Oshkosh Corporation JLG E300AJ Service And Maintenance Manual
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Oshkosh Corporation JLG E300AJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
E300AJ
E300AJP
S/N 0300138358
to Present
P/N - 3121253
October 24, 2013

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  • Page 1 Service and Maintenance Manual Model E300AJ E300AJP S/N 0300138358 to Present P/N - 3121253 October 24, 2013...
  • 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 FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN platform. It is of utmost importance that maintenance per- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON- sonnel pay strict attention to these warnings and precau- NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISON LOG Original Issue - October 27, 2009 Revised - February 3, 2010 Revised - August 23, 2012 Revised - October 24, 2013 – JLG Lift – 3121253...

  • 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 Wear and Damage .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.11 Battery Charger ..............3-56 Operating Instructions .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM JLG Control System Analyzer Kit Instructions ........6-1 Introduction .
  • Page 9 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Hydraulic Oil Specifications ............1-3 1-2.
  • Page 10 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-6. Lower Boom Torque Values ............4-11 4-7.
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-14. DT/DTP Contact Installation ............7-11 7-15.
  • Page 12 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating specifications - E300AJ ..........1-1 Operating specifications - E300AJP .
  • Page 13 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 14: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-3. Dimensional Data - E300AJ Table 1-1. Operating specifications - E300AJ Turning Radius (Inside) 5 ft. (1.52 m) Capacity: Unrestricted: 500 lbs. (227 kg) Turning Radius (Outside) 10ft.

  • Page 15: Capacities

    SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES NOTE: Aside from JLG recommendations, it is not advis- able to mix oils of different brands or types, as they Table 1-5. Capacities may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil Hydraulic Oil Tank 2.9 Gal.
  • Page 16 SECTION 1 - SPECIFICATIONS AIR TEMPERATURE ° F ° C HYDRAULIC FLUID OPERATION CHART Fluid Properties Base Classifications MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPER- Mobilfluid 424 ATURE BOUNDRIES OUTLINED IN THE Mobil DTE 11M HYDRAULIC FLUID OPERATION CHART MAY RESULT IN PREMATURE WEAR OR Mobil DTE 10 Excel 15...

  • Page 17: Function Speeds

    SECTION 1 - SPECIFICATIONS 1.7 FUNCTION SPEEDS Machine Orientation When Doing Speed Tests Table 1-9. Function Speeds NOTE: All tests are to be performed on a smooth, level sur- Speed face. Function in seconds (unless otherwise noted) Lift: Boom Retracted. Telescope Retracted. Lift Up, Record Time, Lift Down, Record Time.
  • Page 18 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance and Lubrication Diagram 3121253 – JLG Lift –...

  • Page 19: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.8 OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth NOTE: The following numbers correspond to those in Fig- ure 1-2., Operator Maintenance and Lubrication Diagram. Table 1-10. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees F.
  • Page 20 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 5. Wheel Drive Hub OIL LEVEL CH 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 - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full Mark Interval - Check level every 3 months or 150 hrs of Lube - HO operation;...
  • Page 21 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque Torque (Loctite® 242 or 271 Tensile (Loctite® 262 or Vibra- Size Bolt Dia Clamp Load Stress Area (Dry) Lubricated OR Vibra-TITE...
  • Page 22 SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque Tensile (Loctite® 242 or 271 (Loctite® 262 or Vibra- (Dry or Loctite® 263) Size Bolt Dia Clamp Load Stress Area OR Vibra-TITE 111 or TITE 131) K= 0.20...
  • Page 23 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load Torque Size Bolt Dia OR Vibra-TITE 111 or (Dry) K = .17 or Vibra-TITE 131) Stress Area See Note 4 140 OR Precoat 85®...
  • Page 24 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Torque Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load (Dry) Size Bolt Dia OR Vibra-TITE 111 or or Vibra-TITE 131) Stress Area See Note 4 K = .20 140 OR Precoat 85®...
  • Page 25 SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® Torque Tensile Clamp Torque (Loctite® 262 or 271 (Dry or Loctite® Size PITCH Stress Load (Lub) OR Vibra- OR Vibra- Area TITE 131) TITE 111 or 140) Sq mm [N.m]...
  • Page 26 SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque (Lub OR Loctite® Torque Torque Tensile (Dry or Loctite® Clamp or 271 (Loctite® 262 Size PITCH Stress Load Vibra-TITE 111 or Vibra-TITE...
  • Page 27 SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque (Lub OR Loctite® Torque Tensile (Loctite® 262 (Dry or Loctite® Clamp Load or 271 Size PITCH Stress OR Vibra-TITE See Note 4 OR Vibra-TITE Area 131)
  • Page 28 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 29: Section 2 - General

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

  • Page 30: 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 Inspec- Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG...

  • Page 31: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the text, standard torque values should be used on When disassembling or reassembling a component, com- heat-treated bolts, studs, and steel nuts, in accor- plete the procedural steps in sequence.

  • Page 32: Hydraulic Oil

    SECTION 2 - GENERAL Changing Hydraulic Oil 2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter 1. Filter elements must be changed after the first 50 entering a system can cause wear or damage to the hours of operation and every 300 hours (unless components and generally results in faulty opera-...

  • Page 33: Cylinder Drift

    SECTION 2 - GENERAL Cylinder Drift 4. Re-assembly of pinned joints using filament wound bearings. Table 2-2. Cylinder Drift a. Housing should be blown out to remove all dirt and debris...bearings and bearing housings Max. Acceptable Drift Cylinder Bore Diameter in 10 Minutes must be free of all contamination.
  • Page 34 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre- Weekly Monthly Annual AREA Delivery Every 2 Pre-Start Preventive Preventive (Yearly) Years Inspection or Frequent Maintenance Maintenance Inspection Inspection Boom Assembly 1,2,4 1,2,4 Boom Weldments 1,2,9,12 1,2,9,12 Hose/Cable Carrier Installations Pivot Pins and Pin Retainers Sheaves, Sheave Pins...
  • Page 35 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre- Weekly Monthly Annual AREA Delivery Every 2 Pre-Start Preventive Preventive (Yearly) Years Inspection or Frequent Maintenance Maintenance Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 36 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre- Weekly Monthly Annual AREA Delivery Every 2 Pre-Start Preventive Preventive (Yearly) Years Inspection or Frequent Maintenance Maintenance Inspection Inspection All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated...
  • Page 37 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 38: Section 3 - Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten Tire Wear and Damage the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper...
  • Page 39 SECTION 3 - CHASSIS & TURNTABLE RIGHT SIDE VIEW WITH HUB REMOVED 1. Axle Assembly 2. Spindle Assembly 3. Tie Rod 4. Steer Cylinder 5. Thrust Washer 6. Thrust Bearing Torque 35 ft. lbs. (48 Nm) Threadlocker JLG P/N 0100011 Figure 3-1.
  • Page 40 SECTION 3 - CHASSIS & TURNTABLE 1. Drive Motor 2. Gasket 3. Drive Brake 4. Drive Hub 5. Gasket 6. Speed Sensor 7. Tire & Wheel 8. Lug Nut Note 1 Note 2 Thread Locking Compound JLG P/N 0100019 Note 1: Torque to 240 ft. lbs. (325 Nm) Note 2: Before installing brake and motor, apply a light coat of grease to the splined shafts Figure 3-2.

