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JLG 330LRT, Service And Maintenance Manual

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JLG 330LRT Service And Maintenance Manual Download Page 9

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TABLE OF CONTENTS

4.8

Hydraulic Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Main Hydraulic Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-7
Main Hydraulic Valve (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-10
Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-12
Leveling Jack Directional Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-13
Leveling Jack Valves (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-14
Leveling Jack Manifold Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Pressure Relief Valve - Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-16

4.9

Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.10

Axial HI 45 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

General Repair Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-21
Start-Up Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-21
Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-22
Electric Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-23
Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-23
Shaft Seal, Roller Bearing & Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-24
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-24
Charge Check/HPRV  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-26
Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-26
Pressure Limiter Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-27

4.11

Charge Pump Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4.12

Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-29
Cleaning and Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-31

4.13

Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Oscillating Axle Cylinder Bleeding Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-41

4.14

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

SECTION

5  - JLG CONTROL SYSTEM

5.1

Analyzer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Connecting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-1
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-2
Changing the Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-3
Adjusting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-4
Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-4
System Fault/DTC Indication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-5

5.2

ANALYZER MENU FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3

Diagnostic Troubleshooting codes (DTC’s) and Flash Codes Description . . . . . . . . . . . . . . . . . . . . 5-9

5.4

Chassis Tilt Sensor Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.5

Location of Additional Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5.6

Calibration Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Chassis Tilt Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-20
Oscillating Axle Tilt Sensor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-20
Set Stow Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-21
Load Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-21
Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   5-21

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Summary of Contents for 330LRT

Page 1: ...Service and Maintenance Manual Models 330LRT 430LRT PVC 1910 31215079 September 13 2019 Rev A AS NZS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 2: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 3: ...tem pressure prior to disconnecting or removing any por tion of the system Relieve system pressure by cycling the applicable con trol several times with the engine stopped and ignition on to direct an...

Page 4: ...INTRODUCTION A 2 31215079 REVISON LOG Original Issue A September XX 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 5: ...3 1 4 Hydraulic Pressure Settings 1 4 1 5 Hydraulic Cylinder Specifications 1 4 1 6 Engine Specifications 1 4 1 7 Elevation Tilt Limit Settings 1 6 1 8 ThreadLocking Compound 1 9 1 9 Torque Charts 1 1...

Page 6: ...Prop 2 7 General Maintenance Tips 2 8 Fuel Tank 2 9 Drive Hub 2 9 Scissor Arms Sliding Wear Pads 2 9 Hydraulic Oil Tank 2 9 Hydraulic Charge Filter 2 9 Oil Change with Filter 2 10 Fuel Water Separato...

Page 7: ...Assembly 3 35 3 6 Steer Installation All Markets Except for CE and JAPAN 3 36 Steer Cylinder Removal 3 36 Spindle Removal 3 36 Assembly 3 36 3 7 Steer Installation CE and Japan Markets 3 37 Steer Cyli...

Page 8: ...g 3 72 Diagnosis of Actuator 3 73 Adjustment of The Actuator 3 74 Adjustment Verification of Actuator 3 75 SECTION 4 BASIC HYDRAULIC INFORMATION SCHEMATICS 4 1 Cylinders Theory of Operation 4 1 4 2 Va...

Page 9: ...4 11 Charge Pump Filter 4 28 4 12 Cylinder Repair 4 29 Disassembly 4 29 Cleaning and Inspection 4 30 Assembly 4 31 4 13 Cylinder Assemblies 4 35 Oscillating Axle Cylinder Bleeding Procedure 4 41 4 14...

Page 10: ...leshooting 6 8 SECTION 7 GENERAL ELECTRICAL INFORMATION SCHEMATICS 7 1 General 7 1 7 2 Multimeter Basics 7 1 Grounding 7 1 Backprobing 7 1 Min Max 7 1 Polarity 7 1 Scale 7 1 Voltage Measurement 7 2 Re...

Page 11: ...Disassembly 7 11 HD30 HDP20 Series Assembly 7 12 HD30 HDP20 Series Disassembly 7 12 7 7 Switches 7 13 Basic Check 7 13 Limit Switches 7 13 Automatic Switches 7 14 Switch Wiring Low Side High Side 7 1...

