JLG H340AJ Service And Maintenance Manual
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JLG H340AJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
H340AJ
3121634
February 08, 2019 - Rev E
AS/NZS

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  • Page 1 Service and Maintenance Manual Model H340AJ 3121634 February 08, 2019 - Rev E AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A strict attention to these warnings and precautions to avoid SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISION LOG Original Issue A - November 30, 2016 Revised B - September 19, 2017 Revised C - February 28, 2018 Revised D - June 29, 2018 - Revised Covers Revised E - February 08, 2019 3121634...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment .......
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Tires & Wheels..................3-1 Tire Replacement.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.17 Battery Charger ..................3-60 Indications on the Charger 3-LED Display .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Rotary Actuator ..................4-27 Theory of Operation .
  • Page 9 To Connect the JLG Control System Analyzer........
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Oil Sampling Port ................. . 1-2 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-9. Rotator Counterbalance Valve ..............4-41 5-1.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-14. Control Module Location ................6-33 6-15.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-47. Platform to Boom Harness - Sheet 1 of 2............. 7-44 7-48.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-104. Clearsky Harness - Sheet 4 of 4..............7-109 7-105.
  • Page 16 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Dimensional Data .
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. 5-29 British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3 ........5-41 5-30 British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3 .
  • Page 18 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 19: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Table 1-2. Dimensional Data Table 1-1. Operating Specifications Platform Height ANSI 33’ 9" (10.29 m) Capacity: Unrestricted: CE & Australia 33’ 10.5" (10.33 m) ANSI 500 lbs. (227 kg) CE & Australia 500 lbs.

  • Page 20: Hydraulic Oil

    NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- cosities.

  • Page 21: Major Component Weights

    SECTION 1 - SPECIFICATIONS Table 1-9. Mobil EAL H 46 Specs Table 1-6. DTE 10 Excel 15 Specs Type Synthetic Biodegradable ISO Viscosity Grade ISO Viscosity Grade Pour Point, Max -65°F (-54°C) Pour Point -33°C (-27°F) Flash Point, Min. 360°F (182°C) Flash Point 298°C (568°F) Viscosity...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance and Lubrication Diagram 3121634...

  • Page 23: Maintenance And Lubrication

    The following numbers correspond to those in Figure 1-2., Maintenance and Lubrication Diagram. Table 1-12. Lubrication Specifications. SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424. EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or MIL-Spec MIL-L-2105.
  • Page 24 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 5. Wheel Drive Hub OIL LEVEL CHECK AND FILL Lube Point(s) - Level/Fill Plug Capacity - 30.4 oz. (0.9 L)(1/2 Full) Lube - EPGL Lube Point(s) - Fill Cap Interval - Check level every 3 months or 150 hrs of oper- Capacity - 5 Gal.
  • Page 25 SECTION 1 - SPECIFICATIONS 7. Engine Coolant - Kubota 8. Fuel Filter/Water Separator - Kubota Lube Point(s) - Fill Cap Lube Point(s) - Replaceable Element Capacity - 1.6 gal. (6.0L) Interval - Every year or 600 hours of operation Lube - Anti-Freeze (Ethylene Glycol and Water (50/50 Mix)) Interval - Check level daily;...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121634...
  • Page 27 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121634...
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-10 3121634...
  • Page 29 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121634 1-11...
  • Page 30 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-12 3121634...
  • Page 31 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 32: General

    Service Technician as a person who has successfully com- this product will be fit for continued use. pleted the JLG Service Training School for the subject JLG product model. Reference the machine Service and Mainte- Preparation, Inspection, and Maintenance nance Manual and appropriate JLG inspection form for perfor- mance of this inspection.

  • Page 33: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...

  • Page 34: 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 heat- When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with the procedural steps in sequence.

  • Page 35: Hydraulic Oil

    SECTION 2 - GENERAL 2. The design and manufacturing tolerances of the compo- Changing Hydraulic Oil nent working parts are very close, therefore, even the 1. Filter elements must be changed after the first 50 hours smallest amount of dirt or foreign matter entering a sys- of operation and every 300 hours (unless specified oth- tem can cause wear or damage to the components and erwise) thereafter.

  • Page 36: 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 37: Pins And Composite Bearing Repair Guidelines

    2. Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing.
  • Page 38 SECTION 2 - GENERAL 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 1, 2 Pivot Pins and Pin Retainers 1, 2 1, 2 Sheaves, Sheave Pins...
  • Page 39 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 40 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months; Out of service for 3 months or more; Purchased used...
  • Page 41 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.
  • Page 42 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. 1001120075-A Figure 2-2. Engine Oil Operation Chart - Kubota...
  • Page 43 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 44: Chassis & Turntable

    JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE a particular machine model.
  • Page 45 SECTION 3 - CHASSIS & TURNTABLE MAE15930 1. Bolt 5. Pin Keeper 9. Lockout Cylinder Assembly 13. Axle 2. Bolt 6. Thrust Washer 10. Wear Pad 14. Shim 3. Bushing 7. Washer 11. Shim 4. Axle Pivot Pin 8. Bolt 12.
  • Page 46 SECTION 3 - CHASSIS & TURNTABLE MAE15910 1. Bolt Pin Keeper 12. Sensor Pin 17. Spindle 22. Bolt 2. Bolt 8. Thrust Washer 13. Sensor Pin Bracket 18. Tie Rod Link 23. Washer 3. Bolt 9. Washer 14. Spacer 19. King Pin 24.

  • Page 47: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.2 OSCILLATING AXLE SYSTEM 3.3 LOCKOUT CYLINDER BLEEDING The oscillating front axle is attached to the frame by a pivot 1. Turn ON the machine. pin, which allows all four wheels to remain on the ground 2.

  • Page 48: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE 3.4 OSCILLATING AXLE LOCKOUT TEST 12. Have an assistant check to see that right front wheel remains locked in position off of ground. 13. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- When boom reaches center, stowed position, lockout TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS...
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE MAE16250 1. Swing Bearing 3. Hydraulic Oil Tank 5. Oil Filter 7. Fuel Filter 2. Swing Drive 4. Hydraulic Tank Return Filter and Breather 6. Coolant Recovery Tank Figure 3-3. Turntable Component Location 3121634...
  • Page 50 SECTION 3 - CHASSIS & TURNTABLE MAE16280 1. Axle Lockout Cylinder 4. Drive Motor 2. Swing Bearing 5. Wheel Drive Hub 3. Swing Drive Figure 3-4. Chassis Component Location 3121634...

  • Page 51: Drive System

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE SYSTEM 3.6 DRIVE ORIENTATION SYSTEM The Drive system consists of 4 independently controlled asyn- The Drive Orientation System (DOS) is intended to indicate to chronous AC motors, each connected to an electric brake and the operator conditions that could make the direction of drive hub.
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE MAE16240 1. Bolt 6. Washer 11. Anti-Static Strap 16. Bolt 21. Washer 26. Plate 2. Bolt 7. Flange 12. Bolt 17. Clamp 22. Tinnerman Nut 27. Screw 3. Nut 8. Drive Motor Assembly 13. Washer 18.

