Oshkosh Corporation JLG 340AJ Service And Maintenance Manual
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Oshkosh Corporation JLG 340AJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
340AJ
PVC 2001
31215004
December 16, 2019 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Model 340AJ PVC 2001 31215004 December 16, 2019 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Bhydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the mobile elevat- ing work platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION nance personnel pay strict attention to these warnings and COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A precautions to avoid possible injury to themselves or others,...
  • Page 4 INTRODUCTION REVISON LOG A - December 16, 2019 Original Issue 31215004...

  • 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. Cylinder Drift ..................2-5 Theory .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.14 Engine RPM Levels ................. 3-71 Engine Stop RPM.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.13 Rotary Actuator ..................4-23 Theory of Operation .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Oil Sampling ..................5-85 Procedure .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. AMP Connector ..................7-6 Applying Silicone Dielectric Compound to AMP Connectors .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Operator Maintenance and Lubrication Diagram ........... . 1-4 2-1.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-54. Engine Speed Sensor Schematic ..............3-74 3-55.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-26. High Pressure Relief and Charge Check Valve with Bypass Valve in relief mode ..... . . 5-35 5-27.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-27. Valve Harness - Sheet 7 of 8 ............... . 7-22 7-28.
  • Page 15 LIST OF TABLES TABLE NO. TITLE PAGE NO. Kubota D1105-E3 ................. . 1-2 GM 0.97L .
  • Page 16 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 17: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.3 CAPACITIES Capacity: Unrestricted: Hydraulic Oil Tank (to Full Level) 20.6 gal. (77.9 L) ANSI 500 lb (227 kg) 25.5 oz. (0.75 L) CE & Australia 507 lb (230 kg) Drive Hub Maximum Travel Grade, stowed Engine Coolant...

  • Page 18: Engine Data

    SECTION 1 - SPECIFICATIONS 1.5 ENGINE DATA 1.6 HYDRAULIC OIL Hydraulic System S.A.E. Viscosity Table 1-1. Kubota D1105-E3 Operating Grade Temperature Range Type Liquid Cooled +0° to + 180° F (-18° to +83° C) Number of Cylinders +0° to + 210° F (-18° to +99° C) 10W-20, 10W 30 Bore 3.07 in.

  • Page 19: Major Component Weights

    SECTION 1 - SPECIFICATIONS Table 1-3. Mobilfluid 424 Specs Table 1-6. Exxon Univis HVI 26 Specs SAE Grade 10W 30 Specific Gravity 32.1 ISO Viscosity Grade Pour Point -76°F (-60°C) Gravity, API 29.0 Flash Point 217°F (103°C) Density, Lb/Gal. 60°F 7.35 Viscosity Pour Point, Max...
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance and Lubrication Diagram 31215004...

  • Page 21: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.7 OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth NOTE: The following numbers correspond to those in Figure 1-1., Operator Maintenance and Lubrication Diagram. Table 1-7. Lubrication Specifications SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460. Hydraulic Oil.
  • Page 22 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 5. Wheel Drive Hub OIL LEVEL CHECK AND FILL Lube Point(s) - Level/Fill Plug Capacity - 25.5 oz. (0.75 L)(1/2 Full) Lube Point(s) - Fill Cap Lube - EPGL Capacity - 24.8 Gal. (93.9 L), 20.6 Gal. (77.9 L) to Full Interval - Check level every 3 months or 150 hrs of oper- Level;...
  • Page 23 SECTION 1 - SPECIFICATIONS 9. Charge Filter 7. Fuel Filter/Water Separator - Kubota Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation Interval - Change after first 50 hrs. and every 6 months 8. Oil Change with Filter - GM or 300 hrs.

  • Page 24: Threadlocking Compound

    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 25: Torque Charts

    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 26: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 27 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 28: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
  • Page 29 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 30: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 31: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...

  • Page 32: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 33 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 34: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
  • Page 35 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 36: 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 37: 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 38: Component Disassembly And Reassembly

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

  • Page 39: Lubrication

    SECTION 2 - GENERAL Lubrication Changing Hydraulic Oil Service applicable components with the amount, type, and 1. Filter elements must be changed after the first 50 hours grade of lubricant recommended in this manual, at the speci- of operation and every 300 hours (unless specified oth- fied intervals.