  • Page 41: Spindle

    SECTION 3 - CHASSIS & TURNTABLE 3.2 SPINDLE Specifications The end play specification is 0.001”/0.010" (0.025 / 0.254 Setting Wheel Bearing End Play mm) for all units. Checking The end play is checked by clamping the spindle in a fix- BE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT.
  • Page 42 SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Cotter Pin 3. Spindle Nut 4. Spindle Washer 5. Stud Nut 6. Bearing Cone 7. Hub 8. Bearing Cone 9. Seal 10. Spindle Figure 3-3. Spindle Assembly 3121253 – JLG Lift –...

  • Page 43: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB Main Disassembly 1. Perform Roll Check and Leak Check if applicable Roll and Leak Testing prior to disassembling the unit. Torque-Hub units should always be roll and leak tested 2. Drain oil from unit. Note the condition and volume of before disassembly and after assembly to make sure the oil.
  • Page 44 SECTION 3 - CHASSIS & TURNTABLE NOTE: On units with a ratio 48:1, the Sun Gear (11) and the 12. Lift the Ring Gear (1F) off of the Housing (1G). Input Shaft (9) will need to be removed together. 13. Remove the O-ring (18) from between the Housing (1G) and the Ring Gear (1F).
  • Page 45 SECTION 3 - CHASSIS & TURNTABLE Input Shaft 1F. Ring Gear 10. First Stage Sun Gear 1G. Housing 11. Second Stage Sun Gear Output Carrier Subassembly 18. O-ring Retaining Ring 19. Flat Head Bolts Cover Assembly 20. Retaining Ring 6G. Retaining Ring Figure 3-5.

  • Page 46: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly 3. Using a 1/8" diameter punch, drive the Roll Pin (4G) out of the Planet Shaft (4E). NOTE: The Roll Pins (4G) should not be reused when reassembling the 1. Using a 1/8" diameter punch, drive the Roll Pin (4G) unit.
  • Page 47 SECTION 3 - CHASSIS & TURNTABLE 5. Remove 4 Thrust Washers (4B), 28 Needle Rollers 6. Repeat Steps 1 though 5 for the remaining two (4C) and the Thrust Spacer (4D) from the Second Planet Gears (4F). Stage Planet Gear (4F). 7.

  • Page 48: Input Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly (4G) should not be reused when reassembling the unit. 1. Using a 1/8" diameter punch, drive the Roll Pin (4G) 4. Slide the Planet Gear (3F) and the two Thrust Wash- into the Planet Shaft (3E) until it bottoms against the ers (3B) out of the Carrier (3A).

  • Page 49: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Disassembly 6. If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end. 1. Place unit on bench with Spindle (1 A) end down. 7. Remove Seal (1B) from Hub (1G). 2.

  • Page 50: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A). 5. Use appropriate tool to remove O-ring (6E) from 1. Remove O-Ring (17) from groove in Cover (6A). internal groove in Cover (6A). 2.

  • Page 51: Input Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Assembly Output Planet Gear Assembly (Refer to Figure 3-8., Input Carrier) (Refer to Figure 3-7., Planet Gear) 1. Apply a liberal coat of grease to the bore of one 1. Apply a liberal coat of grease to the bore of one Out- Input Planet Gear (3F).

  • Page 52: Output Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Assembly Hub-Spindle Assembly (Refer to Figure 3-9., Hub Spindle) (Refer to Figure 3-6., Output Carrier) NOTE: Spray a light film of oil on all component parts during 1. Place Thrust Washer (4H) into counterbore of Carrier assembly.
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Hub Assembly - Sheet 1 of 2 3-16 – JLG Lift – 3121253...
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE 1A Spindle 3B Thrust Washer 6C Bolt, Hex (.250-20 Unc, .500 Gr5) 1B Lip Seal 3C Needle Bearing 6D Dowel Pin 1C Tapered Bearing Cone 3E Planet Shaft 6E O-ring 1D Tapered Bearing Cup 3F Planet Gear 6F Pipe Plug 1E Tapered Bearing Cone...

  • Page 55: Cover Subassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Subassembly NOTE: The output carrier sub-assembly does not need timed with the spindle splines. (Refer to Figure 3-10., Cover Assembly) 5. Place Output Carrier Sub-Assembly (4) into mesh with Spindle (1A) splines. 1. Grease O-Ring (6E) and insert into internal groove in Cover (6A).
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Cup Pressing Tool Figure 3-14. Cup Pressing Tool 3121253 – JLG Lift – 3-19...

  • Page 57: Drive Brake - Mico

    SECTION 3 - CHASSIS & TURNTABLE 3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in cover (21). Disassembly NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. This 1.
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE NOTE: The speed sensor port in the cover (21) should be 180° from the brake release port in the pressure plate (3). 1. Capscrew 7. Piston 13. Rotor Disc 19. Retaining Ring 2. Washer 8.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Drive Brake Diagnosis Corrective Problem Cause Explanation Action Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions system brake, holding torque will be reduced. in other hydraulic components.

  • Page 60: Speed Sensor Adjustment

    SECTION 3 - CHASSIS & TURNTABLE 3.5 SPEED SENSOR ADJUSTMENT Speed Sensor Installation Verification The motor controller averages the readings from the right and left speed sensors and therefore, it can be difficult to detect if the speed sensors are adjusted properly. When the positrac keeps coming in and out while on level sur- faces, this is a sure indication that one of the speed sen- sors is not adjusted properly.

  • Page 61: Verification W/ Analyzer Procedure

    SECTION 3 - CHASSIS & TURNTABLE Verification w/ Analyzer Procedure 4. Use the right and left cursor keys on the analyzer to highlight "DIAGNOSTICS" and press enter. The motor controller averages the readings from the right 5. Use the right and left cursor keys on the analyzer to and left speed sensors and therefore, it can be difficult to highlight "DRIVE"...