Page 12: ...Kit Disassembly 3 26 3 17 Servo Piston 3 29 3 18 Cylinder Kit Assembly 3 30 3 19 Swash Plate and Journal Bearing 3 30 3 20 Shaft and Front Bearing 3 31 3 21 Cylinder Kit Installation 3 31 3 22 Servo S...

Page 13: ...4 14 4 7 Leveling Jack Manifold Valve 4 15 4 8 Tandem Gear Pump Diesel 4 17 4 9 Gear Pump Dual Fuel Gas LPG 4 18 4 10 Axial HI 45 Pump 4 19 4 11 Axial HI 45 Pump Cross Section View 4 20 4 12 Charge Pu...

Page 14: ...ector Disassembly 7 9 7 11 Connector Installation 7 10 7 12 DT DTP Contact Installation 7 11 7 13 DT DTP Contact Removal 7 11 7 14 HD HDP Contact Installation 7 12 7 15 HD HDP Locking Contacts Into Po...

Page 15: ...CE Only 4 11 4 5 Main Valve Torque Specs CE Only 4 11 4 6 Main Valve Porting Specs CE Only 4 11 4 7 Leveling Jack Directional Valve Torque Specs 4 14 4 8 Leveling Jack Valves Torque Specs 4 14 4 9 Lev...

Page 16: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 17: ...94kg cm2 LevelingJackPadBearing Pressure 69psi 4 85kg cm2 HydraulicSystemPressure MainRelief LiftUpRelief SteerRelief LevelingJackRelief 2700psi 186bar 2700psi 186bar 2500psi 172bar 2500psi 172bar Ele...

Page 18: ...R Range 34 sec 25ft 34 sec 25ft GradeabilityRequirement 45 45 Model 330LRT 430LRT ToeIn Out Max 0 25in 6 35mm 0 25in 6 35mm SteerAngle InsideTire 42 44degrees 42 44degrees SteerAngle OutsideTire 32 3...

Page 19: ...W 30 10W 20 Gravity API 29 0 29 3 Density LB GAL 60 F 7 35 7 3 FlashPoint F C 442 228 380 193 PourPoint F C 46 43 30 34 Viscosity Brookfield cPat 18 C 2700 Brookfield cPat0 F 2500 Viscosity cSTat40 C...

Page 20: ...si 172bar SteerReliefPressureRight 2500psi 172bar LevelingJackReliefPressure 2500psi 172bar Description Bore Stroke Rod Dia LiftCylinder 4 5in 114 3mm 83in 2108 2mm 3 5in 88 9mm LevelingJack Cylinder...

Page 21: ...M LowRPMSet 1200RPM HighRPMSet 3500RPM Alternator 60Amp 12V BeltDrive Battery 112Amp Hour 950ColdCranking Amps 12VDC FuelConsumption LowRPM HighRPM 0 38gal hr 1 45L hr Gas 1 85lb hr 0 84kg hr LP 1 76g...

Page 22: ...tout settings IF THE TILT INDICATOR WARNING LIGHT ALARM IS ACTIVATED WHEN PLATFORM IS RAISED LOWER PLATFORM AND DRIVE TO A SMOOTH FIRM LEVEL SURFACE Table 1 9 Tilt Cutout Settings Model Market Front t...

Page 23: ...ATURE BOUNDARIES OUTLINED IN THE ENGINE OIL OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE LPG OPERATION RECOMMENDED JLG COLD WEATHER PACKAGE RECOMMENDED JLG ARTIC...

Page 24: ...ON 1 SPECIFICATIONS 1 8 31215079 1001120075 C Figure 1 4 Engine Oil Operating Temperature Specifications Kubota Diesel Engine G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a...

Page 25: ...bstituted in place of Vibra TITE 121 JLG PN Loctite ND Industries Description 0100011 242 Vibra TITE 121 MediumStrength Blue 1001095650 243 Vibra TITE 122 MediumStrength Blue 0100019 271 Vibra TITE 14...

Page 26: ...0700 90 122 65 88 100 136 80 108 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135...

Page 27: ...110 150 90 120 9 16 12 0 5625 0 1820 16400 155 210 140 190 115 155 18 0 5625 0 2030 18250 170 230 155 210 130 175 5 8 11 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 23000 240 325 215...