  • Page 40: 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 41: 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 42 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 43 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 44 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 45 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM. Fluid Properties Base...
  • Page 46 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. 1001120074-A Figure 2-2. Engine Oil Operation Chart - GM NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF...
  • Page 47 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 48: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Wheel Installation It is extremely important to apply and maintain proper wheel Tire Replacement mounting torque. JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine.

  • Page 49: Drive Orientation System

    SECTION 3 - CHASSIS & TURNTABLE 3.2 DRIVE ORIENTATION SYSTEM more detail on the drive speeds, and see Chassis Tilt Indicator System in this section for interaction with the tilt sensor. The Drive Orientation System (DOS) is intended to indicate to the operator conditions that could make the direction of movement of the chassis different than the direction of move- 3.4 DRIVE/STEER - BOOM FUNCTION INTERLOCK...

  • Page 50: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive System Mode Chart Engine Speed when Drive Pump Flow Max. Speed Boom Position Drive Selection Drive is Actuated Displacement Dividers MPH (KPH) Max Speed High-3000 RPM Engaged 0.6 (1.0) Out of Transport Mid-Engine Mid-1800 RPM 3.7%...
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE 6. Align the mark on the valve drive (22) with a hole in the 11. Grease the spacer (30) with petroleum jelly to prevent it outer rim. Turn the disc valve (25) counterclockwise until from dropping out.
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE 13. Drain Plug 18. Cardan Shaft 23. Pressure Plate 28. O-ring 33. Seal Plug 14. Washer 19. O-ring 24. Guide Pin 29. O-ring 34. Bolt 15. Not Used 20. Gear Set 25. Channel Plate 30.
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 31215004...
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE 31215004...
  • Page 55 SECTION 3 - CHASSIS & TURNTABLE 31215004...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 31215004...

  • Page 57: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE HUB Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll, Leak and Brake Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 58: Measuring Rolling Torque

    SECTION 3 - CHASSIS & TURNTABLE Measuring Rolling Torque Main Disassembly 1. Screw one bolt down into the housing and rotate the 1. Perform Roll Check, Leak Check and Brake Check if appli- housing so that the bolt is at twelve o’clock. cable prior to disassembling the unit.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 6. Cover 6G. Retaining Ring 15. ID Plate 17. O-ring Figure 3-7. Main Disassembly - Figure 1 9. Input Shaft 1E. Ring Gear 11. Sun Gear 4E. Planet Shaft 18. O-ring 4F. Planet Gear 19.

  • Page 60: Housing-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 4B. Thrust Washer 4C. Needle Bearing 4D. Thrust Spacer 4F. Planet Gear Figure 3-9. Main Disassembly - Figure 3 15. Repeat Steps 12 though 14 for the remaining two Planet 4. Lift Housing (1D) off of Spindle (1 A). Gears Subassemblies (4F).
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1B. Lip Seal 1C. Ball Bearing 1D. Housing 1F. Bearing Nut 1G. Setscrew 1H. Stud Figure 3-10. Housing-Spindle 3-14 31215004...

  • Page 62: Spindle-Brake Subassembly Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 8A. Brake Piston 8B. Ball Bearing 8D. O-ring 8E. Backup Ring 8F. O-ring 8H. Backup Ring 8J. Brake Rotor 8K. Brake Stator 8L. Spring 8M. Spring 21. Bolt Figure 3-11. Spindle-Brake Subassembly - Figure 1 Spindle-Brake Subassembly Disassembly NOTE: This procedure applies only to units with integral input brake.

  • Page 63: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 2. Remove Compression Springs (8L) and (8M) from Brake Cover Disassembly Piston (8A). 1. Remove Thrust Washer (2) from pocket side of the Cover 3. Using an air hose, slowly and carefully pressurize the (6A), if necessary.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 2. Thrust Spacer 6A. Cover 6B. Disengage Cap 6C. Bolt 6D. Dowel Pin 6E. O-ring 6F. Pipe Plug 6K. O-ring Figure 3-14. Cover 31215004 3-17...

  • Page 65: Planet Gear Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Planet Gear Subassembly 3. Place Spacer (4D) into the bore of the Planet Gear (4F). 4. Repeat Step 2 to put in second roll of Needle Rollers 1. Apply a liberal coat of grease to the bore of one of (4C).