  • Page 62: Positrac/Tilt Module

    SECTION 3 - CHASSIS & TURNTABLE 3.6 POSITRAC/TILT MODULE 18. While watching the analyzer display select drive for- ward. Be ready to remove your foot from the foot- When installing a new positrac/tilt module, Refer to switch if the machine lunges forward. JLG Control System Analyzer Kit instructions.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE BLACK WHITE WIRE GREEN WIRE WIRE WIRE NOTCH NOTCH BLACK WIRE WHITE WIRE GREEN WIRE WIRE SENSOR IN SENSOR IN LEFT MOTOR BRAKE RIGHT MOTOR BRAKE WIRE WHITE WIRE GREEN BLACK BLACK WIRE WIRE WIRE GREEN NOTCH...
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE MAIN CONTACTOR FWD/REV POSI-TRAC CONTACTOR CONTACTOR POSI-TRAC/TILT MODULE DRIVE MOTOR B POWER DIODE DRIVE MOTOR A Figure 3-17. Frame Mounted Electrical Components 3121253 – JLG Lift – 3-27...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 3-28 – JLG Lift – 3121253...

  • Page 66: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.7 SWING MOTOR Figure 3-19. Swing Motor - Cutaway IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY.
  • Page 67 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 68 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 6. Commutator Ring 12. Coupling Shaft 17. Backup Ring 22. Not Used 8C. Stator Vane 2. End Cover 7. Manifold 13. Inner Bushing 18. Housing 23. Not Used 8D. Stator Half 3. Seal Ring 8.

  • Page 69: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly flange or port bosses. Remove manifold port O- Rings if applicable. • Before you disassemble the motor unit or any of its components read this entire section. It provides impor- tant information on parts and procedures you will need to know to service the motor.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE these conditions exist, replace commutator and tion of both sides of the manifold to ensure that same commutator ring as a matched set. surface is reassembled against the rotor set. 9. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintain- ing the same rotor vane to stator contact surfaces.
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 12. Remove thrust bearing (11) from top of coupling NOTE: A polished pattern on the wear plate from rotor rota- shaft (12). Inspect for wear, brinelling, corrosion and tion is normal. a full complement of retained rollers. 10.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE keyway. Replace coupling shaft if any of these con- 16. Remove thrust bearing (15) and thrust washer (14). ditions exist. Inspect for wear, brinelling, corrosion and a full com- plement of retained rollers. 17. Remove seal (16) and back up ring (17) from hous- ing (18) and backup washer (25).
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE rosion. Remove burrs that can be removed without replaced. If the housing has passed this inspection changing dimensional characteristics. Inspect the disassembly of the motor is completed. tapped holes for thread damage. If the housing is defective in these areas, discard the housing assem- bly.

  • Page 75: 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 hous- SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN ing (18) without damaging the housing. Remove USING ANY SOLVENT.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE RECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN seal (20) must be pressed in until its’ flange is flush ASSEMBLED. against the housing. 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 6. Assemble thrust washer (14) then thrust bearing (15) coupling shaft (12) into housing (18), seating it that was removed from the motor. against the thrust bearing (15). NOTE: The motor requires one thrust washer (14) with thrust bearing (15).
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal 11. Assemble wear plate (9) over the drive link (10) and ring (4) and insert it into the housing (18) seal ring alignment studs onto the housing (18).
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs NOTE: It may be necessary to turn one alignment stud out and drive link (10) and onto the rotor set. Be sure the of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE of drive link (10) onto manifold (7) with seal ring side 19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).

  • Page 81: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE cover and other components into place with a final 1. Place stator onto wear plate (9) with seal ring (4) torque of 25-30 ft. lbs. (34-41 N m). side down, after following assembly procedures 1 through 13.

  • Page 82: Two Piece Stator Construction

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

  • Page 83: Final Checks

    SECTION 3 - CHASSIS & TURNTABLE 3.8 SWING DRIVE 8. Assemble six vanes, or as many vanes that will read- ily assemble into the stator vane pockets. NOTE: The swing drive must be removed from the machine 9. Grasp the output end of coupling shaft (12) to be serviced.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 1. Bearing 8. Seal 14. Slew Ring 20. Cover Plate 26. Shim 2. Oil Seal 9. Grease Fitting 15. Bearing 21. Worm Cap 27. Shim 3. Capscrew 10. Grease Fitting 16. Ring 22. Pinion 28.

  • Page 85: Assembly

    SECTION 3 - CHASSIS & TURNTABLE 5. Using a press, disassemble the pinion and gear 5. Turn the assembly over and place the spacer (25) on assembly. Support the worm gear (30) on the press the pinion against the gear hub so the large chamfer with the pinion (22) down allowing room for pinion to on the I.D.

  • Page 86: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.9 SWING BEARING 11. Install the worm cap (21) using proper shims (28) to achieve 0.000 to 0.001" (0.000 to 0.025 mm) end play. Apply LocTite 242 to end of 1/2-13 x 1.25" Turntable Bearing Mounting Bolt Condition grade 5 bolts (5) and LocTite #515 sealant to shims.

  • Page 87: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE c. Lower the main boom to horizontal and fully extend the boom. d. At the position indicated on Figure 3-24., Swing Bearing Tolerance Boom Placement try and insert the.0015” feeler gauge between the bolt head and hardened washer at the arrow indi- cated position.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE JIB ELEVATED 90 DEGREES PLATFORM ROTATED 90 DEGREES MAIN BOOM FULLY ELEVATED AJP Models AND FULLY RETRACTED LOWER BOOM FULLY ELEVATED NOTE MEASURING POINT Figure 3-24. Swing Bearing Tolerance Boom Placement 3121253 – JLG Lift – 3-51...
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE MAIN BOOM MAIN BOOM FULLY EXTENDED HORIZONTAL LOWER BOOM FULLY ELEVATED NOTE MEASURING POINT Figure 3-25. Swing Bearing Tolerance Boom Placement 3-52 – JLG Lift – 3121253...

  • Page 90: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE Replacement of Swing Bearing 2. Installation. a. Install bearing to rotation box with two cap 1. Removal. screws, so that fill plug of bearing is as close to gear as bolt pattern will allow. Do not tighten cap a.

  • Page 91: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE f. Following the torque sequence diagram shown k. Following the torque sequence shown in Figure i n F i g u r e 3 - 2 6 . , S w i n g B e a r i n g To r q u e 3-26., Swing Bearing Torque Sequence, tighten Sequence, tighten the bolts to an initial torque of the bolts to an initial torque of 150 ft.

  • Page 92: Battery Maintenance And Charging

    SECTION 3 - CHASSIS & TURNTABLE 3.10 BATTERY MAINTENANCE AND Battery Charging, Daily CHARGING NOTE: To avoid excessive battery charging time, do not allow batteries to become completely discharged. TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR NOTE: To avoid electrolyte overflow, add distilled water to ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC- batteries after charging.