  • Page 53: Drive Motor

    Tighten the bolts to torque 75 ft. lbs. (55 Nm). Ball Bearing Repair/Replacement NOTE: Apply JLG Threadlocker P/N 0100011 to bolts before instal- lation. Both ball bearings are maintenance free. If the bearings are removed, they must be replaced along with any seals.
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE MAE15940 1. Capscrew 9. Pressure Plug 17. Wavy Washer 25. O-Ring 2. Motor Replacement Without Brake 10. Plug 18. O-Ring 26. Temperature Sensor 3. Brake Assembly 11. Plug 19. Speed Sensor 27. Armature 4. Male Plug 12.

  • Page 55: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE HUB Assembly/Disassembly For detail assembly/disassembly instruction, Refer Drive Hub Removal Manual (PN 3128835). NOTE: Refer Figure 3-8., Drive Hub. Installation 1. Place machine on the firm level surface. 1. Use suitable lifting device to support the drive hub. 2.

  • Page 56: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.9 SWING MOTOR 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. Figure 3-9. Swing Motor - Cutaway 3121634 3-13...
  • Page 57 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 manufac- turers specifications. 2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

  • Page 58: 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 59 SECTION 3 - CHASSIS & TURNTABLE MAE15900 1. Bolt 6. Ring 10. Drive Link 14. Thrust Washer 18. Housing 2. End Cover 7. Manifold 11. Coupling Shaft 15. Thrust Bearing 19. Bearing 3. Commutator Seal 8. Rotor Set 12. Woodruff Key 16.

  • Page 60: Preparation Before Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Preparation Before Disassembly Disassembly and Inspection • Before you disassemble the motor unit or any of its compo- 1. Place the motor in a soft jawed vice, with coupling shaft nents read this entire section. It provides important infor- (12) pointed down and the vise jaws clamping firmly on mation on parts and procedures you will need to know to the sides of the housing (18) mounting flange or port...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 7. Remove commutator (5) and seal ring (3) Remove seal 8. Remove manifold (7) and inspect for cracks surface scor- ring from commutator, using an air hose to blow air into ing, brinelling or spalling. Replace manifold if any of ring groove until seal ring is lifted out and discard seal these conditions exist.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 9. Remove rotor set (8) and wearplate (9), together to 10. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 retain the rotor set in its assembled form, maintaining degrees apart) and a roller vane centerline are on the the same rotor vane to stator contact surfaces.
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 12. Remove thrust bearing (11) from top of coupling shaft 14. Remove coupling shaft (12), by pushing on the output (12). Inspect for wear, brinelling, corrosion and a full end of shaft. Inspect coupling shaft bearing and seal sur- complement of retained rollers.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 16. Remove thrust bearing (15) and thrust washer (14). 19. Inspect housing (18) assembly for cracks, the machined Inspect for wear, brinelling, corrosion and a full comple- surfaces for nicks, burrs, brinelling or corrosion. Remove ment of retained rollers.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE this inspection the disassembly of the motor is com- 21. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove pleted. bearing/bushings (19) and (13) from housing (18) with- out damaging the housing.

  • Page 67: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE METHODS ARE Replace all seals and seal rings with new ones each time you reassemble the motor unit. Lubricate all seals and seal rings USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE BEARING/BUSHING with SAE 10W40 oil or clean grease before assembly.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 3. Press a new dirt and water seal (20) into the housing (18) 6. Assemble thrust washer (14) then thrust bearing (15) outer bearing counterbore. The dirt and water seal (20) that was removed from the motor. must be pressed in until its’...
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- 9. Apply a small amount of clean grease to a new seal ring tant grease has been applied to the lower (outer) (4) and insert it into the housing (18) seal ring groove. housing bearing/bushing (19).
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over the drive link (10) and NOTE: It may be necessary to turn one alignment stud out of the alignment studs onto the housing (18). housing (18) temporarily to assemble rotor set (8) or mani- fold (7) over the drive link.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 15. Assemble the manifold (7) over the alignment studs and 18. Assemble a new seal ring (3) flat side up, into commuta- drive link (10) and onto the rotor set. Be sure the correct tor (5) and assemble commutator over the end of drive manifold surface is against the rotor set.
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other compo- nents into place with a final torque of 25-30 ft.

  • Page 73: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets. A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the following proce- dures.

  • Page 74: Two Piece Stator Construction

    2. Secure the swing motor to the swing drive assembly complement of seven vanes. Assemble the seven vanes with the retaining bolts. Apply threadlocker JLG P/N using minimum force. 0100019 to the threads of the retaining bolts and torque to 85 ft.

  • Page 75: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.10 SWING BEARING 4. Securely strap the booms together to prevent any movement during the lifting process. The swing drive assembly has five major components. They are the housing, worm, worm gear, output pinion and gear / pinion cap.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE M20x2.5 Thread NOTE: All measurements shown are in mm. Figure 3-12. Eyebolt for Counterweight 3121634 3-33...
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE 5. Loosen and remove all but a few of the bolts securing 9. 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 lifting.

  • Page 78: Installation

    6. Coat the bearing bolts with JLG Threadlocker P/N 0100019 and install the remaining bolts securing the turntable to the swing bearing. Tighten the bolts snugly but do not torque them at this time.

  • Page 79: Turntable Bearing Mounting Bolt Condition Check

    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. If...
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE POSTION 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 MAE16180 Figure 3-15. Bearing Placement Figure 3-16. Swing Bearing Torque Sequence 3121634 3-37...

  • Page 81: Disassembly

    (2) out the other end of housing. internal), large flat blade screw driver. Also needed are a shim and seal kit (available from the JLG Parts Department), ¾" steel 11. Remove both bearings (2) from worm (32) from worm rod at least 10"...

