS & TURNTABLE Figure 3-56. Rotary Coupling Port Location (9 Port) 31215043 3-75...
Page 130 SECTION 3 - CHASSIS & TURNTABLE 1. Medium Strength Threadlocking Compound 6. Rotary Coupling 11. Ring 16. O-ring 21. Bolt 2. Bolt 7. Spool 12. Seal 17. Valve 22. Nut 3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 23.
Page 131 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Coupling Port Information Table (9 port) Table 3-9. Coupling Port Information Table (7 port) Operating Proof Operating Proof Port Port Port Size Description Pressure Pressure Outlets Port Size Description Pressure Pressure Outlets PSI (Bar) PSI (Bar) PSI (Bar)
Page 132: Generator
SECTION 3 - CHASSIS & TURNTABLE 3.19 GENERATOR EVERY 500 HOURS Every 500 hours of operation, service the generator brushes SkyPower and slip rings. Hostile environments may require more fre- quent service. The optional 4kW and 7.5kW auxiliary generators can be pow- ered by the engine only with the clutch engaged.
Page 133: Overload Protection
SECTION 3 - CHASSIS & TURNTABLE Overload Protection INSPECTING BRUSH POSITION Inspect brush alignment with slip rings. View alignment through the air vents in the stator barrel. The brushes must ride completely on the slip rings. STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER.
Page 134 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2.
Page 135: Troubleshooting
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-11. Troubleshooting Trouble Remedy No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform. Check and secure electrical connections at platform, generator, and control box. Be sure all equipment is turned off when starting unit.
Page 136: Generator Disassembly And Assembly
SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly 2. Remove brush holder assembly. 3. Disassemble generator parts shown in Figure 3-59. Refer to Figure 3-60. and Figure 3-61. to determine if trouble is in stator, rotor, control box, or combination of these compo- 4.
Page 137 SECTION 3 - CHASSIS & TURNTABLE 31215043 3-83...
Page 138 SECTION 3 - CHASSIS & TURNTABLE Figure 3-60. Generator Troubleshooting Circuit Diagram (Sheet 1 of 2) 3-84 31215043...
Page 139 SECTION 3 - CHASSIS & TURNTABLE Figure 3-61. Generator Troubleshooting Circuit Diagram (Sheet 2 of 2) 31215043 3-85...
Page 140 SECTION 3 - CHASSIS & TURNTABLE 3-86 31215043...
Page 141 SECTION 3 - CHASSIS & TURNTABLE 31215043 3-87...
Page 142 SECTION 3 - CHASSIS & TURNTABLE Figure 3-64. Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2) 3-88 31215043...
Page 143 SECTION 3 - CHASSIS & TURNTABLE Figure 3-65. Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2) 31215043 3-89...
Page 144: Lead Connection List For Generator
SECTION 3 - CHASSIS & TURNTABLE Lead Connection List for Generator NOTE: Apply small amount of dielectric grade, nonconductive electric grease to connectors where factory-applied grease NOTE: Table shows physical lead connections and should be used had been present. with circuit diagram (table replaces wiring diagram). Table 3-12.
Page 145 SECTION 3 - CHASSIS & TURNTABLE SN197 COOL TEMP SNSR EC194 ALTERNATOR DETAIL A SW196 OIL PRS SNSR X327 DETAIL B X247 DETAIL J EC195 STRT SOL SEE DETAIL B HV210 PRK BRK VLV HV211 2 SPD VLV SEE DETAIL A SEE DETAIL J 1001226669-H MAF24070H...
Page 146 SECTION 3 - CHASSIS & TURNTABLE FUEL FILTER FUEL PUMP SUPPLY LINE RETURN LINE VENT LINE SECTION K-K FUEL STRAINER DETAIL C SEE DETAIL C 1001226669-H MAF24080H Figure 3-67. Engine Installation - Sheet 2 of 5 3-92 31215043...
Page 147 SECTION 3 - CHASSIS & TURNTABLE ENGINE NEGATIVE CABLE ENGINE NEGATIVE SEE DETAIL D CABLE FROM FUEL PUMP HV326 DRV REV HV325 DRV FWD TO ENGINE ENGINE NEGATIVE CABLE DETAIL D ENGINE POSITIVE CABLE SEE DETAIL M SEE DETAIL E ENGINE POSITIVE DETAIL M CABLE...
Page 148 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL F DETAIL F ENGINE TRAY FUEL RETURN HOSE SECURE BRACKET FROM ENGINE TO FUEL TANK FUEL SUPPLY HOSE FROM FUEL/WATER SEPARATOR TO ENGINE EC193 GLOW PLUGS WH245 ENG FAN DETAIL G X223 SEE DETAIL H PROP FUEL RACK ACT...
Page 149 SECTION 3 - CHASSIS & TURNTABLE SEE DETAIL N X466 X465 DETAIL N ENG/TURN B ENG/TURN A FUEL SUPPLY HOSE FROM FUEL PUMP TO FUEL/WATER SEPARATOR. FUEL SUPPLY HOSE ROUTE BETWEEN ENGINE TRAY FROM FUEL/WATER PIVOT AND TURNTABLE SEPARATOR TO ENGINE. INSTALL LANYARD WITH ENGINE TRAY PINNED IN THE OPEN POSITION SOME ITEMS HIDDEN FOR CLARITY FUEL RETURN HOSE...