  • Page 93: Battery Charger

    SECTION 3 - CHASSIS & TURNTABLE 3.11 BATTERY CHARGER Maintenance Instructions 1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN battery manufacturer.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 1. Battery Terminal Grease 2. Left Battery Box 3. Dielectric Grease 4. Battery Connector 5. Draw Latch 6. Battery 7. Battery Hold Down 8. Right Battery Box 9. Left Cover 10. Right Cover 11. Latch * Apply to Battery Terminal Connections Only ** Apply to Contacts of Connectors Only 1001108560-B...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE NO LIGHTS AT ALL [3 Flashes] - Charge Timeout No Lights at all indicate that AC power to the charger is Indicates the battery failed to charge within the allowed not connected or that the AC voltage is too low. It could time.

  • Page 96: Excessive Battery Watering Requirements Or Strong Sulphur (Rotten Egg) Smell

    SECTION 3 - CHASSIS & TURNTABLE Excessive Battery Watering Requirements or [5 Flashes] - Over Temperature Strong Sulphur (Rotten Egg) Smell This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge These symptoms indicate over-charging or high battery time will be extended significantly.

  • Page 97: Checking/Changing The Battery Charger Algorithm

    SECTION 3 - CHASSIS & TURNTABLE Checking/Changing the Battery Charger 3. Remove the AC power from the charger and recon- nect the charger’s positive connector to the battery. Algorithm It is recommended to check a newly changed algo- rithm by repeating the above steps 1 and 3. The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Table 3-4.

  • Page 98: Drive Orientation System

    SECTION 3 - CHASSIS & TURNTABLE 3.13 DRIVE ORIENTATION SYSTEM turntable is swung past the switch point, the system is ignored until drive/steer is released. When drive is initiated The Drive Orientation System (DOS) is intended to indi- with the boom swung past the switch point, the DOS indi- cate to the operator conditions that could make the direc- cator will flash and the drive/steer functions will be dis- tion of movement of the chassis different than the...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 56.0° WHEN BOOM IS OUTSIDE THIS 56° WINDOW OVER REAR TIRES, DRIVE ORIENTATION OVERRIDE MUST BE ACTIVATED TO ALLOW DRIVE TO BE ENABLED. +.00 -.13 CLEARANCE FOR SWITCH TO TARGET WITH HORIZONTAL SLOTS IN ITEM #14 SWITCH MOUNTING UNLESS OTHERWISE SPECIFIED, ALL BRACKET...
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE * AJ = 6188 ± 130 lbs. (2807 ± 59 kg) * AJP = 6406 ± 130 lbs. (2906 ± 59 kg) COUNTER- WEIGHT* RETAINING HOOK TURNTABLE RETAINING BOLT, NOTE A, NOTE B A - Torque 285 ft.lbs. (388 Nm) B - Apply JLG P/N 0100019Thread Locking Compound Figure 3-30.
  • Page 101 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 102: Section 4 - Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE 14. Unbolt the power track from the boom and remove the power track and hoses/lines from the boom. Removal of the Main Boom 15. Remove the cover at the rear of the boom. 16.
  • Page 103 SECTION 4 - BOOM & PLATFORM 1. Tower Lift Cylinder 2. Tower Upright 3. Upper Upright 4. Upper Lift Cylinder 5. Master Cylinder 6. Level Cylinder 7. Boom Assembly 8. Jib Rotator 9. Jib Figure 4-1. Boom Assembly – JLG Lift – 3121253...

  • Page 104: Inspection

    SECTION 4 - BOOM & PLATFORM Assembly of the Main Boom NOTE: The telescope cylinder weighs approximately 53 lbs. (24 kg). 1. Lubricate the boom sections as shown in Figure 4- 2., Boom Lubrication Instructions. 6. Using a suitable lifting device, remove telescope cyl- inder from the rear of the boom sections.

  • Page 105: Installation Of The Main Boom

    SECTION 4 - BOOM & PLATFORM MODERATELY APPLY BOOM GREASE TO ALL FOUR OUTER SURFACES OF FLY MODERATELY APPLY BOOM GREASE TO OUTER BOOM TUBE IN SPECIFIED LOCATION SURFACE OF WEAR PADS ON FLY BOOM (8X) JLG P/N 3020022 JLG P/N 3020022 12”...
  • Page 106 SECTION 4 - BOOM & PLATFORM POSITION BOTH LEVEL CYL HOSES TO THE OUTSIDE OF PUSH TUBE AS SHOWN PLATFORM SUPPLY HOSE PLATFORM RETURN HOSE LOWER BOOM CONTROL HARNESS WELD LEAD OR AIR LINE A/C CABLE ROUTED ON TOP OF JIB CYL HOSES JIB CYL EXTEND HOSE JIB CYL RETRACT HOSE LEVEL (MASTER) RETRACT HOSE...
  • Page 107 SECTION 4 - BOOM & PLATFORM ORIENT CLAMP BLOCK SECTIONS USING ALIGNMENT HOLES AS SHOWN PUSH NUT CLAMP BLOCK INSTALLATION INSTRUCTIONS 1. TO PROVIDE ORIENTATION OF THREADED STUDS, LOOSELY INSTALL THREADED STUD INTO CLIP NUT UNTIL FIRST SECTION OF CLAMP BLOCK IS INSTALLED 2.
  • Page 108 SECTION 4 - BOOM & PLATFORM Use JLG P/N 0100011 Thread Locking Compound or equivalent Figure 4-2. Boom Thread Locking Compound Location 3121253 – JLG Lift –...
  • Page 109 SECTION 4 - BOOM & PLATFORM A - Torque35 ft.lbs. (48 Nm) B - Torque 85 ft.lbs. (116 Nm) Figure 4-3. Boom Torque Values – JLG Lift – 3121253...
  • Page 110 SECTION 4 - BOOM & PLATFORM 1. Link 6. Upper Upright 2. Level Link 7. Tower Upright 3. Lower Boom 8. Tower Lift Cylinder 4. Mid Boom 9. Bumper 5. Timing Link 10. Hose Channel Figure 4-4. Lower Boom 3121253 –...
  • Page 111 SECTION 4 - BOOM & PLATFORM Use JLG P/N 0100011 Thread Locking Compound or equivalent Figure 4-5. Lower Boom Thread Locking Compound Location 4-10 – JLG Lift – 3121253...
  • Page 112 SECTION 4 - BOOM & PLATFORM A - Torque35 ft.lbs. (48 Nm) B - Torque 85 ft.lbs. (116 Nm) Figure 4-6. Lower Boom Torque Values 3121253 – JLG Lift – 4-11...
  • Page 113 SECTION 4 - BOOM & PLATFORM 1. Platform Rotator 2. Jib Rotator 3. Upper Jib Link 4. Jib Link 5. Jib Cylinder 6. Platform Support 7. Jib Rotator Center Bolt 8. Platform Rotator Center Bolt Figure 4-7. AJP Jib 4-12 –...
  • Page 114 SECTION 4 - BOOM & PLATFORM A,E,F B,E,F NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Torque to 35 ft.lbs. (48 Nm) Torque to 85 ft.lbs. (115 Nm) Torque to 250 ft. lbs. (339 Nm) Torque to 480 ft.
  • Page 115 SECTION 4 - BOOM & PLATFORM NOTE: UPPER BOOM ANGLE TO BE 1° BELOW HORIZONTAL TO 3° ABOVE HORIZONTAL TO ACTIVATE SWITCH. UPPER BOOM ANGLE TO BE 1° TO 4° BELOW HORIZONTAL TO RESET SWITCH. NOTE: LOWER BOOM ANGLE TO BE 1° TO 5°...

