Oshkosh Corporation JLG 1850SJ Service And Maintenance Manual
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Oshkosh Corporation JLG 1850SJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
1850SJ
3121619
May 27, 2019 - Rev K
AS/NZS

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  • Page 1 Service and Maintenance Manual Model 1850SJ 3121619 May 27, 2019 - Rev K AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Bhydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - June 18, 2014 Revised B - September 25, 2014 Revised C - May 15, 2015 Revised D - November 5, 2015 Revised E - January 27, 2016 Revised F - June 8, 2016 Revised G - November 8, 2016 Revised...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires and Wheels ................. . . 3-1 Tire Damage .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 4 - BOOM & PLATFORM Boom Systems ..................4-1 Broken Cable Indicator System .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.15 Broken Boom Cable Proximity Switch ............. . . 4-74 Adjusting the Proximity Switch .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Boom Telescope Cylinder (SN 0300190128 through 0300244677)....... 5-140 Boom Telescope Cylinder (SN 0300244678 to Present).
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Control System Boom Sensors ..............6-55 Sensor #1 - Load Pin (1) .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. This page left blank intentionally viii 3121619...
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-4 1-2.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-50. Engine Installation and Diesel Exhaust Fluid (DEF) System - Sheet 5 of 8 ......3-56 3-51.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-52. Powertrack Locations for Threadlocker Application and Torque - Sheet 4 of 4 ......4-83 4-53.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-51. Piston Disassembly ................. 5-78 5-52.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-108. Piston Disassembly................. 5-102 5-109.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-163. Cylinder Head Installation ................5-130 5-164.
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-220. Charge Pump ..................5-194 5-221.
  • Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-9. Connector Assembly Figure 1 ............... 7-8 7-10.
  • Page 21 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-66. Electrical Installation - Sheet 6 of 10..............7-139 7-67.
  • Page 22 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Dimensional Data .
  • Page 23 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 ........5-48 5-31 Flange Code (FL61 &...
  • Page 24 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 25: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data Horizontal Reach over end Table 1-1. Operating Specifications Unrestricted Capacity 70 ft. 6 in. (21.50 m) Restricted Capacity 59 ft. 6 in. (18.13 m) Capacity - ANSI Unrestricted 500 lbs (227 kg) Horizontal Reach over side...

  • Page 26: Engine Data

    SECTION 1 - SPECIFICATIONS 1.5 ENGINE DATA 1.7 HYDRAULIC OIL Table 1-7. Hydraulic Oil Table 1-5. Engine Data - Deutz TCD 3.6L Type Turbo-charged Diesel Hydraulic System S.A.E. Viscosity Operating Number of Cylinders Grade Temperature Range Bore 3.9 in. (98 mm) +0°...
  • Page 27 SECTION 1 - SPECIFICATIONS Table 1-9. Mobil DTE 10 Excel 32 Specs Table 1-12. Quintolubric 888-46 ISO Viscosity Grade Density 0.92 g/cm Pour Point, Max. -54°C (-65°F) Pour Point <-30°C (<-22°F) Flash Point, Min. 250°C (482°F) Flash Point 300°C (572°F) Viscosity Fire Point 360°C (680°F)
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram 3121619...

  • Page 29: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.8 MAINTENANCE AND LUBRICATION 2. Swing Gearbox NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-14. 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 pressure type.
  • Page 30 SECTION 1 - SPECIFICATIONS 4. Hydraulic Return Filter 6. Hydraulic Charge Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 6 months Lube Point(s) - Replaceable Element or 300 hours thereafter. Interval - Change after first 50 hours and every 6 months 7.
  • Page 31 SECTION 1 - SPECIFICATIONS 8. Hydraulic Oil 10. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap Capacity - 75 Gallons (208 liters) Tank to Full Mark Lube Point(s) - Fill Cap/Spin-on Element 82 Gallons (310.4 L) System Capacity - 9.6 Quarts (9.1 L) Lube - HO Lube - EO Interval - Check level daily.
  • Page 32 SECTION 1 - SPECIFICATIONS 13. Air Filter 11. Fuel Filter - Deutz Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation 12. Fuel Pre-Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments - Check dust valve for dirt daily 14.
  • Page 33 SECTION 1 - SPECIFICATIONS 16. Diesel Exhaust Fluid (DEF) (If Equipped) 18. Optional Fuel Filter/Water Separator Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation Lube Point - Fill Cap Lube - DEF Capacity - 5.7 gal.
  • Page 34 SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-10 3121619...
  • Page 35 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121619 1-11...
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-12 3121619...
  • Page 37 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121619 1-13...
  • Page 38 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-14 3121619...
  • Page 39 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 40: General

    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 41: Service And Guidelines

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

  • Page 42: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING or assemble one part, then start on another. Always recheck LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