Page 28: ...0 5000 0 1599 10700 75 100 71 97 65 88 9 16 12 0 5625 0 1820 11600 90 120 87 118 80 109 18 0 5625 0 2030 12950 105 145 97 132 90 122 5 8 11 0 6250 0 2260 14400 130 175 120 163 115 156 18 0 6250 0 2560...

Page 29: ...130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260...

Page 30: ...0 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 43...

Page 31: ...130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315...

Page 32: ...4 30 36 7 88 66 79 97 14 2 115 50 0 140 105 126 154 16 2 157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 153 5 737 5...

Page 33: ...1 75 84 30 52 5 125 115 95 14 2 115 71 6 200 180 150 16 2 157 97 8 315 280 235 18 2 5 192 119 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3...

Page 34: ...43 40 38 12 1 75 84 30 36 7 75 70 66 14 2 115 50 0 119 110 105 16 2 157 68 3 186 175 165 18 2 5 192 83 5 256 240 225 20 2 5 245 106 5 362 340 320 22 2 5 303 132 0 494 465 435 24 3 353 153 5 627 590 55...

Page 35: ...5 12 1 75 84 30 52 5 105 100 95 14 2 115 71 6 170 160 150 16 2 157 97 8 265 250 235 18 2 5 192 119 5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 222 0 905 850 800 27...

Page 36: ...ction shall be accomplished for each machine in service for 3 months or 150 hours which ever comes first out of service for a period of more than 3 months or when purchased used The frequency of this...

Page 37: ...6 Returns to neutral or off position when released 7 Clean and free of debris 8 Interlocks function properly 9 Check for signs of leakage 10 Decals installed and legible 11 Check for proper fluid leve...

Page 38: ...uardRails 1 2 4 1 2 4 Gate 1 5 1 5 Floor 1 2 1 2 LanyardAnchoragePoint 1 4 10 1 4 10 SCISSORARMS ScissorArms 1 2 4 1 2 4 ArmSafetyProp 1 5 1 5 CylinderPins PivotPins AttachingHardware 1 2 1 2 ArmPins...

Page 39: ...Secure Legible 21 21 AllDecals PlacardsInstalled Secure Legible 21 21 AnnualMachineInspectionDue 21 NoUnauthorizedModificationsorAdditions 21 21 AllRelevantSafetyPublicationsIncorporated 21 21 22 Gen...

Page 40: ...ting structure and the component becomes less than 90 6 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interf...

Page 41: ...mponents sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines 2 The design and manufacturin...

Page 42: ...manufacturers are always the best choice how ever multi purpose greases usually have the qualities which meet a variety of single purpose grease require ments Should any question arise regarding the...

Page 43: ...n hydraulic tank If oil is not visible add oil until oil is visible in both ADD and FULL sight windows on tank Do not overfill tank Any time the pump coupling is removed coat splines of coupling with...

Page 44: ...ube MPG Interval Every month or 50 hours Hydraulic Oil Tank Lube Point Fill Cap Fill Level Lube HO API service classification GL 3 Refer to Figure 1 2 Interval Check oil every 10 hours of operation ch...

Page 45: ...ure Specifications Kubota Diesel Engine Interval Every Year or 200 hours of operation Check oil level daily maintain within marked level 1 Change in accordance with engine manual Fuel Water Separator...

Page 46: ...operation Under severe operating conditions such as a very dusty work area check condition of filter more often Once a week squeeze the evacuator valve 2 on bot tom of air cleaner assembly to allow co...

Page 47: ...wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their...

Page 48: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 49: ...l increase to high idle When a function is selected for operation which requires a higher engine speed than the generator the generator will automatically shut off during the opera tion of the functio...

Page 50: ...ory recom mendations may result in an unsafe condition regard ing stability Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque WHEEL NUTS MUST BE INSTALLED...

Page 51: ...le by removing the 6 Bolts 4 and Washers 5 4 The Drive Motor 6 can be removed from the Drive Hub 3 by removing the 2 Bolts 8 Nuts 10 and Washers 9 INSTALLATION 1 Follow Removal procedures in reverse o...