  • Page 66: Spindle-Brake Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Subassembly 3. Place Brake Rotor (8J) on top of Brake Stator (8K). 4. Repeat steps 2 and 3 until there are a total of nine Brake NOTE: Use an air gun to clean the brake port and make sure there Stators (8K) and eight Brake Rotors (8J) installed.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 6. Use Truarc #0100 or equivalent pliers to install Retaining 15. Press Ball Bearing (8B) in the Mounting Adaptor (1N) and Ring (5) into the retaining ring groove in the then install Retaining Ring (8C) into the retaining ring counterbore the Coupling (7).

  • Page 68: Housing-Spindle Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Spindle Subassembly NOTE: Use enough pressure to press in studs. Don’t use excessively high pressures to press in studs or the housing may crack. NOTE: Spray a light film of oil on all component parts during 5.

  • Page 69: Housing-Ring Gear Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Housing-Ring Gear Subassembly planet shaft that does NOT have the roll pin hole should be inserted into the spindle FIRST. 1. Insert Input Shaft (9) into mesh with Coupling’s (7) inter- 4. Now insert Planet Shaft (4E) through the first set of nal splines and place the Thrust Washer (4H) into coun- Thrust Washers (4B), Planet gear, then the second set of terbore of Spindle (1A).

  • Page 70: Cover Subassembly

    SECTION 3 - CHASSIS & TURNTABLE 6. Repeat Steps (2-6) for the installation of the two remain- 9. Install three Shipping capscrews (19) into Ring Gear (1E) ing Planet Gears (4F). and Housing (1G). Torque them to15-20 ft-lbs. 10. With the non-toothed end facing up, place the Sun Gear NOTE: All components should receive a generous amount of lubri- (11) into mesh with the planet gears from the Housing- cant oil as they are being assembled.

  • Page 71: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE 2. Assemble Disengage Cap (6B) onto Cover (6A) using two Main Assembly Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs. 1. Grease O-Ring (17) and insert into groove in Cover Sub- NOTE: It is not necessary to reinstall the larger O-Ring (6K) unless assembly (6).

  • Page 72: Integral Brake Check Procedure

    SECTION 3 - CHASSIS & TURNTABLE Integral Brake Check Procedure 4. Increase pressure to 3,625 psi and hold for 60 seconds to check for leaks. Repair leaks if necessary. 1. Using appropriate fittings to connect hydraulic line from NOTE: Make sure that brake re-engages when pressure is hand pump to the brake port.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 8J 8K 1A SPINDLE 4B THRUST WASHER 6F PIPE PLUG 8L SPRING 1B LIP SEAL 4C NEEDLE BEARING 6G RETAINING RING 8M SPRING 1C BALL BEARING 4D THRUST SPACER 6K O-RING 9 INPUT SHAFT 1D HOUSING 4E PLANET SHAFT 7 COUPLING...
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE Figure 3-24. Bearing Pressing Tool 31215004 3-27...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE Figure 3-25. Seal Pressing Tool Figure 3-26. Drift Pin for Lining Up Thrustwashers with Output Planet Gear 3-28 31215004...
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE 31215004 3-29...

  • Page 77: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.8 OSCILLATING AXLE SYSTEM which allows the axle to float. The first valve is normally closed and opens when actuated to allow flow to the lock-out cylin- The oscillating front axle is attached to the frame by a pivot der circuit.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 31215004 3-31...

  • Page 79: Chassis Tilt Indicator System

    SECTION 3 - CHASSIS & TURNTABLE 3.9 CHASSIS TILT INDICATOR SYSTEM creep speed mode. The operator is responsible for preventing the machine from attaining an unstable position. The Chassis Tilt Indicator System measures the turntable angle The 6° angle is used exclusively for the purpose of automati- with respect to level ground.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Table 3-3. Swing Motor Troubleshooting Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

  • Page 81: Removal

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Secure this end of the shaft when removing the swing motor. If it starts to pull out with the swing motor it could dam- age the internal seals. Torque the swing motor Swing Motor mounting bolts to 95 ft.lbs.