Page 150: Cold Start System
SECTION 3 - CHASSIS & TURNTABLE 3.20 COLD START SYSTEM 3.21 CLUTCH ADAPTER PLATE INSTALLATION The machine control system monitors the 1. Place the Clutch Adapter Plate against the engine fly- engine coolant and ambient temperature to wheel and start all bolts approximately 1/2 to 1 turn. make an assessment of cylinder preheating 2.
Page 151: Clutch Kit & Release Shaft Installation
SECTION 3 - CHASSIS & TURNTABLE 3.22 CLUTCH KIT & RELEASE SHAFT INSTALLATION Clutch Kit NOTE: To properly install the clutch, JLG service tool PN 1001227898 must be used. NOTE: Don't use power or air tools during this install. 1. Apply blue Medium Strength Threadlocking Compound to all bolts and start all bolts ½...
Page 152: Release Shaft
SECTION 3 - CHASSIS & TURNTABLE Release Shaft 1. Insert shaft from the top of the IMG and through the opening on the side. MAE37940 4. Install bronze bearings, retaining clip on one end and actuation lever on the other. MAE37920 2.
Page 153: Clutch Installation
SECTION 3 - CHASSIS & TURNTABLE 3.23 CLUTCH INSTALLATION 3.24 CLUTCH LINEAR ACTUATOR/THROWOUT BEARING POSITIONING INSTALLATION 1. Place the clutch against the adapter plate and start all PROCEDURE retaining bolts approximately 1/2 turn. 2. Center the friction disk (clutch) in the pressure plate NOTE: To properly position the clutch actuator/throwout bearing, using the alignment tool.
Page 154 SECTION 3 - CHASSIS & TURNTABLE 3. Assemble Clutch Gauge onto the end of the bolt. Rotate 6. Before the continuing, ensure the Linear actuator is in Clutch Gauge and bolt until Gauge is contacting the the fully extended position as shown below. clutch gauge bracket.
Page 155 SECTION 3 - CHASSIS & TURNTABLE 8. Next using a wrench rotate the rear mounting bracket 10. Remove the Clutch Gauge bracket from flywheel hous- toward the engine until the lever arm makes contact ing. Installation is now complete. with the bolt head as shown below. This requires some force to achieve, as it is compressing the pressure plate to set the full throwout bearing stroke possible by the linear actuator.
Page 156: Counterweight
SECTION 3 - CHASSIS & TURNTABLE 3.25 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-73., Counterweight Bolt Torque. *Torque to 260 ft-lb (353 N-m) 1001223979-C MAE37260C Figure 3-73.
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Page 158: Boom & Platform
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM BOOM SYSTEMS Transport Position Interlock System (CE only) The transport position interlock system uses the "above eleva- tion cutout system" switches with the addition of a main Switch Systems boom telescope switch to sense when the boom is out of the transport (nearly stowed) position.
Page 159: Platform
SECTION 4 - BOOM & PLATFORM Platform Upright Level Override System The standard platform utilizes a hinged swing gate for ease of As the tower boom is raised the upright is leveled by a master- entry and 3/4" expanded metal floor mesh. The optional drop slave cylinder arrangement between the tower lift cylinder bar gate platform utilizes 1/2"...
Page 160 SECTION 4 - BOOM & PLATFORM 1. UMS Sensor 3. Tower Boom Angle Switch 5. Tower Lift Plunger Valve 7. Rotator Valve 2. Main Boom Angle Switch 4. Tower Telescope Plunger Valve 6. Proximity Switch 8. Platform Control Valve Figure 4-1. Boom Component Location 31215043...
Page 161 SECTION 4 - BOOM & PLATFORM 1001247099-B MAF25360B 1. Tower Boom Assembly 7. Pin 13. Pin 19. Tower Boom Lift Cylinder Assembly 25. Rotator Assembly 2. Main Boom Assembly 8. Pin 14. Pin 20. Main Boom Lift Cylinder Assembly 26. Jib Lift Cylinder Assembly 3.
Page 162 SECTION 4 - BOOM & PLATFORM 0801136-N MAF25370N 1. Base Boom 4. Pin 7. Boom Rest Block 10. Wear Pad 13. Bushing 2. Fly Boom 5. Pin 8. Wear Pad 11. Shim 3. Telescope Cylinder Assembly 6. Pin Keeper 9. Shim 12.
Page 163: Main Boom Assembly
SECTION 4 - BOOM & PLATFORM MAIN BOOM ASSEMBLY Removal 1. Using a suitable lifting equipment, adequately support boom assembly weight along entire length. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. 2.
Page 164: Disassembly
SECTION 4 - BOOM & PLATFORM 6. Using all applicable safety precautions, carefully lift 4. Inspect inner diameter of boom pivot bearing for scor- main boom assembly clear of upright and lower to ing, distortion, wear, or other damage. Replace bearing ground or suitably supported work surface.