  • Page 116: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.2 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other side of track. Remove the bar/poly roller from the powertrack. . Removing a Link NOTE: Hoses shown in the powertrack are for example only. Actual hose and cable arrangements will be differ- ent.
  • Page 117 SECTION 4 - BOOM & PLATFORM 3. To remove a link, the rivets holding the links together 4. insert the tool into the rolled over end of the rivet as must be removed. Use a right-angle pneumatic die shown. Grind out the middle of the rivet until the grinder with a ¼”...
  • Page 118 SECTION 4 - BOOM & PLATFORM 5. After grinding it may be neccesary to help the rivet 6. Using a flat head screwdriver between the links, out by using a center punch with a hammer. twist the screwdriver and pull the links apart. NOTE: It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links.

  • Page 119: Installing A New Link

    SECTION 4 - BOOM & PLATFORM Installing a New Link 7. Remove the link from the other section of the pow- ertrack using a screwdriver. 1. Squeeze the peanut cut out end of the new link into the half-shear (female) end of the track section. 4-18 –...
  • Page 120 SECTION 4 - BOOM & PLATFORM 2. Spread apart the half-shear (female) end of the new 3. After the new link is installed in the powertrack the link and slide the peanut end of the track section round half-shears will not fit properly in the peanut into it.
  • Page 121 SECTION 4 - BOOM & PLATFORM 4. Pull the moving end out over the track so that the 6. Push pin thru center hole then slide washer on pin. new connection is positioned in the curve of the powertrack. In this position the round half-shears will rotate into the peanut cut outs.
  • Page 122 SECTION 4 - BOOM & PLATFORM 8. Hold new aluminum round bar tightly, then install NOTE: When installing snap rings make sure they are new 8-32 x 0.500 self-threading torx head screw into seated in pin groove and closed properly. one end.
  • Page 123 SECTION 4 - BOOM & PLATFORM 9. Pull up on the other end of the round bar and slide 10. Install a new 8-32 x 0.500 self threading screw on the new poly roller onto the bar. the other side. NOTE: When tightening screws make sure screw head is seated against link with no space in between the link and underside of screw head.

  • Page 124: Replacing Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Fixed End Brackets CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM. 1. Remove the rivets the same way as shown under the link removal instructions. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM.

  • Page 125: Replacing Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replacing Moving End Brackets 3. Take the new bracket and install bracket center pin and snap ring. Repeat on the other bracket if replac- ing it as well. 1. Remove existing pins and center rivet. Remove the NOTE: When installing snap rings make sure they are rivet the same way as shown in the link removal seated in pin groove and closed properly.
  • Page 126 SECTION 4 - BOOM & PLATFORM 2. Take new bracket and install center pin with snap ring. MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM.
  • Page 127 SECTION 4 - BOOM & PLATFORM 3. Install radius pins into their original locations and NOTE: When installing snap rings make sure they are install snap rings. Repeat with other moving end if seated in pin groove and closed properly. replacing as well.

  • Page 128: Boom Cleanliness Guidelines

    SECTION 4 - BOOM & PLATFORM 4.3 BOOM CLEANLINESS GUIDELINES 4.4 TILT SENSOR CHECK The following are guidelines for internal boom cleanliness for machines that are used in excessively dirty environ- ments. PERFORM TILT SENSOR CHECK PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND 1.

  • Page 129: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.7 ROTARY ACTUATOR Required Tools Upon assembly and disassembly of the actuator there are Theory of Operation basic tools required. The tools and their intended func- tions are as follows: The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation.
  • Page 130 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing 3. Piston Sleeve 106.1. Port Plug 204.
  • Page 131 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing 3. Piston Sleeve 106.1. Port Plug 204.

  • Page 132: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out the entire pin. 1. Remove the capscrews (113) over end cap lock pins 4. Install the end cap (4) removal tools provided with (109).
  • Page 133 SECTION 4 - BOOM & PLATFORM 6. Remove the end cap (4) and set aside for later 8. Every actuator has timing marks for proper engage- inspection. ment. 7. Remove the stop tube if included. The stop tube is an available option to limit the rotation of the actua- tor.
  • Page 134 SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike 13. At the point when the piston gear teeth come out of the threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the piston and housing with a marker as shown.
  • Page 135 SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easi- 19. Remove the piston O.D. seal (202). est to cut them using a sharp razor blade being careful not to damage the seal groove. 20.

  • Page 136: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123” or 3.12 mm). 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth.
  • Page 137 SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end 4. Using a seal tool install the main pressure seal (205) cap (4). onto shaft (2) and end cap (4). Use the seal tool in a circular motion.
  • Page 138 SECTION 4 - BOOM & PLATFORM Each T-seal has 2 back-up rings (see drawing for ori- 7. Insert the piston (3) into the housing (1) as shown, entation). until the outer piston seal (202) is touching inside the housing bore. Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in 8.
  • Page 139 SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) 11. Looking from the view shown, use the existing tim- ing marks to line up the gear teeth on the shaft (2) you can see if your timing marks are lining up. When with the gear teeth on the inside of the piston (3).
  • Page 140 SECTION 4 - BOOM & PLATFORM 14. Coat the threads on the end of the shaft with anti- 17. Tighten the end cap (4). In most cases the original seize grease to prevent galling. holes for the lock pins will line up. 18.

  • Page 141: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Testing the Actuator If the equipment is available, the actuator should be tested Refer to Figure 4-12., Rotator Counterbalance Valve. on a hydraulic test bench. The breakaway pressure — the pressure at which the shaft begins to rotate — should be 1.
  • Page 142 SECTION 4 - BOOM & PLATFORM Figure 4-12. Rotator Counterbalance Valve 3121253 – JLG Lift – 4-41...