  • Page 82: Disassembly And Inspection

    SECTION 3 - CHASSIS & TURNTABLE 2. Scribe an alignment mark down and across the motor components from end cover (2) to housing (18) to facili- tate reassembly orientation where required. WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX- IMUM AIR PRESSURE REQUIREMENTS.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used 2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used 3. Seal Ring 8.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 4. Remove end cover assembly (2) and seal ring (4). Discard 6. Remove commutator ring (6). Inspect commutator ring seal ring. for cracks, or burrs. 5. Thoroughly wash end cover (2) in proper solvent and 7.
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 8. Remove manifold (7) and inspect for cracks surface scor- wearplate for cracks, brinelling, or scoring. Discard seal ing, brinelling or spalling. Replace manifold if any of ring (4) that is between the rotor set and wearplate. these conditions exist.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 10. Place rotor set (8) and wear plate (9) on a flat surface and 12. Remove thrust bearing (11) from top of coupling shaft center rotor in stator such that two rotor lobes (180 (12).
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 14. Remove coupling shaft (12), by pushing on the output 16. Remove thrust bearing (15) and thrust washer (14). end of shaft. Inspect coupling shaft bearing and seal sur- Inspect for wear, brinelling, corrosion and a full comple- faces for spalling, nicks, grooves, severe wear or corro- ment of retained rollers.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 19. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimen- sional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, dis- card the housing assembly.

  • Page 89: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 21. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) with- SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The dirt and water seal (20) IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE METHODS ARE must be pressed in until its’ flange is flush against the housing.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 6. Assemble thrust washer (14) then thrust bearing (15) 8. Be sure that a generous amount of clean corrosion resis- that was removed from the motor. tant grease has been applied to the lower (outer) hous- ing bearing/bushing (19).
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring 11. Assemble wear plate (9) over the drive link (10) and (4) and insert it into the housing (18) seal ring groove. alignment studs onto the housing (18).
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE NOTE: It may be necessary to turn one alignment stud out of the 15. Assemble the manifold (7) over the alignment studs and housing (18) temporarily to assemble rotor set (8) or mani- drive link (10) and onto the rotor set. Be sure the correct fold (7) over the drive link.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 18. Assemble a new seal ring (3) flat side up, into commuta- tor (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set.

  • Page 95: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the bolts (1) and screw in finger tight. Remove One Piece Stator Construction and replace the two alignment studs with bolts after the A disassembled rotor stator and vanes that cannot be readily other bolts are in place.

  • Page 96: Two Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE 4. Assemble six vanes, or as many vanes that will readily Two Piece Stator Construction assemble into the stator vane pockets. A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures.

  • Page 97: Final Checks

    SECTION 3 - CHASSIS & TURNTABLE 8. Assemble six vanes, or as many vanes that will readily 3.11 SWING DRIVE assemble into the stator vane pockets. The swing drive assembly has five major components. They 9. Grasp the output end of coupling shaft (12) are the housing, worm, worm gear, output pinion and gear / with locking pliers or other appropriate turning device pinion cap.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 3. Install eyebolts as specified in Figure 3-33., Eyebolt for Counterweight in the counterweight. 4. Securely strap the booms together to prevent any movement during the lifting process. 31215004 3-51...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 6. Remove the access covers on either side of the frame to gain entry to the flow divider valve. 7. Pull out the engine tray as far as it will go. Unbolt the 5. If equipped, remove the LP fuel tank on the side of the charge filter bracket so it can be moved aside for more frame.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE M20x2.5 Thread NOTE: All measurements shown are in mm. Figure 3-33. Eyebolt for Counterweight 31215004 3-53...
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 8. Loosen and remove all but a few of the bolts securing 12. Attach chains and slings to support the upperstructure. the turntable to the swing bearing. Begin with the chain at the approximate lengths as shown below and adjust as necessary to maintain the turntable in a level position during lifiting.

  • Page 102: Installation

    SECTION 3 - CHASSIS & TURNTABLE 5. Install several bearing bolts snuggly to secure the turn- table’s position on the swing bearing assembly, but do not torque them at this time and keep the lifting device in place to support the weight of the turntable. 6.

  • Page 103: Turntable Bearing Mounting Bolt Condition Check

    SECTION 3 - CHASSIS & TURNTABLE Turntable Bearing Mounting Bolt Condition Check Wear Tolerance NOTE: This check is designed to replace the existing bearing bolt TURNTABLE REF. torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE POSITION BEARING BODY TO TURNTABLE AS SHOWN (90°) POSITION POINT OF MINIMAL BACKLASH MARKED WITH AN "X" AND ALSO BLUE PAINT, 90° TO THE FRAME IN THIS POSITION. Figure 3-36. Bearing Placement 31215004 3-57...