  • Page 43: Lubrication

    SECTION 2 - GENERAL Lubrication Hydraulic Oil 1. Refer to Section 1 for recommendations for viscosity Service applicable components with the amount, type, and ranges. grade of lubricant recommended in this manual, at the speci- fied intervals. When recommended lubricants are not avail- Changing Hydraulic Oil able, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

  • Page 44: Cylinder Drift

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

  • Page 45: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on Filament wound bearings. an external structure, or component. 1.
  • Page 46 SECTION 2 - GENERAL NOTE: Refer the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1, 2 1, 2 Hose/Cable Carrier Installations 1, 2...
  • Page 47 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Functions/Controls Platform Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Ground Controls return to neutral/off when released 1, 3, 6, 9 1, 3, 6, 9 Function Control Locks, Guards, or Detents...
  • Page 48 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection General All Decals/Placards Installed, Secure, Legible Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers 1, 2...
  • Page 49 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ 2.9 L04 T4F AND 3.6L4 TCD 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.
  • Page 50 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERATURE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
  • Page 51 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 52: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE The proper procedure for attaching wheels is as follows: 3.1 TIRES AND WHEELS 1. Start all nuts by hand to prevent cross threading. DO Tire Damage NOT use a lubricant on threads or nuts. For pneumatic tires, JLG Industries, Inc.

  • Page 53: Axle Extension System

    SECTION 3 - CHASSIS & TURNTABLE 3.2 AXLE EXTENSION SYSTEM 3.3 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) is intended to indicate to NOTE: The boom must be oriented between the rear wheels to the operator conditions that could make the direction of extend or retract the axles.

  • Page 54: Steering Control System

    SECTION 3 - CHASSIS & TURNTABLE 3.4 STEERING CONTROL SYSTEM There are three different modes of steering selectable by the position of the steer select switch on the platform control panel: crab, coordinated, and conventional two wheel steer- ing. These are shown below. Figure 3-3.

  • Page 55: Drive/Steering Speed Control

    SECTION 3 - CHASSIS & TURNTABLE Axle extend sensor failures will result in an approximated 3.9 GROUND CONTROL ENABLE SYSTEM steering control logic that will allow the operator to move the The ground controls include the use of a function enable sys- machine until it can be repaired.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121619...
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE Figure 3-4. Axle Hose Routing - Sheet 1 of 2 3121619...
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Axle Hose Routing - Sheet 2 of 2 3121619...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 3121619...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 3121619...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 3-10 3121619...
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-11...

  • Page 63: Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.12 DRIVE ASSEMBLY 1. Drive Hub 3. Drive motor 5. Bolt 7. Bolt 2. O-Ring 4. Washer 6. Washer Figure 3-10. Drive Assembly 3-12 3121619...

  • Page 64: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE HUB 1001149921 1. Ring 9. Pin 17. Pinion 25. Flange 33. Seal 41. Plastic Plug 49. O-Ring 2. Screw 10. O-Ring 18. Hub Housing 26. O-Ring 34. Coupling 42. Input Shaft 50. Brake Piston 3.

  • Page 65: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly 4. Remove, Ring (1), Cover (6), O-Ring (7), Shim (8) and O- Ring (10). Do not damage O-Rings. Check and remove 1. Remove plugs (5) and pour lubricant in a container. Gasket (4) if damaged. Reinstall plugs.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 6. Remove two Screws (19), Hub Housing (18) and O-Ring 8. Remove three snap rings (22) and planet wheel (24) (26). Do not damage O-Ring. from spindles on Flange (25). 7. Remove Coupling (34) and Spring (35). 9.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 10. Remove Hub Support (30), Bearing (29), O-Ring (31), 12. Remove Snap Ring (53), Spacer (52), Seal (48), O-Ring Bearing (32), and two Seals (33) from Axle (38). (49), and Brake Piston (50) from Axle (38). Remove five Brake Springs (51) from Brake Piston (50).

  • Page 68: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 14. Remove Split Ring (36), Input Shaft (42), and Bearing (37) 3. Install Seal (46), O-Ring (47), Seal (48), and O-Ring (49) in from Axle (38). Axle (38). Starting with Brake Disk (44) alternate with Iron Disk (43) until a total of eight Brake Disks and nine Iron Discs are installed on Input Shaft (42 - not shown) in Axle.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 5. Install Flange (25) on Axle (38), with Plug (21) and six NOTE: Install Ring Nut with convex part facing bearing. screws (20). 7. Install Ring Nut (27) on Flange (25). Prevent Flange from turning and torque Ring Nut to 295 ft-lb (400 Nm).
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 9. Install Spring (35) and Coupling (34). 11. Install Gear Reduction Assembly (16), Gear Reduction Assembly (13), and Pinion (11) in Planetary Housing. Lubricate all bearings. 10. Install O-Ring (26). Install Planet wheel (18) with two 12.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 13. Install O-Ring (54) and Motor Support (55). Apply JLG 15. Install Pin (9) and Cover (3). Secure with two Screws (2). Threadlocker or equivalent to six Screws (56). Install and Torque to 7 ft-lb (10 Nm). torque Screws to 177 ft-lb (240 Nm).