  • Page 143: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two bleed nipples. Secure them with hose clamps. After installation of the actuator on the equipment, it is Place the vinyl tubes in a clean 5-gallon container to important that all safety devices such as tie rods or safety collect the purged oil.

  • Page 144: Troubleshooting

    SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator. b.
  • Page 145 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 146: Section 5 - Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com- pletely saturated.

  • Page 147: Dip Method

    SECTION 5 - HYDRAULICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this 2.

  • Page 148: Hydraulic Cylinders

    SECTION 5 - HYDRAULICS 5.2 HYDRAULIC CYLINDERS GLAND SEAL DISASSEMBLY Disassembly NOTE: Disassembly of the cylinder should be performed on a clean work surface in a dirt free work area. 1. Drain the oil from the cylinder. 2. Place the cylinder in a suitable holding fixture. 3.
  • Page 149 SECTION 5 - HYDRAULICS 8 10 18** * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max *** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max 1001107886-D 1. Tube Assembly 7. Backup Ring 13. Piston Seal 19. Plug 2.
  • Page 150 SECTION 5 - HYDRAULICS 20** * Torque 25-30 ft.lbs. (34-40.5 Nm) Max ** Torque 20 ft.lbs. (27 Nm) Max *** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max 1001106880-D 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug 2. Rod Assembly 7.
  • Page 151 SECTION 5 - HYDRAULICS 1001105989-B 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing 2. Rod Assembly 7. Backup Ring 12. Piston 17. Plug 3. Gland 8. Bushing 13. Piston Seal 4. Dust Wiper 9. O-ring 14. O-ring 5. Retaining Ring 10.
  • Page 152 SECTION 5 - HYDRAULICS * Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1001105153-C 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing 21. Phase Valve 2. Rod Assembly 7. Backup Ring 12. Piston 17. Counterbalance Valve 3. Gland 8. Bushing 13.
  • Page 153 SECTION 5 - HYDRAULICS 18** * Torque 18-20 ft. lbs. (24.5-27 Nm) Max 19** ** Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1001106878-C 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug 2. Rod Assembly 7. Backup Ring 12.
  • Page 154 SECTION 5 - HYDRAULICS * Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Hex Nut 21. Plug 2. Rod Assembly 7. Backup Ring 12. Piston 17. Bearing 3. Gland 8. Bushing 13. Piston Seal 18.
  • Page 155 SECTION 5 - HYDRAULICS 1001108310-B 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing 2. Rod Assembly 7. Backup Ring 12. Piston 17. Bearing 3. Gland 8. Bushing 13. Piston Seal 18. Plug 4. Dust Wiper 9. O-ring 14. O-ring 5.
  • Page 156 SECTION 5 - HYDRAULICS 18** * Torque 18-20 ft. lbs. (24.5-27 Nm) Max 19** ** Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1001106879-D 1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug 2. Rod Assembly 7. Backup Ring 12.

  • Page 157: Cleaning And Inspection

    SECTION 5 - HYDRAULICS 4. Withdraw the O-ring and back up ring carefully as 11. Inspect the cylinder head outside diameter for dam- not to damage the seals. age, ovality and tapering. If necessary, replace it. 5. It is impossible to disassemble the bushing because 12.

  • Page 158: Phase Check Cartridge

    SECTION 5 - HYDRAULICS Phase Check Cartridge 4. Push the piston to the rod assembly to the end of the thread and then install the piston nut. When The phase valve is a back-to-back pair of check valves, installing the piston nut, gland and valve, refer to one of which is mechanically actuated.

  • Page 159: Pressure Setting Procedure

    SECTION 5 - HYDRAULICS 5.3 PRESSURE SETTING PROCEDURE SWING RIGHT / LEFT – 750 PSI (52 BAR) Adjustments made at the Main Valve Bank MAIN PRESSURE RELIEF VALVE – 3000 PSI (207 BAR) SWING RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank.
  • Page 160 SECTION 5 - HYDRAULICS STEER RIGHT – 1400 PSI (97 BAR)) STEER LEFT – 2000 PSI (138 BAR) STEER LEFT STEER RIGHT RELIEF VALVE RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve 1. Install pressure gauge at port MP of Main Valve Bank.

  • Page 161: Adjustments Made At The Boom Function Valve Bank

    SECTION 5 - HYDRAULICS Adjustments made at the Boom Function JIB LIFT DOWN – 1200 PSI (83 BAR) Valve Bank JIB LIFT UP – 2000 PSI (138 BAR) JIB DOWN RELIEF VALVE 1. Install pressure gauge at port MP of Main Valve Bank.
  • Page 162 SECTION 5 - HYDRAULICS PLATFORM LEVEL UP – 3000 PSI (207 BAR) • at port M15 of Boom Function Valve PLATFORM LEVEL UP RELIEF VALVE 1. Refer to the Main Pressure Relief Valve procedure and temporarily set Main Pressure Relief Valve to •...
  • Page 163 SECTION 5 - HYDRAULICS • at end of platform level up hose (do not use this loca- PLATFORM LEVEL DOWN – 1200 PSI (83 BAR) tion if port 15 was chosen in step 2.) PLATFORM LEVEL UP HOSE 4. Activate Platform Level Up and hold. Take pressure reading.
  • Page 164 SECTION 5 - HYDRAULICS 4. After loosening relief valve jam nut, adjust valve clockwise to increase pressure or counterclockwise to reduce pressure accordingly. 5. Tighten relief valve jam nut. Repeat step 3 and verify the pressure setting. Option 2: 1. Disconnect, cap, and plug the platform level down hose and adapter either at the platform level master cylinder, at the platform level slave cylinder, or at port “16”...
  • Page 165 SECTION 5 - HYDRAULICS NOTE: Coil Resistance (@ 68° F [20° C]) is 7.2 Ohms for Tower Lift Up, Main Lift Up, and Flow Control. All other coils have 9.8 Ohms resistance. These values are all ± 15%. TT-SWG-RT (OUTSIDE COIL) BRK-PRES-SW TWR-LFT-UP TT-SWG-LT...
  • Page 166 SECTION 5 - HYDRAULICS 5 11 11 3 11 2 11 11 Table 5-3. Main Valve Torques Description Ft. Lbs. Description Ft. Lbs. Pressure Switch Relief Valve Solenoid Valve Relief Valve Solenoid Valve Coil Solenoid Valve Coil Solenoid Valve Valve Relief Valve Load Sense Valve Relief Valve...
  • Page 167 SECTION 5 - HYDRAULICS NOTE: Coil Resistance (@ 68° F [20° C]) is 9.8 Ohms ± 15%. TELE-IN TELE-OUT (INSIDE COIL) (OUTSIDE COIL) PLTF-ROT-LT JIB-LEFT (INSIDE COIL) (INSIDE COIL) JIB-RIGHT PLTF-ROT-RT (OUTSIDE COIL) (OUTSIDE COIL) JIB-UP (OUTSIDE COIL) JIB-DN (INSIDE COIL) PLATF-LVL-UP (OUTSIDE COIL) PLATF-LVL-DN...
  • Page 168 SECTION 5 - HYDRAULICS 12 13 11 11 E300AJ E300AJP 11 11 ONLY 11 11 Table 5-4. Boom Function Valve Torques Description Ft. Lbs. Description Ft. Lbs. Description Ft. Lbs. Solenoid Valve Manual Valve Port Plug Solenoid Valve Hand Pump 40.5 Port Plug Relief Valve...
  • Page 169 SECTION 5 - HYDRAULICS HYDRAULIC TANK ELECTRIC MOTOR & PUMP MAIN CONTROL VALVE BOOM FUNCTION VALVE BOOM FUNCTION PUMP VALVE HANDLE ELECTRIC MOTOR & PUMP Torque Ft-Lbs. 14-18 19-24.5 17-23 23-31 8-12 16-20 22-27 Figure 5-12. Hydraulic Components Location 5-24 –...