  • Page 105: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-37. Swing Bearing Torque Sequence Disassembly will come off with cap. Note where sealant is on Cover and plate so when assembling can put sealant in same The servicing of these units requires a press, a 5/16" 12 point place.
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 1. Washer 7. Bolt 13. Grease Fitting 19. Cover Plate 25. Housing 31. Worm Gear 2. Bearing 8. Pressure Vent 14. Slew Ring 20. Worm Cap 26. Cap Shim 32. Worm 3. Oil Seal 9.

  • Page 107: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 7. Remove bearing (15) and Nilos Ring (16) from pinion 7. Install bearing (2) on bore end of worm (32) only. This is (21) using external bearing puller or press. almost a slip fit, may have to be lightly tapped with soft hammer.
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Swing Bearing Removal 31215004 3-61...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE ROUTE HOSES/ CABLES THROUGH GUIDE ROD ON FLY BOOM LEVEL TO LEVEL CYL PORT V1 SYSTEM TANK HOSE & CABLE PULL LENGTHS (UPPER) LEVEL TO LEVEL CYL PORT V2 DIMENSION SYSTEM PRESSURE FROM LAST JIB DESCRIPTION CLAMP (MIN) ROTATOR PRESSURE...
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE SECTION ROTATED 33° CCW (ORIENTATION LOOKING TOWARDS UPPER UPRIGHT) WIRE BUNDLE TO UPRIGHT HYDRAULIC SYSTEM PRESSURE MANIFOLD MAIN LIFT CYLINDER PRESSURE 18/6 CABLE TO MAIN SYSTEM TANK BOOM LIMIT SWITCHES BOOM CABLE AC CABLE 18/6 CABLE TO MAIN BOOM LIMIT SWITCHES TOWER LIFT CYLINDER PRESSURE 18/2 CABLE TO TOWER CYLINDER MANIFOLD...
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE HOSES AND CABLES SHOULD NOT BE HOSES AND CABLES SHOULD BE AGAINST PULLED TIGHT AGAINST THE INSIDE THE OUTSIDE RADIUS OF THE POWER TRACK RADIUS OF THE POWERTRACK INCORRECT CORRECT ROUTE HOSES/ CABLES THROUGH GUIDE ROD ON FLY BOOM SEE DETAIL MAINTAIN HOSE/...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE AC CABLE BOOM CABLE LEVEL TO LEVEL CYL PORT V1 LEVEL TO LEVEL CYL PORT V2 SYSTEM TANK SYSTEM PRESSURE 19 PIN BOOM PLUG/ DETAIL RECEPTACLE LOADING SOCKET WIRE WIRE NUMBER COLOR SIZE AC CABLE SHIELD 18 GA.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE SWITCH SW242 OF LOWER BOOM HARNESS DETAIL LOWER BOOM LIMIT SWITCH LOWER BOOM TO BE 2° TO 5° ABOVE HORIZONTAL TO TRIP SWITCH, 1° BELOW HORIZONTAL TO 5° ABOVE HORIZONTAL TO RESET SWITCH SEE DETAIL SEE DETAIL (3) LIMIT SWITCHES ARE PART OF LOWER BOOM HARNESS...
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE LOWER BOOM HARNESS AC CABLE BOOM CABLE MAIN LIFT CYLINDER PRESSURE SYSTEM PRESSURE TOWER LIFT CYLINDER PRESSURE TOWER LIFT CYLINDER TANK SYSTEM TANK DETAIL SEE DETAIL Figure 3-45. Cable Installation and Identification - Sheet 6 of 8 31215004 3-67...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE CONNECTOR V60 OF UPPER BOOM HARNESS CONNECTOR V61 OF UPPER BOOM HARNESS CONNECTOR V62 OF CONNECTOR V59 OF UPPER BOOM HARNESS UPPER BOOM HARNESS DETAIL UPRIGHT BACK PLATE SHOWN TRANSPARENT SEE DETAIL Figure 3-46. Cable Installation and Identification - Sheet 7 of 8 3-68 31215004...
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE CONNECTOR V57 OF UPPER BOOM HARNESS CONNECTOR V56 OF SEE DETAIL UPPER BOOM HARNESS CONNECTOR V55 OF UPPER BOOM HARNESS DETAIL FLY VALVE COVER SHOWN TRANSPARENT Figure 3-47. Cable Installation and Identification - Sheet 8 of 8 31215004 3-69...