  • Page 72: Free Wheeling Option

    SECTION 3 - CHASSIS & TURNTABLE 3.14 FREE WHEELING OPTION 3.15 GEAR HUB OIL SERVICE Disengage Drive Motors & Brakes for Towing, etc. Check Oil Level (Free Wheel) 1. Position hub as shown in Figure 3-13. 1. Chock wheels. 2. Remove Level Plug (3) and check oil is level with plug opening.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 3160339 1. Bolt 7. Needle Bearing 13. Cylinder Block 19. O-Ring 25. Gasket 31. Shaft 2. Motor End cap 8. Valve Plate 14. Slipper Pin 20. Servo Piston 26. Plug 32. Bearing 3. Locating Pin 9.

  • Page 74: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.16 DRIVE MOTOR Shaft Seal Replacement NOTE: Drive motor servicing is similar for all Series 45 hydraulic REMOVAL motors. The physical appearance of your motor may be 1. Remove snap ring (1) retaining shaft seal, and support slightly different than shown.

  • Page 75: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE INSPECTION 2. Using a 1/4 in hex wrench remove plug (3). Inspect new seal, motor housing seal bore, and sealing area on 3. Remove O-rings (4, 5, and 6). shaft for rust, wear, and contamination. Polish shaft and clean 4.

  • Page 76: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-2. 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 reservoir to proper level. Ensure oil supply to motor is adequate and supply to motor.

  • Page 77: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 25. Valve Plate 28. O-ring 26. End Cap 29. Angle Stop 27. O-ring 30. Servo Spring 22. Screw 23. End Cap Figure 3-21. Valve Plate & Rear Shaft Bearing 24. O-ring Figure 3-20. End Cap DO NOT SCRATCH VALVE PLATE SURFACE.
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE 32. Snap Ring 33. Support Washer 31. Cylinder Kit Assembly 34. Shaft Seal Figure 3-22. Cylinder Kit Figure 3-23. Shaft Seal 18. Turn housing on its side and remove cylinder kit assem- bly (31). Set assembly aside. Do not to scratch running surface.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Lift Here 35. Inner Snap Ring 37. Bearing 36. Snap Ring 38. Shaft Figure 3-24. Shaft & Front Bearing 20. Remove inner snap ring (35) and shaft/bearing assembly. 21. Remove snap-ring (36) retaining shaft front bearing. Pull 39.

  • Page 81: Inspection

    SECTION 3 - CHASSIS & TURNTABLE 27. Turn block over. Using a press, apply pressure on block spring washer (50) to compress block spring. Compress spring enough to safely remove spiral retaining ring (51). While maintaining pressure, unwind spiral retaining ring (51).
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce block height below minimum specification.

  • Page 83: 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 servo piston bearings while feeling for uneven movement. Bearings should (3). Install piston seal over O-ring. spin smoothly and freely.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 6. Install journal bearings (13) in housing seats. Use assem- bly grease to keep bearings seated during assembly. RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES Ensure locating nubs drop into seat cavities. If reusing bearings, install in original location and orientation.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) on shaft (16). Press bearing 11. Lubricate and install servo spring (20) and minimum on shaft with lettering facing out. Lubricate bearing roll- angle stop (21) in housing bore. ers.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 12. Press rear shaft bearing (22) in endcap. Install bearing 15. Install endcap (25) on housing with endcap screws (26). with letters facing out. Press until bearing surface is 0.08 Ensure endcap will properly seat to housing without ±0.01 in (2 ±0.25 mm) above endcap surface.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install a 20. Install orifice poppet (30). new shaft seal (27) with cup side facing motor. Press seal in housing until it bottoms out. Press evenly to avoid binding and damaging seal.

  • Page 88: Initial Start-Up

    SECTION 3 - CHASSIS & TURNTABLE Initial Start-up 2. Place shim between pinion and bearing on bearing high spot. Follow this procedure when starting-up a new motor or when installing a motor that has been removed. INSPECT MOTOR FOR DAMAGE BEFORE INSTALLATION. MAKE CERTAIN ALL SYSTEM COMPONENTS (RESERVOIR, HOSES, VALVES, FITTINGS, HEAT EXCHANGER, ETC.) ARE CLEAN BEFORE FILLING WITH FLUID.

  • Page 89: Turntable Bearing Mounting Bolt Condition Check

    SECTION 3 - CHASSIS & TURNTABLE 5. Apply JLG Thread locking compound P/N 0100019 to 10. Discard shim. the bolts. Pre-torque the five bolts to 45 ft-lb (6 kgm). 11. Rotate bearing high spot 15° to the second drive hub. Repeat procedure.

  • Page 90: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE c. Ensure that the 0.0015” feeler gauge will not pene- d. At the position indicated on Position 1, Figure 3-39., trate under the bolt head to the bolt shank. try and insert the 0.0015” feeler gauge between the bolt head and hardened washer at the arrow indi- d.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Swing Bearing Torquing Sequence 3-40 3121619...