  • Page 82: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly 15. Apply Loctite 242 to end of eight 5/16" 12 point screws (4) and torque to 20 ft. lbs. (0.84 Nm). 1. Press bearing cup (15) into cap (18). 16. Install 4 small screws (30) through cover plate (18) and into housing (25) tighten screws take care not the twist 2.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 3-40 3121634...
  • Page 84 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 85 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 DESCRIPTION FROM LAST JIB CLAMP (MIN) ROTATOR PRESSURE ROTATOR TANK...
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE SECTION A-A ROTATED 33° CCW (ORIENTATION LOOKING TOWARDS UPPER UPRIGHT) WIRE BUNDLE TO UPRIGHT HYDRAULIC MANIFOLD SYSTEM PRESSURE 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 TOWER LIFT CYLINDER TANK...
  • Page 87 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 DETAILD 50 12...
  • Page 88 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 J RECEPTACLE LOADING WIRE WIRE SOCKET SIZE NUMBER COLOR SHIELD 18 GA.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE SWITCH SW242 OF LOWER BOOM HARNESS DETAILR 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 DETAILR (3) LIMIT SWITCHES ARE PART OF LOWER BOOM HARNESS...
  • Page 90 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 S SEE DETAIL S MAE16110 Figure 3-24. Cable Installation and Identification - Sheet 6 of 8 3121634 3-47...
  • Page 91 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 DETAILT UPRIGHT BACK PLATE SHOWN TRANSPARENT SEE DETAILT MAE16100 Figure 3-25. Cable Installation and Identification - Sheet 7 of 8 3-48 3121634...
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE CONNECTOR V57 OF UPPER BOOM HARNESS CONNECTOR V56 OF SEE DETAIL U UPPER BOOM HARNESS CONNECTOR V55 OF UPPER BOOM HARNESS DETAIL U FLY VALVE COVER SHOWN TRANSPARENT MAE16090 Figure 3-26. Cable Installation and Identification - Sheet 8 of 8 3121634 3-49...

  • Page 93: Engine Operating States

    SECTION 3 - CHASSIS & TURNTABLE 3.11 ENGINE OPERATING STATES The Engine Operating State is determined by the Ground Module. There are four different Engine Operating States which include; • Engine Stopped • Engine Cranking • Engine Starting • Engine Running NOTE: Refer Operation and Safety Manual for engine starting procedure.

  • Page 94: Kubota Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.12 KUBOTA ENGINE MAE15980 1. Fuel Tank 4. Oil Filter 7. Air Filter 2. Coolant Recovery Tank 5. Starter 8. Generator 3. Alternator 6. Muffler 9. Fuel Filter/ Water Separator Figure 3-28. Kubota Engine - Sheet 1 of 2 3121634 3-51...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE MAE15990 1. Fuel Tank 3. Radiator 5. Muffler 7. Fuel Pre Filter 2. Pressure Cap 4. Electric Fan 6. Fuel Pump 8. Fuel Level Sensor Figure 3-29. Kubota Engine - Sheet 2 of 2 3-52 3121634...

  • Page 96: Retrieving Engine Hours

    SECTION 3 - CHASSIS & TURNTABLE Retrieving Engine Hours 4. The analyzer screen should read: 1. Plug the analyzer into the connector inside the Ground control box. 2. Position the Platform/Ground select switch to the Ground position. 5. Use the arrow button to reach MENU: OPERATOR ACCESS.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 6. Press Enter. The screen will read: 9. Use the arrow keys to scroll to Diagnostics. The screen will read: 7. Using the Up and Down Arrow Keys, enter Access Code, 10. Using the arrow keys, scroll to Diagnostics Datalog The 33271.

  • Page 98: Fuel Level Sensor

    12. After recording the engine hours, press in the Emer- gency stop switch, place the Platform/ Ground Selector Switch in the Off position, and remove the JLG Analyzer. Fuel Level Sensor The fuel level sensor is mounted in the fuel tank and consists of a float device guided by a rod.

  • Page 99: Coolant Sensor

    SECTION 3 - CHASSIS & TURNTABLE Coolant Sensor Engine Oil Pressure Switch The coolant sensor operates by providing variable resistance The engine oil pressure switch monitors oil pressure and sends to ground based on coolant temperature. an electronic message to the control system. This is accom- plished by creating an open electrical circuit for normal oil pressure and a closed electrical circuit for low pressure.

  • Page 100: Glow Plugs

    SECTION 3 - CHASSIS & TURNTABLE Glow Plugs Table 3-5. Glow Plug Conditions Engine Pre-Glow Start/Run The diesel engine has two in-cylinder glow plugs to assist in Battery Ambient Coolant Plug Glow Plug cold starting. The ground module controls the glow plugs and Voltage Temperature Temperature...

  • Page 101: Chassis Tilt Indicator System

    0/0 “FUEL LEVEL LOW – ENGINE SHUT- (Market based machine setup on the JLG Analyzer). The tilt DOWN” on the analyzer. There is an analyzer personality set-...

  • Page 102: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.16 GENERATOR Ball Bearing Repair/Replacement The machine is equipped with an engine powered AC genera- Both ball bearings are maintenance free. If the bearings are tor with controller that converts to DC which connected in removed, they must be replaced along with any seals.

  • Page 103: Battery Charger

    The charger may become hot during charging. Use hand pro- tection to safely handle the charger during charging. JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED Extension cords must be 3-wire cord no longer than 30m (100') FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.

  • Page 104: Troubleshooting Instructions

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Instructions If a fault occurs, count the number of red flashes between pauses and refer to the table below. Table 3-6. LED Flashes Flashes Cause Solution Battery high voltage Check battery size and condition. This fault will clear automatically once the condition has been corrected.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE Table 3-7. Detailed LED Fault Indications Flashes Explanation and Solution High Battery Voltage Detected - starting voltage above 2.5V/cell or voltage during charge rose above 2.7V/cell (algorithm dependent). ­ Check that the battery charger voltage is consistent with the battery pack voltage. ­...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Charger/Converter Troubleshooting Symptom Possible Causes and Solutions No or low output ­ Input voltage out of range: ­ 35 - 87V for the 48V model ­ 50 - 130V for the 72V model ­...
  • Page 107 Number Algorithm 1001197707 922-4854-08 Table 3-11. Charging Profile (Algorithm) Matrix Approved Battery Description Optimized Battery JLG Part Number Other Tested Batteries May be Compatible with * Manufacturers 150 - 260Ah Trojan T105 T875, T1260, T1275, T145 Flooded 150-260Ah flooded Temperature...
  • Page 108 Table 3-11. Charging Profile (Algorithm) Matrix Approved Battery Description Optimized Battery JLG Part Number Other Tested Batteries May be Compatible with * Manufacturers JLG 200Ah Flooded, no- Douglas Flooded 0400215 GES BATTERY A1055 TRO- temperature compen- 0400216 JAN T105 sated...
  • Page 109 1001102534 DISCOVER EVL16A-A 200-400Ah AGM 400Ah), temperature compensated #151 FullRiver 220-290Ah AGM FullRiver DC250-6 220-290Ah AGM Temperature compen- sated #173 JLG 400Ah flooded, non US Battery L16 400055 US BATT L16 US Batt L16HC temperature compen- 0400202 sated 3-66 3121634...

  • Page 110: Instructions For Using The Delta-Q Quiq Programmer Ctquiq Programming Kit

    SECTION 3 - CHASSIS & TURNTABLE Instructions for using the Delta-Q QuiQ Programmer CTQuiQ Programming Kit CONTENTS OF THE QUIQ PROGRAMMING KIT (JLG PART NUMBER: 2915230) • ­ QuiQ USB Interface Module • ­ QuiQ Programmer CT Installation CD • ­ USB Cable •...