Page 165: Installation
SECTION 4 - BOOM & PLATFORM Installation c. Install the barrel end retaining pin. Install the bolt and keeper pin securing the master cylinder barrel end pin to the base boom section. 1. Using all applicable safety precautions, carefully lift boom assembly to align the pivot holes in the boom with those of the upright.
Page 166: Upright
SECTION 4 - BOOM & PLATFORM UPRIGHT 4. Disconnect wiring harness to horizontal limit switch. 5. Disconnect the Upright Level Cylinder as follows: Removal a. Using a suitable lifting device, support the Upright. b. Remove mounting hardware securing hose bracket in upright, and remove the hose bracket.
Page 167: Installation
SECTION 4 - BOOM & PLATFORM Installation NOTE: Steps 1 thru 4 are only necessary if the upright level cylin- der is to be removed. 1. Using a suitable lifting device, carefully install the upright lift cylinder into place in the tower boom. 2.
Page 168 SECTION 4 - BOOM & PLATFORM 0801132-H MAF25380H 1. Base Boom 4. Support 7. Bushing 10. Wear Pad 2. Fly Boom 5. Attach Block 8. Wear Pad 11. Shim 3. Tower Telescope Cylinder Assembly 6. Shim 9. Shim 12. Boom Rest Pad Figure 4-5.
Page 169: Tower Boom Assembly
SECTION 4 - BOOM & PLATFORM TOWER BOOM ASSEMBLY 7. Remove the Tower Fly as follows: a. Mark all hoses and wiring harnesses at bracket on Removal rear end of tower base boom for future assembly. Remove hoses and wiring from tower boom Pow- ertrack.
Page 170: Assembly
SECTION 4 - BOOM & PLATFORM 3. Inspect inner diameter of tower boom pivot bearings for 8. Attach internal Powertrack to tower base boom at bot- scoring, distortion, wear, or other damage. tom only and extended out of boom that the Pow- ertrack links are opened at top.
Page 171: Tower Out Of Sync
SECTION 4 - BOOM & PLATFORM Tower Out of Sync 3. The counterbalance valve in the piston end of the upright level cylinder. There could be a leak path from Tower is out of sync backwards, upright leaning toward the the valve port to the pilot port.
Page 172 SECTION 4 - BOOM & PLATFORM Tower is out of sync forwards, upright leaning away from the the pilot port to the valve port. Replace the counterbal- platform. ance valve. When towering down, the lower lift cylinder bottoms out before the upright level cylinder. This is caused by too much oil between the two cylinders.
Page 173: Upright Monitoring System (Ums)
SECTION 4 - BOOM & PLATFORM UPRIGHT MONITORING SYSTEM (UMS) 7. Repeat steps 3 thru 6 if necessary until the upright is 90° (vertical) relative to the chassis. The UMS provides a visual and audible warning to the opera- tor when the limits of the upright assembly alignment have been reached.
Page 174 SECTION 4 - BOOM & PLATFORM 31215043 4-17...
Page 175: Calibration
SECTION 4 - BOOM & PLATFORM Calibration IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THE GROUND CON- 1. Connect the JLG Hand-held analyzer to the original ana- TROL MODULE AT THIS TIME. HOWEVER, WHEN THE TILT SENSOR IN THE lyzer connection in the ground box.
Page 176 SECTION 4 - BOOM & PLATFORM c. Scroll left to right through the above menu items until "UMS SENSOR" sub menu appears on the bot- e. Press "ENTER" and the next screen will display to m l i n e o f t h e a n a l y ze r d i s p l ay. Pre s s t h e the following, asking if the machine is on a level sur- face: "ENTER"...
Page 177 SECTION 4 - BOOM & PLATFORM g. After the main boom has been fully elevated, press "ENTER" . The analyzer will display the follow- ing: CAL FAILED-UMS SENSOR MOVEMENT NOT DETECTED Should you get the above message, verify that the sensor is installed correctly and verify the sensor connection to the sensor harness is secure.
Page 178 SECTION 4 - BOOM & PLATFORM i. When viewing the above display, press “ENTER” . The screen will display the following: If the calibration has been completed successfully, the screen will automatically change to: j. Lower the tower boom onto the boom stop. Con- tinue to hold the tower boom down function for at least twenty (20) seconds WITHOUT RELEASING THE FUNCTION SWITCH.
Page 179: Calibration Faults
SECTION 4 - BOOM & PLATFORM If the calibration has not been completed success- Calibration Faults fully, the display will automatically change to: CAL Failed-Chassis Not Level In the event the turntable tilt switch input is logic low indicat- ing that the machine is not level the UMS calibration screens shall display this fault.
Page 180 SECTION 4 - BOOM & PLATFORM 4. Scroll through the top level menu until SERVICE MODE 6. The controller will now display the following: appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the following screens will be displayed: or, by pressing the up and down arrow keys: 7.
Page 181: Service Mode/Tower Boom Retrieval
SECTION 4 - BOOM & PLATFORM 8. From the ground controls, raise the tower boom several 4. Scroll through the top level menu until SERVICE MODE feet. Verify that the tower boom will not lower. appears. Press "ENTER" to select this menu item. 9.