  • Page 92: Swing Bearing Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE 3.19 SWING BEARING WEAR TOLERANCE 5. Position the machine as follows and as seen in Figure 3- 30., Swing Bearing Wear Tolerance, Position 2: See Figure 3-39., Swing Bearing Wear Tolerance. a. Do not rotate the turntable 1.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Swing Bearing Wear Tolerance 3-42 3121619...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-43...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 3-44 3121619...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-45...
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 3-46 3121619...

  • Page 98: Swing Control System

    SECTION 3 - CHASSIS & TURNTABLE 3.20 SWING CONTROL SYSTEM main boom length is less than 1477.7 inches in the 500 lb mode or 1442.8 inches in the 1000 lb mode. The swing control system uses the turntable swing angle sen- The 8.0º...

  • Page 99: Water In Fuel Sensing System (Optional)

    SECTION 3 - CHASSIS & TURNTABLE 3.23 WATER IN FUEL SENSING SYSTEM (OPTIONAL) AFTER SERVICING After servicing the engine or turbocharger, ensure the turbo- The Water in Fuel Sensing System detects when there is an charger is pre-lubed by adding clean engine oil into the turbo- excessive amount of water in the fuel and sets a DTC code in charger oil inlet until full.

  • Page 100: Diesel Exhaust Fluid (Def) Tank

    SECTION 3 - CHASSIS & TURNTABLE 3.25 DIESEL EXHAUST FLUID (DEF) TANK Cleaning and Flushing the Tank Refer to Figure 3-44. and Figure 3-45. If contaminated fluid or foreign material is found in the tank, the tank must be cleaned. Use the following procedure for Diesel exhaust fluid (DEF) is a urea solution consisting of 32.5% cleaning.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Figure 3-44. Diesel Exhaust Fluid (DEF) Tank - Sheet 1 of 2 3-50 3121619...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE 1. Coolant Tube 13. Header 2. Level Tube 14. Metallic Flange 3. DEF Filter 15. Cover 4. Tie-Wrap 16. Screw 5. Rubber Bushing 17. Spring Tube 6. Float Assembly 18. Urea Quality Sensor 7. Suction Tube 19.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 3-52 3121619...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-53...
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE 3-54 3121619...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-55...
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE 3-56 3121619...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-57...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE 3-58 3121619...
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE 3121619 3-59...
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 3-60 3121619...

  • Page 112: Deutz Engine With Diesel Exhaust Fluid (Def)

    SECTION 3 - CHASSIS & TURNTABLE 3.26 DEUTZ ENGINE WITH DIESEL EXHAUST FLUID WINTER OPERATION WITH DIESEL FUEL Special demands are placed on the cold behavior (tempera- (DEF) ture limit value of the filtrability) for winter operation. Suitable fuels are available in winter. Engine Oil Mixing with petrol is not permissible for safety and technical reasons (cavitation in the injection system).

  • Page 113: Selective Catalytic Reduction (Scr) - Machines Using Diesel Exhaust Fluid (Def)

    SECTION 3 - CHASSIS & TURNTABLE 3.27 SELECTIVE CATALYTIC REDUCTION (SCR) - 1. The Selective Catalytic Reduction Indica- tor will flash when standstill cleaning is MACHINES USING DIESEL EXHAUST FLUID (DEF) required. Selective Catalytic Reduction (SCR) is an emissions control used in diesel engines and requires operator interaction to ensure proper operation of the system.