  • Page 111: Connecting A Quiq Charger To Your Computer

    SECTION 3 - CHASSIS & TURNTABLE Connecting a QuiQ Charger to your Computer 5. Connect the Wire Assembly to the QuiQ USB Interface Module. CHARGER OUTPUTS GREATER THAN 40VDC POSE AN ENERGY AND/OR SHOCK HAZARD UNDER NORMAL USE. DO NOT ENERGIZE CHARGER WITH AC UNTIL WIRE ASSEMBLY CLIPS ARE SECURELY CONNECTED TO CHARGER OUTPUT, AND ALL LEADS ARE SECURED AGAINST MOVEMENT.

  • Page 112: Starting Quiq Programmer Ct

    SECTION 3 - CHASSIS & TURNTABLE 8. Upon connection, Windows will detect the QuiQ USB 4. The QuiQ Programmer CT interface will appear. The con- Interface Module and install drivers for it. If Windows nection status area at the bottom of the window will does not detect the QuiQ Module you will need to rein- indicate if the QuiQ USB Interface Module is properly stall QuiQ Programmer CT.

  • Page 113: Programming Delta-Q Quiq And Quiq-Dci Chargers

    SECTION 3 - CHASSIS & TURNTABLE Programming Delta-Q QuiQ and QuiQ-dci Chargers Click on the Charger Status tab to activate the Charger Status tab. Then click Browse, to select the folder on your PC contain- ing the QuiQ charger software and algorithms. Table 3-12.

  • Page 114: View Charge Tracking Data With Quiq Programmer Ct

    SECTION 3 - CHASSIS & TURNTABLE View Charge Tracking Data with QuiQ Programmer Selecting a Charge Profile Delta-Q's QuiQ Charger can store up to 10 charging profiles, also called charge algorithms. This section shows how to iden- Requirement: To view the charge tracking data in your charger, tify the default profile and select a new profile using the "tap your charger must have version 3.X software.

  • Page 115: Battery Testing

    SECTION 3 - CHASSIS & TURNTABLE SELECT A NEW PROFILE 1. Disconnect the AC power source from the charger, either from the wall outlet, or from the IEC320 connector on the charger. 2. Reconnect AC power. 3. Touch the positive lead to the positive terminal for 3 sec- onds (+/- 0.5 seconds), then remove the lead.

  • Page 116: Counterweight

    SECTION 3 - CHASSIS & TURNTABLE 3.19 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-40., Counterweight Bolt Torque. Torque to 150 ft.lbs. (204 Nm) ± 3% 1001115782-B MAF06930B Figure 3-40.
  • Page 117 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 118: Boom & Platform

    • Above Elevation - Drive Speed Cutback System alarm will sound at the standard JLG duty cycle of 5sec ON/ 2sec OFF and all platform controls (except emergency • Drive/Steer-Boom Function Interlock System (CE Only) descent) will be disabled.

  • Page 119: Platform

    SECTION 4 - BOOM & PLATFORM 4.2 PLATFORM 5. Remove the bolts and washers securing the support to the rotator. Support Removal Figure 4-1. Location of Components Platform Support 6. Using a suitable brass drift and hammer, remove the 1. Disconnect electrical cables from control console. rotator shaft, then remove the support from the rotator.

  • Page 120: Support Installation

    7. Connect the electrical cables to the platform control console. 3. Apply JLG Threadlocker P/N 0100011 to the bolts and washers securing the support to the rotator and install the bolts and washers. 4. Torque the nut on the rotator center bolt to 250-270 ft.
  • Page 121 NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. Torque to 40 ft.lbs. (55 Nm) JLG Threadlocker P/N 0100011 Torque 250-270 ft. lbs. (340-365 Nm) Check torque every 150 hours of operation Figure 4-2. Platform Support Torque Values (Without LSS)
  • Page 122 SECTION 4 - BOOM & PLATFORM NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued. B, C A, C 1001217227-E MAF06920E Torque to 40 ft.lbs. (55 Nm) Torque 250-270 ft. lbs. (340-365 Nm) Check torque every 150 hours of operation Figure 4-3.

  • Page 123: Boom Removal And Installation

    SECTION 4 - BOOM & PLATFORM 4.3 BOOM REMOVAL AND INSTALLATION 10. Carefully remove the master cylinder assembly from upper upright. Main Boom Removal 11. Attach an adequate lifting device to support the rear of the main boom. NOTE: The main boom alone weighs approximately 472 lbs. 12.

  • Page 124: Lower Boom Removal

    SECTION 4 - BOOM & PLATFORM 5. Remove the upper upright from mid boom assembly. Lower Boom Removal NOTE: The mid and lower booms together weighs approximately 1126.56 lbs. (511 kg). 1. Using a suitable lifting equipment, adequately support lower boom assembly weight along entire length. 2.

  • Page 125: Lower Boom Installation

    SECTION 4 - BOOM & PLATFORM 7. Remove the lower upright from lower boom assembly. Lower Boom Installation NOTE: The mid and lower booms together weighs approximately 1126.56 lbs. (511 kg). 1. Using all applicable safety precautions, carefully lift lower boom assembly to align the pivot holes in the lower boom with those of the turntable.

  • Page 126: Main Boom Installation

    SECTION 4 - BOOM & PLATFORM Main Boom Installation 4.4 BOOM MAINTENANCE NOTE: The main boom alone weighs approximately 472 lbs (214.1 Disassembly of the Main Boom kg). 1. Loosen the wear pad retaining bolts at the rear of fly 1.
  • Page 127 SECTION 4 - BOOM & PLATFORM 4. Remove the retaining ring and pin securing the tele- 6. Using a suitable lifting device, remove telescope cylin- scope cylinder rod end to the fly boom section. der from the rear of the boom sections. 7.

  • Page 128: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 3. Using JLG threadlocker P/N 0100011 compound or equivalent, install the front wear pads and shims as 1. Inspect all boom pivot pins for wear, scoring or other noted during disassembly on the base boom section.
  • Page 129 SECTION 4 - BOOM & PLATFORM 5. Align the telescope cylinder rod end with the corre- 6. Using JLG P/N 0100011 thread locking compound or sponding hole in the fly boom section. If necessary, equivalent, secure the rear of the telescope cylinder to...
  • Page 130 SECTION 4 - BOOM & PLATFORM 1. Master Cylinder 6. Upper Upright 2. Upper Lift Cylinder 7. Mid Boom Link 3. Jib 8. Mid Boom 4. Main Boom 9. Jib Cylinder 5. Level Cylinder Figure 4-4. Main Boom Assembly 3121634 4-13...
  • Page 131 SECTION 4 - BOOM & PLATFORM 1. Rotator 5. Hose Carrier 2. Jib Cylinder 6. Lower Jib Link 3. Jib Pivot 7. Upper Jib Link 4. Platform Support Figure 4-5. Jib/ Platform Support 4-14 3121634...