  • Page 117: Engine Operating States

    SECTION 3 - CHASSIS & TURNTABLE 3.12 ENGINE OPERATING STATES • Engine Cranking • Engine Starting The Engine Operating State is determined by the Ground • Engine Running Module. There are four different Engine Operating States which include; • Engine Stopped (Engine Starter Engaged &...

  • Page 118: Engine Start Conditions

    SECTION 3 - CHASSIS & TURNTABLE 3.13 ENGINE START CONDITIONS 3.14 ENGINE RPM LEVELS Engine starting is controlled by the Ground Module. The NOTE: The RPM levels are set in the Analyzer Personalities menu. Ground Module will allow the starter to be engaged and keep the starter energized if all of the following conditions are satis- Multi- High...

  • Page 119: Multi-Function Rpm

    SECTION 3 - CHASSIS & TURNTABLE Multi-Function RPM 3.15 ENGINE CONTROLS Multi-Function RPM occurs when all of the following condi- The Kubota and GM engines are both controlled electronically, but in different manners. The Kubota engine is controlled pri- tions exist; marily by the JLG Control System and the GM engine is con- 1.

  • Page 120: Engine Startup Procedure (Kubota)

    SECTION 3 - CHASSIS & TURNTABLE 3.16 ENGINE STARTUP PROCEDURE (KUBOTA) NOTE: The following procedure is necessary when engine or fuel system maintenance has been performed that will require Ground Module the fuel system to be primed. 1. With the engine off, disconnect the fuel line connection at the engine’s fuel injection pump.

  • Page 121: Kubota Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.17 KUBOTA ENGINE Engine Speed Sensor The engine speed sensor is a variable reluctance sensor used Engine Oil Pressure Switch to measure engine speed by monitoring the flywheel teeth while the engine is running. The engine oil pressure switch monitors oil pressure and sends an electronic message to the control system.

  • Page 122: Coolant Sensor

    SECTION 3 - CHASSIS & TURNTABLE Coolant Sensor Glow Plugs The coolant sensor operates by providing variable resistance The diesel engine has three in-cylinder glow plugs to assist in to ground based on coolant temperature. cold starting. The ground module controls the glow plugs and uses a relay to switch battery current.

  • Page 123: Engine Speed Actuators

    SECTION 3 - CHASSIS & TURNTABLE The Ground Module calculates the length of time the glow Engine Speed Actuators plugs are energized prior to startup based upon ambient tem- Engine speed on the Kubota engine is controlled by two actu- perature, engine coolant temperature, and battery voltage.

  • Page 124: Engine Start

    SECTION 3 - CHASSIS & TURNTABLE PROPORTIONAL FUEL RACK ACTUATOR Alternator Excitation The Proportional Fuel Rack Actuator controls engine speed For the alternator to charge, it must be rotating and the alter- whenever the Control System calls for an engine RPM between nator excitation terminal must be energized by an external Idle and High Engine.
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE 1. Fuel Tank 5. Starter 8. Battery 11. Starter Relay 2. Coolant Recovery Tank 6. Main Pump 9. Air Filter 12. Full Speed Relay 3. Alternator 7. Gear Pump 10. Muffler 13. Glow Plug Relay 4.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE 1. Coolant Recovery Tank 5. Air Filter 7. Fuel Pump 9. Fuel Tank 2. Muffler 6. Fuel Filter/ 8. Fuel Level 10. Radiator 3. Main Pump Water Separator Sending Unit 11. Pressure Cap 4. Gear Pump Figure 3-64.
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE NEGATIVE / GROUND TERMINAL POSITIVE TERMINAL 6,7,8 V83 TO C1 COIL V82 TO C2 COIL CONNECTION ON MAIN PUMP CONNECTION ON MAIN PUMP 1. Radiator 4. Mid Engine Harness 7. Full Speed Relay 10. Gear Pump 12.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE 1. Muffler 5. Negative Battery Post 8. Positive Battery Post 11. Radiator 2. Main Pump 6. Battery 9. Fuel Supply Line 12. Fuel Tank 3. Gear Pump 7. Positive Battery Terminal 10. Fuel Return Line 13.