Page 182 SECTION 4 - BOOM & PLATFORM 5. Scroll left to right through the above menu items until followed by: "TOWER LIFT DOWN?" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key. 6. The controller will now display the following: The flashing and scrolling messages will repeat until the "ENTER"...
Page 183 SECTION 4 - BOOM & PLATFORM 9. Before using tower lift down adhere to the following: • Make sure the main boom is fully retracted. • Make sure the tower boom is fully retracted. • Slowly lower the tower boom. 10.
Page 184 SECTION 4 - BOOM & PLATFORM Figure 4-9. UMS Sensor Location 31215043 4-27...
Page 185: Ums Troubleshooting And Diagnostic Trouble Codes (Dtc)
SECTION 4 - BOOM & PLATFORM UMS TROUBLESHOOTING AND DIAGNOSTIC Out of Usable Range DTC (2531) TROUBLE CODES (DTC) UMS SENSOR OUT OF USABLE RANGE Backward Stability Concern DTC (2532) When both the Chassis tilt sensor and the UMS sensor read greater than 10°...
Page 186: Platform
SECTION 4 - BOOM & PLATFORM 4.7 PLATFORM Platform Valve Installation 1. Install platform control valve onto the mounting bracket Platform Valve Removal and secure using hardware. 1. Tag and disconnect the hydraulic lines from the plat- 2. Install the mounting bracket onto the platform support form control valve.
Page 187: Platform Support Removal
SECTION 4 - BOOM & PLATFORM Platform Support Removal 5. Remove the bolts and locknuts securing the support to the rotator. BOLTS ROTATOR PLATFORM SUPPORT SHAFT MAF24140 Figure 4-10. Location of Components Platform Support MAF24120 1. Disconnect electrical cables from control console. 6.
Page 188: Support Installation
SECTION 4 - BOOM & PLATFORM Support Installation 4. Torque the nut on the rotator center bolt to 586 ft. lbs. (795 Nm). Torque the retaining bolts to 40 ft. lbs. (55 Nm). 1. Using a suitable device, support the platform support and position it on the rotator.
Page 189 SECTION 4 - BOOM & PLATFORM A, B, D NOTE: If any rotator bolts are replaced, replace all bolts on the rotator and torque them. C, D Torque to 40 ft.lbs. (55 Nm) Medium Strength Threadlocking Compound Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 64 ft.
Page 190: Bolt-On External Fall Arrest
SECTION 4 - BOOM & PLATFORM BOLT-ON EXTERNAL FALL ARREST GAP SHOWING: The bolt-on external fall arrest system is designed to provide a INCORRECT lanyard attach point while allowing the operator to access areas outside the platform. Exit/Enter the platform through the gate area only.
Page 191 SECTION 4 - BOOM & PLATFORM 2. Attach the fall arrest cable to the right hand bracket Using the attaching bolt and nut. Orient the bolt as shown below. Do not tighten the nut so cable can still rotate. BOLT 6.
Page 192: Articulating Jib
SECTION 4 - BOOM & PLATFORM 4.9 ARTICULATING JIB Disassembly NOTE: Pin numbers listed in the following procedures are refer- 1. Remove mounting hardware from articulating jib boom enced in Figure 4-13., Location of Components-Articulat- pivot pins (3) and (4). Using a suitable brass drift and ing Jib.
Page 193: Assembly
SECTION 4 - BOOM & PLATFORM 4. Inspect lift cylinder attach pin for wear, scoring, tapering Installation and ovality, or other damage. Ensure pin surfaces are protected prior to installation. Replace pins as neces- NOTE: The Jib assembly weighs approximately 269 lb (122 kg). sary.
Page 194: Rotator And Slave Cylinder
SECTION 4 - BOOM & PLATFORM 4.10 ROTATOR AND SLAVE CYLINDER Installation NOTE: The platform level cylinder weighs approximately 79.6 lb Removal (36.1 kg). 1. Remove the Platform and Platform Support. (Section 4.7, Platform). 1. Support the platform level cylinder. Using a soft head mallet install pin #4 to the fly boom.
Page 195: Sequence For Hose Replacement In The Tower Boom
SECTION 4 - BOOM & PLATFORM 4.11 SEQUENCE FOR HOSE REPLACEMENT IN THE 4.12 LIMIT SWITCHES ADJUSTMENT TOWER BOOM Main Boom Horizontal Limit Switch 1. Remove the tower boom front cover bolts, exposing the 1. Place machine on level surface. Powertrack.
Page 196 SECTION 4 - BOOM & PLATFORM UPPER SWITCH (DUAL CAPACITY BOOM ANGLE SWITCH) SHOWN FOR REFERENCE ONLY. SWITCH TO ACTIVATE WHEN MAIN BOOM IS RAISED 5˚ TO 10˚ ABOVE HORIZONTAL. SWITCH TO RESET WHEN MAIN BOOM IS LOWERED 1˚ BELOW TO 4˚ ABOVE HORIZONTAL. SWITCH TO ACTIVATE WHEN TOWER BOOM IS RAISED TO 8˚...