  • Page 132: Jib

    SECTION 4 - BOOM & PLATFORM 4.5 JIB Disassembly 1. Remove bushings and mounting hardware from jib Removal pivot pin. Using a suitable brass drift and hammer, remove the pin from jib pivot. 1. Lower the jib and platform assembly to the ground or 2.

  • Page 133: Assembly

    1. JLG recommends the use of the JLG Hostile Environment 6. Inspect all threaded components for damage such as Package if available to keep the internal portions of a stretching, thread deformation, or twisting.
  • Page 134 SECTION 4 - BOOM & PLATFORM SEE DETAIL A 2, 1 SEE DETAIL B SEE DETAIL C DETAIL A 7, 2 DETAIL B 4, 3 DETAIL C 1001119504-C MAF06900C 1. Bolt 3. Nut 5. Hose and Cable Carrier 7. Bolt 2.

  • Page 135: Hose Routing

    SECTION 4 - BOOM & PLATFORM 4.7 HOSE ROUTING 2. Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. For proper hose routing, refer to Figure 3-19. thru Figure 3-26. It is important to periodically inspect hoses, wraps and clamps for proper slack adjustments and clamping integrity (pull check).
  • Page 136 SECTION 4 - BOOM & PLATFORM NOTE: It may be necessary to loosen fixed end brackets from machine to move track section enough to disconnect links. REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE. 3. To remove a link, rivets holding links together must be removed.
  • Page 137 SECTION 4 - BOOM & PLATFORM 6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using links apart. screwdriver. 4-20 3121634...

  • Page 138: Install New Link

    SECTION 4 - BOOM & PLATFORM Install New Link 2. Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use a screwdriver if nec- 1. Squeeze cut-out end of new link into half-shear (female) essary.
  • Page 139 SECTION 4 - BOOM & PLATFORM 4. Pull moving end over track so new connection is posi- 6. Push pin through center hole then slide washer on pin. tioned in curve of powertrack. Round half-shears will rotate into cut-outs. 7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.
  • Page 140 SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar and slide new poly properly. roller on bar. Correct Incorrect 1. Install new 8-32 x 0.500 self-threading torx head screw in end of new aluminum round bar.

  • Page 141: Replace Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM 3. Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets side. Torque to 18-20 in. lbs. (2-2.25 Nm). REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE. 1.

  • Page 142: Replace Moving End Brackets

    SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. Replace Moving End Brackets 3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE.
  • Page 143 SECTION 4 - BOOM & PLATFORM 2. Install center pin with snap ring in new bracket. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. Incorrect Correct 4. Make sure both brackets rotate correctly. 3.

  • Page 144: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.9 ROTARY ACTUATOR The shaft is supported radially by the large main radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the main and lower thrust washers. The Theory of Operation end cap is adjusted for axial clearance and locked in position by set screws or pins.

  • Page 145: Required Tools

    SECTION 4 - BOOM & PLATFORM Required Tools Making a Seal Tool The seal tool is merely a customized standard flat head screw- Upon assembly and disassembly of the actuator there are driver. basic tools required. The tools and their intended functions are as follows: TO AVOID INJURY BE CAREFUL WHILE HANDLING THE HOT SCREWDRIVER.
  • Page 146 SECTION 4 - BOOM & PLATFORM PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 106. Port Plug 202. T-Seal 304. Thrust Washer 401. Counterbalance Valve 3. Piston Sleeve 109. Lock Pin 204.
  • Page 147 SECTION 4 - BOOM & PLATFORM 420.1 420.2 VIEW A-A 90° PARTS HARDWARE SEALS BEARINGS ACCESSORIES 1. Housing 103. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube 2. Shaft 106. Port Plug 202. T-Seal 304. Thrust Washer 401. Counterbalance Valve 3.

  • Page 148: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 5/16 in. drill bit to a depth of 1/2 in. (12.7 mm) to drill out the entire pin.
  • Page 149 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 equipped. The stop tube is an available option to limit the rotation of the actuator.
  • Page 150 SECTION 4 - BOOM & PLATFORM 10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis- ton and housing with a marker as shown.
  • Page 151 SECTION 4 - BOOM & PLATFORM 16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202) from the piston. cut them using a sharp razor blade being careful not to damage the seal groove. 20.

  • Page 152: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123 in. or 3.12 mm). SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED. 1. Clean all parts in a solvent tank and dry with com- pressed air prior to inspecting.
  • Page 153 SECTION 4 - BOOM & PLATFORM 2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto (4). shaft (2) and end cap (4). Use the seal tool in a circular motion.
  • Page 154 SECTION 4 - BOOM & PLATFORM 6. Install the O-ring (204) and back-up ring (207) into the 8. Beginning with the inner seal (200) insert one end of b/u inner seal groove on the end cap (4). ring in the lower groove and feed the rest in using a cir- cular motion.
  • Page 155 SECTION 4 - BOOM & PLATFORM 10. Looking from the angle shown, rotate the piston (3) until 12. Install the shaft (2) into the piston (3). Be careful not to the marks you put on the piston and the housing (1) damage the seals.
  • Page 156 SECTION 4 - BOOM & PLATFORM 14. Install 2 bolts in the threaded holes in the flange. Using a 17. Install the 0-ring (204) and back-up ring (207) into the bar, rotate the shaft in a clockwise direction until the inner seal groove on the end cap (4).
  • Page 157 SECTION 4 - BOOM & PLATFORM 19. Tighten the end cap (4). In most cases the original holes 21. Insert the set screws (113) over the lock pins. Tighten for the lock pins will line up. them to 25 in. lbs. (2.825 Nm). 20.

  • Page 158: Installing Counterbalance Valve

    If possible, 3. The bolts that come with the valve are grade 8 bolts. test this using a hydraulic hand pump or electric test. New bolts should be installed with a new valve. JLG Figure 4-9. Rotator Counterbalance Valve 3121634...

  • Page 159: Greasing Thrust Washers

    SECTION 4 - BOOM & PLATFORM Greasing Thrust Washers Testing the Actuator If the equipment is available, the actuator should be tested on 1. After the actuator is assembled but before it is put into a hydraulic test bench. The breakaway pressure — the pres- service, the thrust washer area must be packed with sure at which the shaft begins to rotate —...

  • Page 160: Installation And Bleeding

    SECTION 4 - BOOM & PLATFORM Installation and Bleeding 2. With an operator in the platform, open both bleed nip- ples 1/4 turn. Hydraulically rotate the platform to the After installation of the actuator on the equipment, it is impor- end of rotation (either clockwise or counterclockwise), tant that all safety devices such as tie rods or safety cables are and maintain hydraulic pressure.