  • Page 114: Maintenance Standstill Cleaning Initiation Methods

    SECTION 3 - CHASSIS & TURNTABLE Unsuccessful Cleaning Event If there is an unsuccessful cleaning event, The SCR icon will show on the display gauge. Possible causes of an Unsuccessful Cleaning Event are: • Engine is not warmed up • DEF tank is frozen •...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Maintenance Standstill Cleaning Machine Hours Standstill Cleaning System Distress SCR Cleaning Since Last Derate Comments Levels Light Light Cleaning 0-500 Between 500 and 1000 hours, clean- Normal None ing cycle can be initiated with JLG Operation 500-1000 analyzer.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523927 7-3-3 UB5; Short circuit to battery error of actuator Suspected Components: ECU PIN A04, A05 Check wiring harness and connected loads on relay 5.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 2-2-3 Charge air pressure messured by sensor is Charge air pressure above shut off threshold. Check waste gate system if necessary replace above the shut off threshold.
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523935 7-6-3 Timeout Error of CAN-Transmit-Frame Fault is detected if a TimeOut of the EEC3VOL1 Check wiring harness and customer nodes EEC3VOL1;...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 6-9-3 Range check cannot be done or interrupted. Defect EGR differential Pressure sensor or defect Check wiring harness and connected EGR. !!If an wiring error occurs, always check the delta P sensor and the Venturi tube for damage or contamina-...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 2-2-8 Fuel filter water level sensor: the voltage of Fuel filter water level sensor: the voltage of sen- Check wiring, sensor, ECU sensor measured by ECU is out of the target sor measured by ECU is out of the target range.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1-5-4 Injector cyl. 1: interruption of electrical con- Interruption of electronic connection Injector Threshold for error detection is an internal ECU nection cyl.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523615 1-3-5 Fuel metering unit: the current drain mea- short circuit to ground high side Threshold for error detection is an internal ECU sured by ECU is above the target range threshold.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523612 5-5-5 Diagnostic fault check to report the plausi- Implausible injection energizing time for either Threshold for error detection is an internal ECU bility error between level 1 energizing time PiIx or MI1 or PoIx.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 2-2-4 Oil pressure sensor: the voltage of sensor short circuit to battery or cable break check battery and wiring Check cabling. If sen- measured by ECU is out of the target range sor not working, check sensor and if necessary replace it, check connection cable and if neces-...
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 6-9-3 The sensed raw voltage EGR Delta pressure Sensor defect Check cabling, if charge EGR Delta pressure Air_uRawPEGRDeltaP is above the maxi- sensor is not working, check sensor and if neces- mum threshold.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 3251 6-9-2 The difference pressure sensor value exceeds sensed differential pressure across DPF < shut- Check tubes from exhaust line to DPF differen- an applicable lower shutoff threshold.
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523009 2-5-3 The pressure relief valve (PRV) has reached Rail pressure has exceeded the trigger thresh- Replace pressure relief valve (PRV) and reset the allowed opening time.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523613 1-3-4 Rail pressure: the fuel pressure in rail calcu- Rail pressure exceeds the limiting value. (A) Check backflow pressure lated by ECU is above the target range. (B) Check pressure relief valve and metering unit.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523721 6-8-9 Supply module heater: Dutycycle timing out Duty cycle for temperature readout from supply When the received supply module duty cycle of valid range.
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 1079 2-8-2 Internal hardware monitoring: the ECU Suspected components EDC17cv52 Check cabling of external components, check detects a deviation of the target range of the Pin A19: DEF press / Exh.PressBeforeTurb (P3) / working voltage and if necessary correct it, power supply voltage of sensor output 1.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 5-1-2 Start relay (low side power stage): the cur- Shortcut LowSide-Output to battery. Threshold for error detection is an internal ECU rent drain measured by ECU is above the threshold.
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 2-3-3 Charge air temperature downstream calcu- Charge air temperature (downstream) over Check CAC system and clean it. Check fan func- lated by ECU is above the target range. The warning threshold.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 5763 1025 5-9-4 Actuator of the external EGR valve: the ECU Short cut to ground Check cabling, actuator defect, check actuator detects a short circuit to ground.