Page 197 SECTION 4 - BOOM & PLATFORM ADJUST GAP TO WITHIN 0.20 in. (5 mm) (PREFERRED GAP 0.125 in. (3.175 mm) WHEN LOWER BOOM IS FULLY RETRACTED AND AFTER LEDS WILL LIGHT WHEN POWER IS VALVE IS ADJUSTED ADJUST SWITCH BY LOOSENING CLAMP ON ON AND TARGET IS WITHIN SENSING TELE ROD AND SLIDING TO APPROXIMATE 0.125 in.
Page 198 SECTION 4 - BOOM & PLATFORM 31215043 4-41...
Page 199: Boom Valve Adjustment
SECTION 4 - BOOM & PLATFORM 4.13 BOOM VALVE ADJUSTMENT Main Boom 1. Adjust the screws so the plunger on the valves has 1. Shim up wear pads to within 1/32 in. (0.8 mm) clearance 0.250 in. (6.35 mm) travel remaining when the lower between wear pad and adjacent surface.
Page 200: Boom Cleanliness Guidelines
SECTION 4 - BOOM & PLATFORM 4.14 BOOM CLEANLINESS GUIDELINES 3. Debris and foreign matter inside of the boom can cause premature failure of components and should be The following are guidelines for internal boom cleanliness for removed. Methods to remove debris should always be machines that are used in excessively dirty environments.
Page 201: Main Boom Powertrack
SECTION 4 - BOOM & PLATFORM 4.15 MAIN BOOM POWERTRACK 6. Remove hardware(2) securing the push tube on the mid boom section. Removal 7. With Powertrack supported and using all applicable safety precautions, remove hardware (3), (4) and (5) 1. Disconnect wiring harness connectors located in tower securing rail to the base boom section.
Page 202 SECTION 4 - BOOM & PLATFORM 31215043 4-45...
Page 203 SECTION 4 - BOOM & PLATFORM 4-46 31215043...
Page 204 SECTION 4 - BOOM & PLATFORM 31215043 4-47...
Page 205 SECTION 4 - BOOM & PLATFORM 4-48 31215043...
Page 206: Powertrack Maintenance
SECTION 4 - BOOM & PLATFORM 4.16 POWERTRACK MAINTENANCE Round Bar/Poly Bar Removal 1. Use a small ¼” ratchet with a T-25 Torx bit. Remove the Flat Bar Removal 10-24 x 0.812 screw. (If the bar spins then grip the bar and poly tightly with a vise-grip).
Page 207: Removing And Installing Links
SECTION 4 - BOOM & PLATFORM 3. While gripping the bar tightly, remove the other 10-24 x Removing and Installing Links 0.812 screw. 1. To remove the links, the rivets holding the links together must be removed. The following will show one way this can be done.
Page 208 SECTION 4 - BOOM & PLATFORM 3. After grinding, it is sometimes necessary to use a center 4. To install new links, extend the main moving end over the lower part of the track so the new connection point punch to punch out the rivet from the link. is in the curved part of the track.
Page 209 SECTION 4 - BOOM & PLATFORM 5. Install the pin into the center hole, then slide the washer NOTE: When installing snap rings make sure they are seated in over the pin. Install the snap ring into the groove in the the pin groove and closed properly.
Page 210: Installing A New Flat Bar
SECTION 4 - BOOM & PLATFORM 6. Install more pins, washers, and snap rings into all the Installing a New Flat Bar links where a rivet was removed. 1. While holding the flat bar, install new 8-32 x 0.500 self threading torx screws into both holes on each side of track.
Page 211: Installing A New Round Bar/Poly Roller
SECTION 4 - BOOM & PLATFORM Installing a New Round Bar/Poly Roller NOTE: Maximum tightening torque for the 10-24 screw is 45-50 in-lbs (5-5.6 Nm). 1. While tightly holding the round bar, install the new 10- 24 x 0.812 self threading torx screw. Next lift up the Replacing a Fixed End Bracket other end and slide a new poly roller on.
Page 212: Replacing A Moving End Bracket
SECTION 4 - BOOM & PLATFORM Replacing a Moving End Bracket Replacing a One Piece Bracket 1. Remove bracket by removing all pins, washers, and snap 1. Remove all pins, washers, and snap rings and slide the rings. Replace with a new bracket and reinstall the pins, bracket off of the links.
Page 213 SECTION 4 - BOOM & PLATFORM 2. To install a new bracket, slide the bracket over the links and reinstall the pins, washers, and new snap rings. After installing the new bracket make sure that it rotates cor- rectly. 4-56 31215043...
Page 214: Rotator Assembly
SECTION 4 - BOOM & PLATFORM 4.17 ROTATOR ASSEMBLY The shaft is supported radially by the large main radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the main and lower thrust washers. The Theory of Operation endcap is adjusted for axial clearance and locked in position by set screws or pins.
Page 215 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 216 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 217: Disassembly
SECTION 4 - BOOM & PLATFORM Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). SECURE PRODUCT TO SLOTTED TABLE OR VISE. CONTENTS UNDER PRESSURE. WEAR APPROVED EYE PROTECTION. USE CAU- TION WHEN REMOVING PORT PLUGS AND FITTINGS. MAKE SURE WORK AREA IS CLEAN.