  • Page 161: Troubleshooting

    SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s pressure specifications. Load may be above maximum capacity of the actuator.
  • Page 162 SECTION 4 - BOOM & PLATFORM Table 4-1. Troubleshooting Problem Cause Solution 4. Selected position cannot be main- a. Control or counterbalance valve has a. Disconnect hydraulic lines and bypass tained internal leak valve. Leave valve ports open and operate the actuator through housing ports (do not exceed OEM’s operating pressure).

  • Page 163: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.10 SKYGUARD® Function Test Operation SKYGUARD ONLY Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2). When the SkyGuard sensor is activated, functions in use at From the Platform Control Console in an area free from obstruc- the time of actuation will reverse or cutout.

  • Page 164: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains CLOSED while the Sky- Guard sensor is actively engaged, a power or ground wire may If SkyGuard does not function when the sensor is engaged, not be making good contact or may be loose or broken.
  • Page 165 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 166: Basic Hydraulic Information & Hydraulic Schematics

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

  • Page 167: Dip Method

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

  • Page 168: Hydraulic Connection Assembly And Torque Specification

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

  • Page 169: Straight Thread Types, Port Connections

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

  • Page 170: Assembly And Torque Specifications

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

  • Page 171: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

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

  • Page 172: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT Thread Tapered (BSPT) Connections procedure requirements.

  • Page 173: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - 1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.
  • Page 174 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel Type/Fitting Identification Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75...
  • Page 175 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Wrench Thread ØA* ØB* [Ft-Lb] [N-m] Resistance Size Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75...

  • Page 176: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using 1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section.
  • Page 177 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Thread ØA* ØB* [Ft-Lb] [N-m] Size Dash Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 5/8-18 0.56 14.30 0.63 15.90 3/4-16...
  • Page 178 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
  • Page 179 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in)

  • Page 180: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
  • Page 181 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-9. DIN 24°Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...

  • Page 182: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2.
  • Page 183 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12...
  • Page 184 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5...
  • Page 185 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Table 5-17 while using the Double Wrench Method. Fittings a. The table headings identify the straight thread O- ring port and the type on the other side of the fit- 1.
  • Page 186 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size...
  • Page 187 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24...
  • Page 188 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 189 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm)
  • Page 190 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Thread Size ØA* Torque MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33) 3/8-24 0.37 9.52...
  • Page 191 1.19 30.10 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on 1 5/8-12 1.63 41.30 JLG applications. Consult specific service procedure if encountered. 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION...

  • Page 192: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5- Metric (MFF) Fittings 23 while using the Double Wrench Method.
  • Page 193 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 194 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 195 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
  • Page 196 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
  • Page 197 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 198 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...

  • Page 199: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method. Port Assembly Stud Ends a. The table headings identify the Metric port and the 1.
  • Page 200 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 201: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5- (BSPP) Fittings 30 while using the Double Wrench Method.
  • Page 202 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121634 5-37...
  • Page 203 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-38 3121634...
  • Page 204 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121634 5-39...
  • Page 205 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-40 3121634...
  • Page 206 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 3121634 5-41...
  • Page 207 G 3/4A dure in this Service Manual. G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings 5-42 3121634...

  • Page 208: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See Figure for O-ring installation instructions. 3.
  • Page 209 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws...
  • Page 210 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws...

  • Page 211: Double Wrench Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose To prevent undesired hose or connector rotation, two is twisted.

  • Page 212: Ffwr And Tfft Methods

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

  • Page 213: O-Ring Installation (Replacement)

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

  • Page 214: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.3 HYDRAULIC CYLINDERS 2. Prepare all the necessary tools and replacement parts. Refer to Table 5-34, Required Tools. Holding (counterbalance) valves are used in the Lift, Level, Jib, General Information Telescope, and Axle Lockout circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak 1.
  • Page 215 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Check the oil leakage status on the rod surface with a flow of 20cc - 40cc. Oil leakage in an amount as shown in example A is unac- ceptable. Examples B-G are acceptable. 2m m 1m m Figure 5-15.
  • Page 216 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-34. Required Tools Item No. Description Quantity Flat-head Screwdriver 1Set Allen Wrench Set Vise 1Set Spanner Wrench Punch 1Set Torque Wrench Plastic Hammer Crescent Wrench Hera (Seal Disassembly) 3121634 5-51...

  • Page 217: Disassembly Procedure

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Disassembly Procedure Table 5-35. Special Tools 1. Remove the oil from the cylinder. 2. Fix the cylinder in a vertical or horizontal position. Verti- Name of Tool Description cal position is convenient for disassembly and assembly. Bushing for Disassembly Fix the base by inserting the pin not to be rotated.
  • Page 218 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS c. After the Rod assembly is pulled from the barrel, 5. Place the Rod assembly on blocking as shown below. unscrew the head using a spanner wrench. Use the pin hole to keep it from rotating. d.
  • Page 219 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 8. Piston nut, piston, gland disassembly. d. The du bushing is pressed in and must be removed by using a tool as shown below. a. Unscrew the Piston Nut. b. Take the piston apart by sliding off the rod in the direction of the rod threads.

  • Page 220: Assembly

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Assembly b. Rod seal assembly (Keep the right direction and do not make damage to seal). TAKE CARE NOT TO LET ANY PAINT CHIPS OR DIRT FALL INSIDE THE CYLINDER. P A R T 2 THIS COULD CAUSE LEAKAGE.
  • Page 221 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS c. Install du bushing assembly and dust wiper assem- c. Using a proper tool, press the piston seal onto the bly as shown below. piston. When installing the piston seal, it is stretched while passing over the head.
  • Page 222 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS d. Torque the Piston nut as specified in Table 5-36, Pis- 6. Gland assembly. ton Nut Torque. Lack of the torque can result in internal leakage, the piston coming unscrewed, and Install the gland using a spanner wrench as shown thread damage.

  • Page 223: Tower Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Tower Lift Cylinder 21** 18*** *Torque 19-21 ft.lbs. (26-28 Nm) **Torque 14-4 ft.lbs. (20 Nm) ***Torque 25 ft.lbs. (34 Nm) MAE15110D 1. Barrel 7. Backup Ring 13. Piston Seal 19. Plug 2.

  • Page 224: Main Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Main Lift Cylinder 23** 20*** *Torque 19-21 ft.lbs. (26-28 Nm) **Torque 14.4 ft.lbs. (20 Nm) ***Torque 25 ft.lbs. (34 Nm) MAE15120H 1. Barrel 7. Backup Ring 13. Piston Seal 19. Solenoid Valve 2.

  • Page 225: Master Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Master Cylinder MAE15130B 1. Barrel 7. Backup Ring 13. Piston Seal 2. Rod 8. Bearing 14. Wear Ring 3. Head 9. O-ring 15. O-ring 4. Wiper Ring 10. Backup Ring 16. Nut 5.