  • Page 170: Initial Hydraulic Pump Start-Up Procedure

    SECTION 5 - HYDRAULICS 5.4 INITIAL HYDRAULIC PUMP START-UP 4. Insert the other end of the pressure test hose into the hydraulic reservoir’s breather/filler port. PROCEDURE This procedure must be used when the hydraulic pump or pump/motor assembly is removed or replaced to ensure there is no air trapped in the hydraulic system.
  • Page 171 SECTION 5 - HYDRAULICS 6. Continue activating the platform rotate switch NOTE: An audible change in the tone of the gear pump momentarily until the assistant sees a clear, uniform should be heard when the air is purged from the stream of hydraulic fluid flowing from the test hose gear pump.
  • Page 172 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 173: Section 6 - Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT The JLG designed Control System is a 48 volt based motor control unit installed on the boom lift. INSTRUCTIONS The JLG Control System has reduced the need for exposed terminal strips, diodes and trimpots and provides Introduction simplicity in viewing and adjusting the various personality...

  • Page 174: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Using the Analyzer The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which With the machine power on and the analyzer connected may be accessed for troubleshooting. Optional equip- properly, the analyzer will display the following: ment includes an hour meter, beacon light, function cut- out, and ground alarm.

  • Page 175: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DRIVE DIAGNOSTICS BOOM ACTIVATE TEST SYSTEM ACCESS LEVEL DATALOG PERSONALITIES VERSIONS...

  • Page 176: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit of Analyzer the password, 3. Once you have gained access to level 1, and a personality Then using the RIGHT arrow key, position the cursor to item is selected, press the UP or DOWN arrow keys to the right one space to enter the second digit of the pass-...

  • Page 177: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: When a machine digit item is selected, press the UP or ELEVATION CUTBACK DOWN arrow keys to adjust its value, for example: CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- FORMANCE OF YOUR MACHINE.
  • Page 178 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Platform Control Module Location - Sheet 1 of 2 – JLG Lift – 3121253...
  • Page 179 SECTION 6 - JLG CONTROL SYSTEM MATING MATING MATING MATING POSITION TYPE POSITION TYPE CONNECTOR TERMINAL CONNECTOR TERMINAL FUNCTION FUNCTION 4460226 ANALYZER PWR (12V) POWER OUTPUT 4460226 FSWIN DIGITAL INPUT 4460226 RS-232 RECEIVE SERIAL INPUT 4460226 SOFT TOUCH O/R INPUT DIGITAL INPUT 4460321...
  • Page 180 SECTION 6 - JLG CONTROL SYSTEM Figure 6-4. Ground Control Module Location - Sheet 1 of 2 – JLG Lift – 3121253...
  • Page 181 SECTION 6 - JLG CONTROL SYSTEM MATING MATING POSITION TERMINAL TYPE POSITION TERMINAL TYPE CONNECTOR CONNECTOR FUNCTION FUNCTION 4460227 TOWER LIFT UP INPUT DIGITAL INPUT 4460226 4460226 CAN HIGH (1) SERIAL 4460227 TOWER LIFT DOWN INPUT DIGITAL INPUT 4460321 4460226 CAN LOW (1) SERIAL 4460227...
  • Page 182 SECTION 6 - JLG CONTROL SYSTEM Figure 6-6. Power Module Location - Sheet 1 of 2 6-10 – JLG Lift – 3121253...
  • Page 183 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR PIN TAGNAME FUNCTION TYPE PLTEMS PLATFORM EMS VBAT INPUT GNDEMS GROUND EMS VBAT INPUT FSW IN FOOTSWITCH DIGITAL INPUT GROUND MODULE POWER +12V OUTPUT FSW OUT FOOTSWITCH SIGNAL PASSTHROUGH DIGITAL OUTPUT GROUND MODULE POWER +12V OUTPUT TILT MODULE POWER...
  • Page 184 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR PIN TAG NAME FUNCTION TYPE ENCPWR POWER OUTPUT (12V) POWER OUTPUT SPEED DIGITAL INPUT GROUND RETURN POWER INPUT DIRECTION DIGITAL INPUT CONNECTOR PIN TAG NAME FUNCTION TYPE CANH CAN HIGH SERIAL CANL CAN LOW SERIAL CAN SHIELD POWER...
  • Page 185 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT BOOM CONTROL SYSTEM JOYSTICK BOOM LENGTH ANGLE MODULE...
  • Page 186 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP VOLT VERSION VALVE...
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-15...
  • Page 188 SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121253...
  • Page 189 SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-17...
  • Page 190 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: When configuring the E300 machine, the machine configuration must be completed before any personality set- tings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Default Configuration Digit Number Description Number No - Sounds continuously when above elevation and tilted only. (Platform Alarm) Fault Code - Sounds continuously when above elevation and tilted, and in conjunction with fault code flashes.
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults Adjustment Default Adjustment Range Value DRIVE ACCEL 0.5 to 5 sec 1.5s DECEL 0.1 to 2 sec 0.5s 0 to 25% 0 to 100% ELEVATED MAX 0 to 25% CREEP MAX 0 to 45% POSITRAC 0 to 60 sec...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults Adjustment Default Adjustment Range Value MIN OUT 0 to 50% MAX OUT 0 to 100% PLATFORM LEVEL ACCEL 0.5 to 5 sec 1.0s DECEL 0.1 to 3 sec 1.0s MIN UP 0 to 50% MAX UP 0 to 80%...
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code EVERYTHING OK The "normal" help message in platform mode GROUND MODE OK The "normal" help message in ground mode 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX"...
  • Page 195 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code 2252 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY Input was CLOSED during startup SELECTED 2253 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED Input was CLOSED during startup 2254 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY Input was CLOSED during startup...
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code 2514 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven AND is configured to not allow simultaneous drive & boom opera- tion.
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code 33364 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was energized. This maybe due to an open circuit traction motor or power wiring error 33369 REVERSE CONTACTOR COIL - OPEN CIRCUIT...
  • Page 198 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code STALLED PUMP MOTOR OR POWER WIRING ERROR The power module pump MOSFET protection circuit is active, This is due to a massive current drain and could be a stalled pump motor or a power wiring error OPEN CIRCUIT PUMP MOTOR WIRING Pump point A is collapsing when the pump MOSFETs are pulsed,...
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. E300 Diagnostic Fault Codes Flash Fault Message Description Code 99133 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardware failsafe the contactor drive failsafe did not trip within the allowed test time 99134 POWER MODULE FAILURE - HWFS CODE 16 Hardware failsafe tests failed because the hardware failsafe the...