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 4768 1036 6-8-3 Static plausibility check: The exhaust tem- Static plausibility check: The exhaust tempera- Check ambient temperature => value plausi- perature value from the sensor before DOC, ture value from the sensor before DOC, the ble? upstream DOC sensor mounted within...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 4360 1069 6-6-8 The filtered DEF cat upstream temperature is Sensed temperature upstream SCR > physical Check temperature difference across DOC greater than an applicable maximum tem- high limit (Exh_tOxiCatDs-Exh_TOxiCatUs) at higher...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 4343 1094 6-7-3 DEF pressure line heater: the current drain Open load Threshold for error detection is an internal ECU measured by ECU is above the target range Broken wiring, broken heating element in pres- threshold sure line If this error detected during the heat-...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523719 1109 6-7-2 DEF supply module heater: the current drain Shortcut to ground Threshold for error detection is an internal ECU measured by ECU is above the target range Broken wiring threshold...
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 3031 1135 6-6-9 DEF temperature in DEF tank is to high.The Sensed urea tank temperature > physical range Case "CANBUS sensor": DEF tank temperature sensor detects a value high limit Check urea tank temperature: really hot?
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 5763 1229 5-9-4 Actuator EGR-valve: short cut to battery on Short-Circuit to ground on component Threshold for error detection is an internal ECU ECU pin is detected threshold.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 3711 1455 7-1-1 Temperature Phy_tPfWgh, the weighted temperature Phy_tPfWgh, the weighted DPF Check temperature upstream DOC DPF temperature < Threshold 1 temperature, is below or above the target tem- Exh_tSensOxiCatUs within Stand-still: >...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524076 1535 2-4-8 Open line sensor internally at NOx-sensor Open line sensor internally at NOx-sensor Threshold for error detection is an internal ECU downstream SCR NOx Sensors are CAN Sen- downstream SCR threshold.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524080 1539 2-5-7 sensed lambda value of Nox-sensor sensed lambda value of Nox-sensor upstream Check whether NOx-sensor upstream SCR cata- upstream SCR catalyst is > physical high SCR catalyst is >...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524065 1598 8-9-2 Comparison of urea cat upstream exhaust absolut value of difference between sensed Check electric connector: 4h pin open / new gas- and environment pressure, the differ- pressure upstream SCR catalyst and environ- connector type used? pressure exchange from...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 523612 1857 5-5-5 Fault in the monitoring during the engine wiring is not according DEUTZ requirements Threshold for error detection is an internal ECU start.
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524178 1864 9-9-6 The urea pump is not able to control the urea The urea pump controller is not able to control Make sure that DEF lines, pump and tank are not pressure between 9bar and 11 bar.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524067 1868 8-9-4 absolute diference of sensed temperature of absolute diference of sensed temperature of Compare SCR_tSMT with SCR_tSMHtrT, EnvT_t supply module temperature and ambient supply module temperature and ambient tem- and CEngTds_tand SCR_tAdapUTnkT =>...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524193 1893 2-7-5 The total time in standstill-regeneration Stand-still mode is very often aborted by the Read out stand-still statistics => see service mode exceeds the long-limit threshold operator.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 3519 1895 2-7-7 The integrated temperature sensor of the Temperature sensor inside the UQS defect. CAN Check the temperature sensor signal for plausi- Urea Quality Sensor measures higher tem- Communication corrupted.
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524195 1900 2-7-9 The standstill request of detected crystalli- Back pressure upstream SCR catalyst has Dismount urea injector from exhaust line and zation is ignored for more than reached a level which indicates crystallisation inspect visually the injector andthe exhaust line...
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE Table 3-10. Engine Fault Codes Deutz Blink Description Possible Cause Action Code Code 524267 2007 2-8-7 Announcement triggers the Inducement not used not used Level 2 524025 2008 8-4-5 Max. launch time for stand still exceeded not used not used (60min).
  • Page 151 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.
  • Page 152 SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM SYSTEMS Beyond Transport - Drive Speed Cutback System When boom is positioned beyond the Transport Position as described in The transport position sensing system, the drive Broken Cable Indicator System motors are automatically restricted to their maximum dis- The boom on this model is a 5 section proportionally driven placement position (slow speed).
  • Page 153 SECTION 4 - BOOM & PLATFORM Envelope Control System tions due to moment system violations related to forward reach are disallowing jib functions, lift down, telescope out, The Envelope Control System is the primary means of control- swing, drive, and steer. The restricted functions due to ling the stability of the machine by restricting the working moment system violations related to backward reach are disal- envelope of the main boom.