Page 218 SECTION 4 - BOOM & PLATFORM 6. Remove the endcap (4) and set aside for later 8. Every actuator has timing marks for proper engage- inspection. ment. 7. Remove the stop tube if equipped. The stop tube is an available option to limit the rotation of the actuator. 9.
Page 219 SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis- ton and housing with a marker as shown.
Page 220 SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202) from the piston. cut them using a sharp razor blade being careful not to damage the seal groove. 20.
Page 221: Inspection
SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123” or 3.12 mm). SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED. 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting.
Page 222 SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and endcap 4. Using a seal tool install the main pressure seal (205) onto (4). shaft (2) and endcap (4). Use the seal tool in a circular motion.
Page 223 SECTION 4 - BOOM & PLATFORM 6. Install the O-ring (204) and backup ring (207) into the Repeat this step for the outer seal (202). inner seal groove on the endcap (4). 8. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the hous- 7.
Page 224 SECTION 4 - BOOM & PLATFORM 9. Looking from the angle shown, rotate the piston (3) until 11. Install the shaft (2) into the piston (3). Be careful not to the marks you put on the piston and the housing (1) damage the seals.
Page 225 SECTION 4 - BOOM & PLATFORM 13. Install 2 bolts in the threaded holes in the flange. Using a 16. Install the 0-ring (204) and backup ring (207) into the bar, rotate the shaft in a clockwise direction until the inner seal groove on the endcap (4).
Page 226 SECTION 4 - BOOM & PLATFORM 18. Tighten the endcap (4). In most cases the original holes 20. Insert the set screws (113) over the lock pins. Tighten for the lock pins will line up. them to 25 in. lbs. (2.825 Nm). 19.
Page 227: Installing Counterbalance Valve
SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Strength Threadlocking Compound should be applied to the shank of the three bolts at the time of installation. Refer to Figure 4-25., Rotator Counterbalance Valve. 4. Torque the 1/4-inch bolts 110 to 120 in.lbs. (12.4 to 13.5 1.
Page 228: Greasing Thrust Washers
SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on 1. 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 229: 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 230: Troubleshooting
SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.
Page 231: Skyguard
SECTION 4 - BOOM & PLATFORM 4.19 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 232: Diagnostics & Troubleshooting
SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains CLOSED while the Sky- Guard sensor is actively engaged, a power or ground wire may not be making good contact or may be loose or broken. Addi- If SkyGuard does not function when the sensor is engaged, tionally, there is a low probability that both relays may have first verify the configuration under the...
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Page 234: Basic Hydraulic Information & Hydraulic Schematics
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.
Page 235: Dip Method
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. The following is needed to correctly oil the o-ring in this man- 2.
Page 236: Hydraulic Connection Assembly And Torque Specification
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 60° 30° Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.
Page 237: Straight Thread Types, Port Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 238: Assembly And Torque Specifications
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 239: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 240: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT Thread Tapered (BSPT) Connections procedure requirements.
Page 241: Assembly Instructions For 37° (Jic) Flare Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) 1. Inspect the flare for obvious visual squareness and con- Thread - Aluminum/Brass while using the Double centricity issues with the tube OD.
Page 242 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel Thread OD 37° 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...
Page 243 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass Thread OD 37° TYPE/FITTING IDENTIFICATION Torque Flats from Wrench Thread ØA* ØB* [Ft-Lb] [N-m] Resistance Size Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28...
Page 244 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 31215043 5-11...
Page 245: Assembly Instructions For 45° Sae Flare Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using 1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
Page 246 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Thread ØA* ØB* [Ft-Lb] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16...
Page 247: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 248 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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)
Page 249: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 250 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 251: Assembly Instructions For Bulkhead (Bh) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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.
Page 252 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 253 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 254 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 31215043 5-21...
Page 255 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Boss 6. Torque the fitting or nut to value listed in Table 5-12 thru Table 5-17 while using the Double Wrench Method. (ORB) Fittings a. The table headings identify the straight thread O- ring port and the type on the other side of the fit- 1.
Page 256 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size...
Page 257 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
Page 258 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
Page 259 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
Page 260 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52...
Page 261 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-17. O-ring Boss (ORB) - Table 6 of 6 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 3/8-24 0.37 9.52...
Page 262 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 31215043 5-29...
Page 263 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Adjustable Port 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5- End Metric (MFF) Fittings 23 while using the Double Wrench Method.
Page 264 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 265 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 266 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 267 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 268 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 269 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-23. 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 S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...
Page 270 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 31215043 5-37...
Page 271: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the type on the other side of the fitting.
Page 272 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) Note: Metric O-ring only style (ISO 6149) requires o-ring chamfer in the port, similar to ISO 11926 (SAE ORB), but is not interchangeable. STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION...
Page 273: Assembly Instructions For Adjustable Port End (Bspp) Fittings
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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, Table 5-28, Table 5-29, or Table 5- (BSPP) Fittings 30 while using the Double Wrench Method.
Page 274 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 275 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 276 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 277 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 Bonded Washer Seal Bonded Washer Bonded Washer (e.g. Dowty) Seal FORM A** (SEALING WASHER) FORM B** (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS...