  • Page 200: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM System Self Test up switch. When the controller sees that the tower lift up switch has been closed, it will move on to the The system self test is utilized to locate typical problems. next input.
  • Page 201 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages RUNNING Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BAD POWER WIRING The capacitor bank is not charged or pump point A is low or traction point A is high or low.
  • Page 202 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open-and short- circuit valve coils. The valves are tested in the order: STEER L, STEER R, BRAKE, FLOW, TWR U, MAIN U, SWING L, SWING R, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, JIB L, JIB R, TELE I, TELE O NOTE: in platform mode, the footswitch must be closed.
  • Page 203 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral. In platform mode, inputs are tested in the order: MAIN U, MAIN D, SWING L, SWING R, SWING JOY, LEVEL U, LEVEL D, PUMP POT, ROTATE L, ROTATE R, TWR U, TWR D, JIB U, JIB D, JIB L, JIB R, TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY, STEER L, STEER R,...
  • Page 204 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. System Test Messages TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends. If ENTER is pressed, each operator input is prompted for in turn. In platform mode, operator inputs are tested in the order: POSITRAC, MAIN U, MAIN D, SWING L, SWING R, LEVEL U, LEVEL D, PUMP POT, CREEP , ROTATE L, ROTATE R, TWR U, TWR D, JIB U, JIB D, JIB L, JIB R, TELE I, TELE O, DRIVE FWD, DRIVE REV, STEER L, STEER R...
  • Page 205 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 206: Section 7 - Basic Electrical Information & Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS GENERAL Polarity Getting a negative Voltage or current reading when This section contains basic electrical information and expecting a positive reading frequently means the leads schematics to be used for locating and correcting most of are reversed.

  • Page 207: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing Figure 7-2. Resistance Measurement continuity •...

  • Page 208: Current Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE.

  • Page 209: Installation Of Dielectric Grease

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Deutsch HD, DT, DTM, DRC Series 3. Anderson connectors for the battery boxes and bat- tery chargers should have silicone grease applied to The Deutsch connector system is commonly used for the contacts only. harsh environment interconnect.

  • Page 210: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Fol- low the installation instructions. Figure 7-6. Use of Seal Plugs Exclusions AMP Mate-N-Lok A limited number of connectors do not benefit from dielec- tric grease, or may be permanently damaged by applica- Follow the installation instructions.
  • Page 211 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corro- This type of connector uses back-seals for moisture integ- sion and an o-ring seal for moisture integrity. If dielectric rity.

  • Page 212: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the Assembly contact (See Figure 7-9.). Check to be sure the wedge lock is in the open, or as- shipped, position (See Figure 7-7.).
  • Page 213 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 214: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ- lock tabs.
  • Page 215 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13. Connector Installation 7-10 – JLG Lift – 3121253...

  • Page 216: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 5. Remove wedgelock using needlenose pliers or a 1. Grasp crimped contact about 25mm behind the con- hook shaped wire to pull wedge straight out.

  • Page 217: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact 11. With rear insert toward you, snap appropriate size crimp barrel.
  • Page 218 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FOOTSWITCH PLATFORM FLOODLIGHTS INVERTER STROBE LIGHT PLATFORM CONTROL BATTERY CHARGER DRIVE ORIENTATION SWITCH DIAGNOSTIC ANALYZER GROUND B– CONTROL ACCY Figure 7-20. Electrical Components - Sheet 1 of 2 7-14 – JLG Lift – 3121253...
  • Page 219 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AC POWER AT PLATFORM BATTERIES POSI-TRACK/ TILT MODULE RH DRIVE LH DRIVE BRAKE/MOTOR BRAKE/MOTOR PUMP MAIN BOOM LIFT CYLINDER MAIN BOOM 300AMP FUSE LIMIT SWITCH (UL Only) BOOM FUNCTION VALVE TOWER BOOM MAIN LIMIT SWITCH VALVE...
  • Page 220 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS INDICATOR LAMP PANEL TRACTION CONTROL BRN/WHT 47-4 BRN/WHT 47-5 PLATFORM CONTROL MODULE BRN/WHT 47-1 BRN/WHT 47-2 9 SOCKET CREEP BRN/WHT 47-3 BRN/WHT 47-6 BRN/WHT 47-7 6 PIN 9 PIN 4 SOCKET 15 PIN TILT 2 3 4 1 FAULT...
  • Page 221 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SEE ZONE G-5 WHT/RED 57-5 WHT/BLK 58-8 1 2 3 ANALYZER BRN/WHT 47-9 CONNECTION OPTIONAL: 4 PIN 3 PIN J1 CNCTR ON LSS MOD 6 PIN 9 PIN BLUE 27-3 BLUE 28-3 DOWN BLACK 16/3 CABLE FOOTSWITCH...
  • Page 222 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-24. Hydraulic Schematic - E300AJ - Sheet 1 of 2 7-18 – JLG Lift – 3121253...
  • Page 223 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001112910-A Figure 7-25. Hydraulic Schematic - E300AJ - Sheet 2 of 2 3121253 – JLG Lift – 7-19...
  • Page 224 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Hydraulic Schematic - E300AJP - Sheet 1 of 2 7-20 – JLG Lift – 3121253...
  • Page 225 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001112910-A Figure 7-27. Hydraulic Schematic - E300AJP - Sheet 2 of 2 3121253 – JLG Lift – 7-21...
  • Page 227 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 228 3121253...

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