  • Page 154 SECTION 4 - BOOM & PLATFORM end of manual telescope commands when using multiple not used elsewhere within the envelope or when telescoping functions with lift. The telescope command can be used inde- out. Envelope tracking is disabled with any envelope or pendently or in combination with other functions.
  • Page 155 SECTION 4 - BOOM & PLATFORM Platform Load Sensing System Boom Control Select The Platform Load Sensing System (LSS) consists of 1 load cell The boom control select switch is mounted on the platform and 2 linkages mounted to the platform rotator and replaces control panel and allows the operator the ability to select the platform support on machines that get this optional instal- between two different modes of boom control functionality:...
  • Page 156 SECTION 4 - BOOM & PLATFORM Platform Control Enable System Boom Recovery Mode The platform controls make use of a time dependent enable Boom Recovery Mode allows the boom to be lifted down and circuit to limit the time availability of “live” or enabled controls. telescoped in, in the event CAN bus communication is lost to To operate any directional function, the footswitch must be both the Jib Control Module and the Platform Module.
  • Page 157 SECTION 4 - BOOM & PLATFORM Press ENTER , the screen should read: Use the Left or Right arrow key until you see: To enable the override mode 58237 must be entered as the code. When the code is entered, the screen will show: Press Enter .
  • Page 158 SECTION 4 - BOOM & PLATFORM 4.2 PLATFORM NOTE: The platform support weighs approximately 125 lbs. (56.8 kg). Platform/Support Removal 3. Using a suitable device, support the platform support. 4. Remove the bolts and locknuts securing the support to the rotator. CENTER BOLT BOLT ROTATOR...
  • Page 159 SECTION 4 - BOOM & PLATFORM Platform/Support Installation 5. Using a suitable lifting device., position the platform on the platform support and install the bolts securing the platform to the platform support. See Figure 4-2. and NOTE: The platform support weighs approximately 125 lbs. Figure 4-3.
  • Page 160 SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A,B,D MAF09620 Torque to 35 ft. lbs. (50 Nm) JLG Threadlocker P/N 0100011 Torque to 480 ft. lbs. (651 Nm) Check torque every 150 hours of operation Torque to 85 ft.
  • Page 161 SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. A,B,D MAF09630 Torque to 35 ft. lbs. (50 Nm) JLG Threadlocker P/N 0100011 Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque to 74 ft.
  • Page 162 SECTION 4 - BOOM & PLATFORM 4.3 ROTATOR Installation NOTE: The rotator approximately weighs 230 lbs. (104 kg). Removal NOTE: The jib lift cylinder approximately weighs 194.7 lbs. 1. Remove the Platform and Platform Support. Refer to (87.6 kg). Section 4.2, Platform. 2.
  • Page 163 SECTION 4 - BOOM & PLATFORM JIB LIFT CYLINDER PIN 1 PIN 2 ROTATOR MAF09640 Figure 4-4. Rotator Removal/Installation 4-12 3121619...
  • Page 164 SECTION 4 - BOOM & PLATFORM 4.4 BOOM REMOVAL AND INSTALLATION Removal 1. If necessary, remove the platform. 2. If necessary, remove the jib. 3. Tag and disconnect hoses T2 T3, 7, 8, and Pressure Filter lines from the main valve. Cap or plug all openings. 3121619 4-13...
  • Page 165 SECTION 4 - BOOM & PLATFORM 4-14 3121619...
  • Page 166 SECTION 4 - BOOM & PLATFORM 4. Tag and disconnect all electrical lines from the limit 9. Carefully lift the boom from the machine, taking care to switches and generator that go to from the turntable to feed the hydraulic and electrical lines up alongside the the powertrack.
  • Page 167 SECTION 4 - BOOM & PLATFORM 5. Raise the front of the boom enough to allow connection 4.5 BOOM ASSEMBLY of the lift cylinder. Assembly NOTE: Throughout this procedure, boom sections are identified numerically, 1-5. Boom Section 1 is at the base, Boom Sec- tion 5 is the fly.
  • Page 168 SECTION 4 - BOOM & PLATFORM 2. Install the side rear wear pads and shims. Coat the 5. Install the section 5 extend ropes into the mounting holes in the bottom of section 5. Place tape over the retaining bolts with JLG threadlocking compound P/N holes to keep the cables in place during assembly as 0100011 and secure the wear pads with the bolts and shown.
  • Page 169 SECTION 4 - BOOM & PLATFORM 4-18 3121619...
  • Page 170 SECTION 4 - BOOM & PLATFORM 3121619 4-19...
  • Page 171 SECTION 4 - BOOM & PLATFORM 4-20 3121619...
  • Page 172 SECTION 4 - BOOM & PLATFORM 3121619 4-21...
  • Page 173 SECTION 4 - BOOM & PLATFORM 4-22 3121619...
  • Page 174 SECTION 4 - BOOM & PLATFORM 3121619 4-23...
  • Page 175 SECTION 4 - BOOM & PLATFORM 4-24 3121619...
  • Page 176 SECTION 4 - BOOM & PLATFORM 3121619 4-25...
  • Page 177 SECTION 4 - BOOM & PLATFORM 4-26 3121619...
  • Page 178 SECTION 4 - BOOM & PLATFORM 3121619 4-27...
  • Page 179 SECTION 4 - BOOM & PLATFORM 4-28 3121619...
  • Page 180 SECTION 4 - BOOM & PLATFORM 3121619 4-29...
  • Page 181 SECTION 4 - BOOM & PLATFORM 4-30 3121619...
  • Page 182 SECTION 4 - BOOM & PLATFORM 3121619 4-31...
  • Page 183 SECTION 4 - BOOM & PLATFORM 4-32 3121619...
  • Page 184 SECTION 4 - BOOM & PLATFORM 3121619 4-33...