Page 278 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 279 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-30. British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 Note: BSPP O-ring only style (ISO 228-1) requires o-ring chamfer in the port, similar to ISO 11926 (SAE ORB), but is not interchangeable.
Page 280 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 31215043 5-47...
Page 281: Assembly Instructions For Flange Connections: (Fl61 And Fl62)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 Figure for O-ring installation instructions. 3.
Page 282 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 283 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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...
Page 284: Double Wrench Method
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.
Page 285: Ffwr And Tfft Methods
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 286: O-Ring Installation (Replacement)
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Position #1 Position #2 Position #4 Position #3 Position #5 Locknut in position to Locknut and Washer Connector backed Hand tightened into port Connector tightened protect the backup backed oò with o-ring oò...
Page 287: Hydraulic Cylinders
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.3 HYDRAULIC CYLINDERS ASSEMBLY NOTE: Prior to cylinder assembly, ensure that the proper cylinder Axle Lockout Cylinder seal kit is used. See your JLG Parts Manual. DISASSEMBLY NOTE: Apply a light film of hydraulic oil to all components prior to assembly.
Page 288 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS * Torque 22 ft.lbs (30 Nm) 1001204560 A 1. Barrel 4. Rod Seal 7. O-ring Plug 2. Rod 5. Wear Ring 8. O-ring Plug 3. Wiper 6. Counterbalance Valve 9. Bleeder Valve Figure 5-15.
Page 289: Slave Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Slave Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews, and remove capscrews DISASSEMBLY from cylinder barrel. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 290 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 17*** 16*** 20** *Torque 10 ft. lbs. (13 Nm) **Torque 37 ft. lbs. (50 Nm) ***Torque 50 -55 ft. lbs. (67-75 Nm) 1001228030-C MAE36460C 1. Barrel 6. Wear Ring 11. Lock Ring 16.
Page 291 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 292 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. STEEL BUSHING COMPOSITE...
Page 293 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 9. Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the ring into the applicable cylinder head gland groove.
Page 294 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 12. Rotate the capscrews evenly and progressively in rotation. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, 13. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
Page 295: Upright Level Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Upright Level Cylinder NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001251041-A MAF23940A Figure 5-31. Upright Level Cylinder 5-62 31215043...
Page 296: Jib Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lift Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews, and remove capscrews DISASSEMBLY from cylinder barrel.
Page 297 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 20** 20** 16*** *Torque to 5 ft. lbs. (7 Nm) **Torque to 50-55 ft. lbs. (68-75 Nm) ***Torque to 18 ft. lbs. (25 Nm) 1001248012-B MAE33410B 1. Barrel 6. Wear Ring 11.
Page 298 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 299 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. STEEL BUSHING COMPOSITE...
Page 300 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Install the bolts in tapered bushing. cable cylinder head gland groove. Install a new wear 11. Assemble the tapered bushing loosely into the piston ring into the applicable cylinder head gland groove.
Page 301 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 14. Rotate the capscrews evenly and progressively in rotation to 5 ft.lbs. (7 Nm). EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, 15. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON.
Page 302: Main Boom Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Boom Lift Cylinder NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001251010-A MAF23950A Figure 5-47. Main Boom Lift Cylinder 31215043 5-69...
Page 303: Tower Boom Lift Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Tower Boom Lift Cylinder NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001251009-A MAF23960A Figure 5-48. Tower Boom Lift Cylinder 5-70 31215043...
Page 304: Master Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Master Cylinder 4. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews, and remove capscrews DISASSEMBLY from cylinder barrel. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Page 305 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 17** * Torque to 10 ft. lbs. (13 Nm) ** Torque to 35 ft. lbs. (50 Nm) 1001228050-A MAF06810A 1. Barrel 5. Rod Seal 9. Piston 13. Backup Ring 17. Capscrew 2.
Page 306: Cleaning And Inspection
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 307 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. STEEL BUSHING COMPOSITE...
Page 308 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- 10. Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the ring into the applicable cylinder head gland groove.
Page 309 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm). EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, 14. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON.
Page 310 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Steer Cylinder 4. Using a hook spanner, loosen the spanner nut retainer and remove spanner nut from cylinder barrel. DISASSEMBLY DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SPANNER NUT SURFACE IN A DIRT FREE WORK AREA.
Page 311 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001150539 F 1. Piston 6. Barrel 11. Spanner Nut 2. Wear Ring 7. Head 12. Wiper Seal 3. Seal 8. O-ring 13. Rod Seal 4. Setscrew 9. Backup Ring 14. Bushing 5.
Page 312 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Using suitable protection, clamp the cylinder rod in a 11. If applicable, inspect rod and barrel bearings for signs of vise or similar holding fixture as close to the piston as correct excessive wear or damage.
Page 313 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS ASSEMBLY 2. Use a soft mallet to tap a new wiper seal into the appli- cable cylinder head gland groove. Install a new wear NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
Page 314 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 9. Place new seal and wear ring in the outer piston diame- ter grooves. (A tube, with I.D. slightly larger than the O.D. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, of the piston is recommended to install the solid seal).