  • Page 226: Level Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Level Cylinder 22** *Torque 26-30 ft.lbs. (35-40 Nm) **Torque 2 ft.lbs. (3 Nm) 1001117375-E MAE15140E 1. Barrel 7. Backup Ring 13. Piston Seal 19. Cartridge Valve 2. Rod 8. Bearing 14. Wear Ring 20.
  • Page 227 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1001225990-A *Torque 25-30 ft.lbs. (34-40 Nm) MAE06910A 1. Barrel 7. Backup Ring 13. Piston Seal 19. Cartridge Valve 2. Rod 8. Bearing 14. Wear Ring 20. Plug 3. Head 9. O-ring 15.

  • Page 228: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Jib Lift Cylinder 22*** 21**** 25** *Torque 19-21 ft.lbs. (26-28 Nm) **Torque 14.4 ft.lbs. (20 Nm) ***Torque 30-37 ft.lbs. (41-50 Nm) ****Torque 25 ft.lbs. (34 Nm) MAE15150D 1. Barrel 8. Bearing 15.

  • Page 229: Steer Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Steer Cylinder MAE15160C 1. Barrel 6. Bearing 11. Piston Seal 2. Rod 7. O-ring 12. Wear Ring 3. Head 8. Backup Ring 13. Bushing 4. Wiper Ring 9. O-ring 5. Rod Seal 10.

  • Page 230: Telescope Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Telescope Cylinder 21** *Torque 25-30 ft.lbs. (34-40 Nm) **Torque 25 ft.lbs. (27 Nm) MAE15170C 1. Barrel 7. Backup Ring 13. Piston Seal 19. Counterbalance Valve 2. Rod 8. Bearing 14. Wear Ring 20.

  • Page 231: Axle Lockout Cylinder

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Axle Lockout Cylinder *Torque 22 ft.lbs. (30 Nm) MAE15180D 1. Plug 6. Rod Seal 2. Plug 7. Bleeder 3. Plug 8. Cartridge Valve 4. Wear Ring 9. Barrel 5. Wiper Ring 10.

  • Page 232: Hydraulic System

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.4 HYDRAULIC SYSTEM PORT "V2" PORT "J2" (LEVEL CYL.) (VALVE, FLY BOOM) PORT "V2" "ROD END" (MASTER CYL.) PORT "V1" (LEVEL CYL.) "BARREL END" (MASTER CYL.) PORT "J1" PORT "V1" (VALVE, FLY BOOM) LEVEL CYL.
  • Page 233 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB LIFT CYL LEVEL CYL. VALVE, FLY BOOM FLY BOOM LEVEL CYL. MASTER CYL. MAIN LIFT CYL. PORT "ROD END" PORT "V2" (LEVEL CYL.) PORT "ROD END" PORT "L2" (VALVE UPRIGHT) PORT "V1"...
  • Page 234 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PORT "M2" PORT "M1" VALVE, UPRIGHT PORT "6" TOWER LIFT CYL. PORT "V1" (VALVE, MAIN CONTROL) PORT, RETURN FILTER PORT "V2" TOWER LIFT CYL. SUCTION PORT (HYD TANK) SUCTION PORT (HYD TANK) INLET PORT (MANUAL PUMP) INLET...
  • Page 235 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS MAIN LIFT CYL. PORT "ROD END" PORT "V2" (MASTER CYL.) PORT "V1" PORT "T2" PORT "T1" PORT "P1" (VALVE, UPRIGHT) (VALVE, UPRIGHT) VALVE, UPRIGHT PORT "3" (VALVE, MAIN CONTROL) PORT "V2" PORT "V1"...
  • Page 236 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PORT "M2" PORT "M1" PORT "P1" PORT "CP" PORT "P4" PORT "P" (OSC VALVE) PORT "P1" (VALVE, UPRIGHT) MAIN CONTROL VALVE & HOSES TO TANK PORT "P2" RETURN OIL FILTER HYD TANK LOCTITE SEALENT #567 (OR EQUAL) HYD TANK...
  • Page 237 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PORT "A" SWING MOTOR (MOTOR SWING) PORT "B" (MOTOR SWING) PORT "5" PORT "4" TEST PORT (VALVE, MAIN) PORT "4" PORT "5" (VALVE, MAIN) PORT "B" PORT "A" (MOTOR, SWING) ROUTE HOSES THROUGH ACCESS (MOTOR, SWING) PROVIDED IN HOOD SUPPORT AND TRAY...
  • Page 238 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS ROUTE OSC HOSES THROUGH PORT "P" PORT "V" THE FRAME CUT-OUT TO OSC VALVE PORT "T" PORT "2" (VALVE, OSC CONTROL) PORT "P" PORT "1" (VALVE, OSC CONTROL) OSC CONTROL HOSES PORT "P"...
  • Page 239 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS ROUTE ALL HOSES THROUGH ACCESS PROVIDED IN TURNTABLE/BEARING TO VALVE ROUTE THE SWING MOTOR HOSES THROUGH THE CUT-OUT OF PLT, HOOD MOUNT ENGINE SIDE ROUTE THE HOSES IN A CIRCLE AS SHOWN PORT "1"...
  • Page 240 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 1. Bolt 2. Washer 3. Oil Return Filter 4. Fill Cap 5. Fitting 6. Hydraulic Tank MAE15100E Figure 5-33. Hydraulic Tank 3121634 5-75...
  • Page 241 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS TORQUE 10-14 FT.LBS. (14 - 19 Nm) JLG THREADLOCKER P/N 0100011 JLG THREADLOCKER P/N 0100011 FLY BOOM CONTROL VALVE FLY BOOM TORQUE 10-14 FT.LBS. (14 - 19 Nm) TORQUE 10-14 FT.LBS. (14 - 19 Nm)
  • Page 242 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS TORQUE 10-14 FT.LBS. (14 - 19 Nm) MANUAL PUMP JLG THREADLOCKER P/N 0100011 MAIN CONTROL VALVE HANDLE PUMP JUNCTION MANIFOL VALVE TORQUE 10-14 FT.LBS. (14 - 19 N JLG THREADLOCKER P/N 0100011...
  • Page 243 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Table 5-38. Main Control Valve Specifications Torque Item Ohms ft.lbs. Solenoid /w Integral Relief Valve 24-26 32.7-35.4 Solenoid /w Integral Relief Valve 24-26 32.7-35.4 Solenoid Valve 16-20 24.4-27.1 Solenoid Valve 16-20 24.4-27.1 Relief Valve 19-21...
  • Page 244 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS LIFT UP TOWER LIFT UP FLOW CONTROL SWING LEFT STEER LEFT SWING RIGHT STEER RIGHT HIGH FLOW DUMP V240 LOW FLOW DUMP MAE15740I Figure 5-37. Main Control Valve Identification 3121634 5-79...
  • Page 245 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS TO PORT "P1" (HELAC) PORT "R2" PORT "MP" TO PORT "P2" (HELAC) PORT "R1" TO PORT "V2" (JIB LIFT CYL) PORT "J2" TO PORT "V1" (JIB LIFT CYL) PORT "J1" PORT "P " TO PORT "P2"...
  • Page 246 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS PORT "V1" (LIFT CYL) PORT "V2" PORT "V1" PORT "V2" (TELE CYL) (TELE CYL) (LIFT CYL) PORT "T1" (VALVE, UPRIGHT) PORT "T2" (VALVE, UPRIGHT) PORT "P1" (VALVE, UPRIGHT) NOTE: Solenoid Valves are torqued 19-21 ft.lbs. (25.8-28.6 Nm). Coils are torqued 4-5 ft.lbs.