  • Page 185 SECTION 4 - BOOM & PLATFORM 4-34 3121619...
  • Page 186 SECTION 4 - BOOM & PLATFORM 3121619 4-35...
  • Page 187 SECTION 4 - BOOM & PLATFORM 6. Place boom section 4 on a proper supporting device. 10. Install the wire rope retainer blocks to the front of sec- tion 4 boom using the washers, bolts, and nuts. 7. Apply Super Lube® lubricant (JLG p/n 3020042) to all 4 sides of the boom approximately 3 to 4 feet on both ends.
  • Page 188 SECTION 4 - BOOM & PLATFORM 19. Install the rear bottom wear pads to the outside of sec- 22. Install the section 4 extend ropes to section 4. tion 4. Coat the retaining bolts with JLG threadlocking compound P/N 0100011 and secure the wear pads with the bolts and washers.
  • Page 189 SECTION 4 - BOOM & PLATFORM 25. Install the fixed sheave shields, and deflector sheaves 27. Coat the bolts with JLG Threadlocker P/N 0100011 and using the retaining bolts and washers. Coat the bolts install the section 5 extend ropes to section 3 using nuts, with JLG Threadlocker P/N 0100011 before installation.
  • Page 190 SECTION 4 - BOOM & PLATFORM 29. Apply a thin coat of moly paste on I.D. of sheave bear- washers, bolts, and shims. Torque the bolts to 28 ft.lbs. ings. Coat the bolts with JLG Threadlocker P/N 0100011 (38 Nm)) and install the sheaves to the front of section 3 using the pin, keeper, bolt, and washer.
  • Page 191 SECTION 4 - BOOM & PLATFORM 33. Coat the bolts with JLG Threadlocker P/N 0100011. Install the adjustment nuts and lock nuts to the section Install the rear upper wear pads to section 3 using wash- 4 extend ropes. ers, bolts, and shims. Torque the bolts to 28 ft.lbs. (38 44.
  • Page 192 SECTION 4 - BOOM & PLATFORM 51. Apply moly paste to the I.D. of the sheave bearings. 57. Coat the bolts with JLG Threadlocker P/N 0100011. Install the sheaves to section 2 boom. Install the front bottom wear pads to section 1 using washers, bolts, and shims.
  • Page 193 SECTION 4 - BOOM & PLATFORM 4.6 TELESCOPE CYLINDER 4. Remove the bolts securing the adjustment mount and disconnect the adjustment mount from boom section 1. Removal 1. Remove the boom from the machine. Refer to Section - Boom Recovery Mode. 2.
  • Page 194 SECTION 4 - BOOM & PLATFORM 6. Remove the bolts securing the extend rope support and 4.7 BOOM SHIMMING PROCEDURE disconnect the support from boom section 3. NOTE: Throughout this procedure, boom sections are identified numerically, 1-5. Boom Section 1 is at the base, Boom Sec- tion 5 is the fly.
  • Page 195 SECTION 4 - BOOM & PLATFORM 9. Repeat steps 1-7 above to install the Section 5/4 assem- 4.9 BOOM CLEANLINESS GUIDELINES bly into boom Section 3. The following are guidelines for internal boom cleanliness for 10. Repeat steps 1-7 above to assemble the Section 5/4/3 machines that are used in excessively dirty environments.
  • Page 196 SECTION 4 - BOOM & PLATFORM 4.10 HOSE ADJUSTMENT PROCEDURE 5. With clamp D set, pull the hoses and cables until they are resting against the flat bars on the outside radius of the power track. Force additional hydraulic hose slack 1.
  • Page 197 SECTION 4 - BOOM & PLATFORM Figure 4-24. Hose Adjustment 4-46 3121619...
  • Page 198 SECTION 4 - BOOM & PLATFORM 3121619 4-47...
  • Page 199 SECTION 4 - BOOM & PLATFORM 4-48 3121619...
  • Page 200 SECTION 4 - BOOM & PLATFORM 3121619 4-49...
  • Page 201 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09080D 4-50 3121619...
  • Page 202 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09090D 3121619 4-51...
  • Page 203 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09100D 4-52 3121619...
  • Page 204 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09110D 3121619 4-53...
  • Page 205 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09120D 4-54 3121619...
  • Page 206 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09130D 3121619 4-55...
  • Page 207 SECTION 4 - BOOM & PLATFORM 1001157243-D MAF09140D 4-56 3121619...
  • Page 208 SECTION 4 - BOOM & PLATFORM 4.11 JIB 8. Remove the bolt and keeper pin securing the jib level pivot pin and remove the pin. Place blocking under the cylinder rod or a soft material under the cylinder rod to Removal protect the rod from being scratched.
  • Page 209 SECTION 4 - BOOM & PLATFORM 9. Attach an adequate supporting device to the jib to sup- threads and secure the pin in place with the keeper pin port its weight. Remove the bolt and keeper pin secur- and bolt. Torque the bolt to 165 ft.lbs. (224 Nm). ing the jib pivot pin and remove the pin.
  • Page 210 SECTION 4 - BOOM & PLATFORM RUBBER PAD Adhesive PN# 0100081 HOSE CLAMP BOLT KEEPER PIN TORQUE 60 FT.LBS. (82 Nm) JLG Threadlocker PN# 0100011 BOLT KEEPER PIN TORQUE 120 FT.LBS. (163 Nm) JLG Threadlocker PN# 0100011 BOLT KEEPER PIN TORQUE 60 FT.LBS.
  • Page 211 SECTION 4 - BOOM & PLATFORM BOLT TORQUE 190 FT.LBS. (260 N JLG THREADLOCKER PN# 0100011 JLG THREADLOCKER PN# 0100019 BOLT JIB PIVOT JIB LIFT CYLINDER BOLT KEEPER PIN TORQUE 120 FT.LBS. (163 N JLG THREADLOCKER SHIMS PN# 0100011 BOLT TORQUE340 FT.LBS.
  • Page 212 SECTION 4 - BOOM & PLATFORM BOLT LOCKPIN CYLINDER CAP ALIGN CUTOUT IN CAP INWARD AS SHOWN (SEE SECTION A-A BELOW) ALIGN LOCK CYL WITH PROTRUSIONS CAP JIB LOCK CYLINDER (SEE SECTION A-A BELOW) LOCKNUT LOCKPIN CYLINDER CAP ALIGN HOLES IN LOCK CYL WITH PROTRUSIONS IN CAP AS SHOWN ALIGN CUTOUT IN CAP...

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