Page 315: Main Boom Telescope Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Boom Telescope Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews, and remove capscrews DISASSEMBLY from cylinder barrel.
Page 316 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 21*** 22** * Torque 10 ft. lbs. (13 Nm) ** Torque 35 ft. lbs. (50 Nm) *** Torque 85 ft. lbs. (115 Nm) 1001228087-F 07050 1. Barrel 6. Wear Ring 11. Piston Seal 16.
Page 317 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 318 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. STEEL BUSHING COMPOSITE...
Page 319 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- NOTE: When installing the tapered bushing, piston and mating cable cylinder head gland groove. Install a new wear end of rod must be free of oil.
Page 320 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 14. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm). EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, 15. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON.
Page 321: Tower Boom Telescope Cylinder
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Tower Boom Telescope Cylinder 5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews, and remove capscrews DISASSEMBLY from cylinder barrel.
Page 322 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 23**** 21** 9***** 27****** 24*** * Torque to 24 ft. lbs (33Nm) ** Torque to 10ft. lbs (13 Nm) ***Torque to 55 ft. lbs (75 Nm) ****Torque to 48 ft. lbs (65 Nm) *****Torque to 126 ft.
Page 323 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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 324 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC 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. STEEL BUSHING COMPOSITE...
Page 325 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Use a soft mallet to tap a new wiper seal into the appli- NOTE: When installing the tapered bushing, piston and mating cable cylinder head gland groove. Install a new wear end of rod must be free of oil.
Page 326 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 13. Rotate the capscrews evenly and progressively in rotation to 10 ft.lbs. (13 Nm). EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, 14. Remove the cylinder rod from the holding fixture. HEAD, AND PISTON.
Page 327: Cylinder Removal And Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.4 CYLINDER REMOVAL AND INSTALLATION NOTE: The Main Boom weighs approximately 2226 lb (1010 kg). 4. Using a suitable sling and lifting device, secure the plat- Main Boom Telescope Cylinder Removal form end of the boom.
Page 328 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Using auxiliary power from ground controls, retract the lift cylinder rod completely. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- 8. Remove hardware securing cover plate on the rear of CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS- the main boom.
Page 329: Main Boom Telescope Cylinder Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Boom Telescope Cylinder Installation 5. Remove the lifting device from the main telescope cylin- der and retract the main telescope cylinder. NOTE: The Main Boom Telescope Cylinder weighs approximately 6. Extend the main lift cylinder using the auxiliary control 477.8 lb (216.7 kg).
Page 330: Main Lift Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Lift Cylinder Removal NOTE: The Main Boom weighs approximately 2226 lb (1010 kg). 1. Place the machine on a flat and level surface. Attach a suitable lifting device and sling, sufficient to lift the main boom assembly, to the approximate center of the main boom assembly.
Page 331: Main Lift Cylinder Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Lift Cylinder Installation 5. Using a suitable drift drive cylinder rod attach pin through the aligned holes, taking care to align the grooved pin holes. Secure the pin in place and torque NOTE: The Main Lift Cylinder weighs approximately 493 lb (224 the bolt to 285 ft.
Page 332: Upright Level Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Upright Level Cylinder Removal NOTE: The Upright weighs approximately 1167 lb (529.3 kg). HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. 1.
Page 333: Upright Level Cylinder Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Upright Level Cylinder Installation 6. Install Main Lift Cylinder. 7. Install Main Boom. Refer to Main Boom installation. 1. Put the leveling cylinder in position in the tower boom, align holes in the tower boom and leveling cylinder rod 8.
Page 334: Tower Boom Lift Cylinder Installation
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 7. Remove mounting hardware securing the tower lift cyl- 4. Using an appropriate brass drift, drive the tower lift cyl- inder barrel pin to the turntable. Using a suitable brass inder rod end attach pin through the aligned bushings. drift, drive out the tower lift cylinder barrel pin.
Page 335: Tower Telescope Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Tower Telescope Cylinder Removal Tower Telescope Cylinder Installation 1. Place machine on flat and level surface. 1. Slide the telescope cylinder into the boom, aligning the cylinder port block end with slotted holes in Base Boom. 2.
Page 336: Master Cylinder Removal
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Master Cylinder Removal Master Cylinder Installation NOTE: The Master Cylinder weighs approximately 63 lb (28.6 kg). 1. Remove caps from the hydraulic hoses and attach hoses to the proper cylinder ports. 1.
Page 337: Pressure Setting Procedures
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.5 PRESSURE SETTING PROCEDURES c. To make an adjustment to this pressure, go to the engine compartment, locate the function pump. Cold temperatures have a significant impact on pressure read- There are (2) adjustments at the top of the pump. ings.
Page 338: Adjustments Made At The Main Valve Block
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS c. To make an adjustment to this pressure, go back to 4 WHEEL STEER the engine compartment to the function pump. The high pressure relief adjustment is the lower one of 1.
Page 339 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PLATFORM LEVEL DOWN 4 WHEEL STEER (IF EQUIPPED) 1. Install a high pressure gauge at gauge port “M2”, of the 1. At the platform console using the steer select switch Platform Valve. activate “4 wheel steer”.

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