  • Page 247: Gear Pump

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.5 GEAR PUMP 4. Carefully place the gear pump on the clean working sur- face. Removal Installation ENSURE THE PRESSURE IS PROPERLY RELIEVED FROM THE HYDRAULIC SYS- DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK TEM BEFORE PROCEEDING TO REMOVAL OF THE PUMP MOTOR.

  • Page 248: Pressure Setting Procedure

    Cold temperatures have a significant impact on pressure read- gauge should read 2500 ± ings. JLG Industries Inc. recommends operating the machine 150 psi (172 ± 10.3 Bar). until the hydraulic system has warmed to normal operating temperatures prior to checking pressures.

  • Page 249: Swing Relief Valve

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3. Swing Relief Valve 1. Install a pressure gauge at port M2. 2. Activate telescope in, or The swing relief valve is located on the T port face of the valve remove the hose from port block next to the T port.

  • Page 250: Steer Relief Valve

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Activate swing until the turntable is bottomed out at the 1. Install a pressure gauge at port M2. stop. You can also remove the hose from port 5. Plug and cap. 2.

  • Page 251: Platform Level Down Relief Valve

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 2. Remove the hose from port L1 located on the bottom of 6. Platform Level Down Relief Valve the valve. Plug and cap. 1. This relief valve is located on the valve manifold inside the tower boom upright.

  • Page 252: Oil Sampling

    5. Place a drip pan under the spout and push in for approx- NOTE: Refer JLG Oil Analysis Test Kit (PN 1001112446) for more imately 10 seconds. This should flush out the valve. information about Oil sampling. Contact the local JLG 6.
  • Page 253 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS JIB CYLINDER BARREL: 2.48" (63mm) ROD: 1.57" (40mm) SLAVE CYLINDER TELESCOPE CYLINDER STROKE: 22.8" (580mm) PLATFORM ROTATOR BARREL: 3.0" (75mm) BARREL: 2.0" (50mm) ROD: 1.3" (32mm) DISPLACEMENT: 7.91 CUBIC INCH ROD: 1.3"...
  • Page 254 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS MAIN LIFT CYLINDER LOWER LIFT CYLINDER BARREL: 3.5" (90mm) BARREL: 2.95" (75mm) ROD: 1.96" (50mm) ROD: 1.77" (45mm) STROKE: 26.29" (668mm) STROKE: 29.6" (751.8mm) STEER CYLINDER SWING DRIVE BARREL: 2.5" (65mm) ROD: 1.75"...
  • Page 255 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 256: Jlg Control System

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH The JLG Control System controller has a built in LED to indicate AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- any faults. The system stores recent faults which may be TRIES, INC.

  • Page 257: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer With the machine power on and the analyzer connected prop- 1. Connect the four pin end of the cable supplied with the erly, the analyzer will display the following:...

  • Page 258: 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 DIAGNOSTICS DRIVE SYSTEM TEST BOOM SYSTEM OPERATOR ACCESS...

  • Page 259: 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. Analyzer Once you have gained access to Service Access, and a person- Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 260: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF When a machine digit item is selected, press the UP YOUR MACHINE. DOWN arrow keys to adjust its value, for example: ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- TRONIC COMPONENTS.
  • Page 261 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING FLOW ALTERNATING CURRENT FLOW ACCEL ACCELERATE FRONT ACTIVE FORWARD ANALOG DIGITAL CONVERTER COUNT FORWARD AMB. AMBIENT FOOT SWITCH ANGLE FUNC FUNCTION AUXILIARY...
  • Page 262 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING PRESSURE PROPORTIONAL CONTROL VALVE PLAT PLATFORM PLATFORM PLATFORM MODULE POTENTIOMETER PRESS PRESSURE PRES PRESSURE PRESSURE POINT PULSE WIDTH MODULATION REAR or RIGHT RELIEF REVERSE or REVISION RETRACT ROT.
  • Page 263 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information (Software Version P1.4) Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal- ity settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
  • Page 264 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information (Software Version P1.4) Default Configuration Digit Number Description Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine for high coolant temperature fault or low oil pressure fault.
  • Page 265 YES: AC inverter installed JIB: NO: No jib installed. YES: Jib installed which has up and down movements only. * This menu item not visible for H340AJ SKYGUARD: NO: No SkyGuard system installed. YES: SkyGuard system installed. * Only visible under certain market selections.
  • Page 266 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information (Software Version P1.4) Default Configuration Digit Number Description Number LOAD SYSTEM: NO: No load sensor installed. WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
  • Page 267 NO: High Ambient temperature cooling fans are not installed YES: High Ambient temperatures cooling fans are installed DC OUTLET: NO: No DC outlet is installed. YES: DC outlet is installed. * This menu item not visible for H340AJ 1001184134 -E 6-12 3121634...
  • Page 268 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings (Software Version P1.4) (Software Version P1.4) H340AJ H340AJ Model Number Market Load System Genset Engine Glow Plug Function Cutout Starter Lockout Display Unit...

  • Page 269: Machine Personality Settings And Function Speeds

    SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. FUNCTION SPEEDS Table 6-4. Machine Personality Settings and Function Speed H340J H340J...
  • Page 270 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speed H340J H340J FUNCTION ADJUSTMENT RANGES MODEL MODEL TIME RANGE DEFAULTS (IN SECONDS) TOWER LIFT Accel 0.0 to 5.0 s Decel 0.0 to 5.0 s 250 to 1400 mA...
  • Page 271 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speed H340J H340J FUNCTION ADJUSTMENT RANGES MODEL MODEL TIME RANGE DEFAULTS (IN SECONDS) JIB LIFT Accel 0.0 to 5.0 s 1.2 s Decel 0.0 to 5.0 s 0.5 s...
  • Page 272 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Personality Settings and Function Speed H340J H340J FUNCTION ADJUSTMENT RANGES MODEL MODEL TIME RANGE DEFAULTS (IN SECONDS) GROUND MODE Left 250 to 1400 mA 850 mA SWING Right 250 to 1400 mA...

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