  • Page 129: Gm Dual Fuel Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.18 GM DUAL FUEL ENGINE Oil Pressure The Ground Module calculates the engine oil pressure based Unlike the Kubota engine, the GM Dual Fuel engine is con- on information sent to it by the engine ECU. trolled by its own Electronic Control Unit (ECU).
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE 1. Fuel Tank 5. Starter 8. Battery 2. Coolant Recovery Tank 6. Main Pump 9. Muffler 3. Radiator 7. Gear Pump 10. Fuel Mixer 4. Oil Filter Figure 3-67. GM Engine - 1 of 6 31215004 3-83...
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE 1. Coolant Recovery Tank 5. Negative/Ground Terminal 8. Gear Pump 2. Fuel Tank 6. Positive Terminal 9. Battery 3. Radiator 7. Main Pump 10. Muffler 4. Oil Filter Figure 3-68. GM Engine - 2 of 6 3-84 31215004...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE VENT HOSE FROM CARBON CANISTER TO LP MIXER PURGE POINT V82 TO C2 COIL V83 TO C1 COIL CONNECTION ON MAIN PUMP CONNECTION ON MAIN PUMP 1. Alternator 4. Main Pump 7. Gear Pump 10.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE 9,10 1. Dipstick 6. Negative Battery Cable 11. Air/Fuel Mixer 16. Fuel Tank 2. Relays 7. Negative Battery Post 12. Air Filter 17. Fuel Lock-off Valve 3. Muffler 8. Battery 13. Fuel Pump 18. Engine Oil Fill Cap 4.
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE EC210 - NEGATIVE TERMINAL ON FUEL PUMP EC210-POSITIVE TERMINAL ON FUEL PUMP SUPPLY FUEL HOSE FROM FILTER TO ENGINE 1. Fuel Level Sensor 5. Gear Pump 8. Fuel Pump 2. Fuel Lock-off Valve 6. Fuel Pump Harness 9.
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE LP MIXER PURGE POINT, HOSE FROM CARBON CANISTER 1. Air Mixer Valve 5. Alternator 8. Carbon Cannister 11. Fuel Mixer 2. Muffler 6. Fuel Level Sensor 9. Coolant Recovery Tank 12. Fuel Lock-off Valve 3.
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description 1561 AUX analog Pull-Down 2 high voltage 1561 AUX analog Pull-Down 3 high voltage 1561 AUX analog Pull-Down 2 low voltage 1561 AUX analog Pull-Down 3 low voltage 1621 RS-485 Rx inactive 1622...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description IAT voltage high IAT voltage low IAT higher than expected stage 1 MAP voltage low MAP pressure high 2229 BP pressure high BP pressure low 1522 CHT higher than expected stage 2 ECT higher than expected stage 2...
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description 1614 Microprocessor failure - RTI 3 1615 Microprocessor failure - A/D 1616 Microprocessor failure - Interrupt Microprocessor failure - RAM CRANK input signal noise Crank signal loss Crank and/or cam could not synchronize du 1629...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description CAM input signal noise Loss of CAM input signal EGO1 open / lazy Knock1 excessive or erratic signa Knock1 sensor open or not present 1643 Buzzer control short to power 1641...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description 1277 2327 Spark coil 10 primary open or short to ground 1277 2328 Spark coil 10 primary shorted 1321 Start relay coil short to power 1321 Start relay ground short 1321...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description 3221 8904 UEGO cal resistor voltage high 3221 8905 UEGO cal resistor voltage low 3221 8901 UEGO microprocessor internal fault 3222 8916 UEGO sense cell impedance high 3222 8902 UEGO heater supply high voltage...
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. GM Engine Diagnostics Codes SPN Code FMI Code Description 520219 1541 AUX analog Pull-Up/Down 1 high voltage 520219 1542 AUX analog Pull-Up/Down 1 low voltage 520220 1543 AUX analog Pull-Up/Down 2 high voltage 520220 1544 AUX analog Pull-Up/Down 2 low voltage...

  • Page 143: Fuel Reserve / Cut-Out System

    SECTION 3 - CHASSIS & TURNTABLE 3.19 FUEL RESERVE / CUT-OUT SYSTEM 3.20 COLD START SYSTEM (DIESEL ENGINE) The Fuel Shutoff System senses when the fuel level is getting The machine control system monitors the engine coolant and low and automatically shuts the engine down before the fuel ambient temperature to make an estimate of cylinder preheat- tank is emptied.

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