Page 52: ...leak in a seal o ring or gasket replace the part immedi ately Tightening and Torquing Bolts If you use an air impact wrench to tighten bolts take extreme care to ensure that you do NOT tighten the bo...

Page 53: ...her C Needle Roller D Spacer E Planet Shaft F Cluster Gear G Roll Pin 4 Ring Gear 5 O Ring 6 Cover Sub Assembly A Cover B Cover Cap C Bolt D Disconnect Cap E Disconnect Rod F O Ring G O Ring H Pipe Pl...

Page 54: ...9 27 25 26 17 18 32 31 34 33 36 35 38 16 12 1A 1B 1C 1D 1J 1G 1E 1F 1H 1 1 15 2 7 7A 7D 7D 7C 7B 6 6B 9 13 8 14 3B 3F 3C 3D 3C 3B 3 3A 3E 3G 5 4 5A 6A 11 11 6C 6D 6G 6H 6G 6I 6E 6F 10 1I 24 24 Figure...

Page 55: ...nnectRod 6E DisengageCap 6F Bolt1 2 20NCx1 2 6G PipePlug 6H Rivet 6I IDPlate 7 InputShaftAssembly 7A Shaft 7B RetainingRing 7C Spring 7D ThrustSpacer 8 SunGear 9 ThrustWasher 10 Bolt 11 DowellPin 12 C...

Page 56: ...RBORE WHEN YOU REMOVE THE O RING 16 Remove o ring 5 from the counterbore in hub 1G Discard the o ring 17 At this point the main disassembly for drive hub is complete Hub Spindle Disassembly NOTE Start...

Page 57: ...et shaft from the car rier 2 Using a punch and hammer drive the planet shaft 3E out of the planet shaft hole in the carrier housing 3A 3 When removing the planet shaft 3E from the carrier housing one...

Page 58: ...ar 3F large end toward roll pin hole in carrier housing onto the planet shaft 3E 7 Following the cluster gear place one more thrust washer 3B onto planet shaft 3E through the oppo site planet shaft ho...

Page 59: ...ct rod 6E into cover cap 6B 4 Set cover 6A on table exterior side up Place cover cap 6B onto cover 6A aligning the pipe plug hole in the cover cap over the pipe plug hole in the cover 5 Place two of t...

Page 60: ...ng a torque wrench apply 2 95 to 3 69 ft lbs 4 to 5 Nm of torque to both bolts 6C 10 Apply a light coat of Never Seize to pipe plug 6H and tighten it into the pipe plug hole in the cover 6A Hub Spindl...

Page 61: ...ub 1G over onto its small end Press bearing cup 1E down into the counterbore in the deep end of the hub 1G 5 Set hub 1G onto its large end Place bearing cone 1D into bearing cup 1C 6 Press seal 1B int...

Page 62: ...EWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O RING 1 Grease o ring 5 and place it into the counterbore in hub 1G NOTE O ring may be stretched or pinched together to make it fit the counter...

Page 63: ...er 7D onto the smooth end of input shaft 7A WEAR SAFETY GLASSES DURING THIS STEP AND BE AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT IF THE RING IS RELEASED BE...

Page 64: ...lder bolt holes in the hub Mark the location of shoulder bolt holes on the outside of ring gear and hub NOTE You may lift the ring gear off the hub to align the shoulder bolt holes The ring gear and c...

Page 65: ...lign ment prior to disassembly 18 Place four flatwashers 16 on top of the bolt holes in the cover sub assembly 19 Place shoulder bolts 13 into the four shoulder bolt holes in cover 6 and tighten by ha...

Page 66: ...pindle 1A 24 Roll test the unit in both clockwise and counterclock wise directions Perform the same number of turns in each direction as the ratio of the unit The ratio is the last two digits of the m...

Page 67: ...brakes EQUIPMENT REQUIRED 1 Hydraulic power supply hand pump capable of pro ducing 200 psi 13 8 bar 2 Hydraulic fittings to adapt hydraulic supply to brake release port on hub PROCEDURE 1 Using approp...

Page 68: ...pis ton allows smooth acceleration and deceleration with relatively large circuit orificing Shaft Seal Replacement REMOVAL 1 Remove the snap ring 1 retaining the shaft seal and support washer 2 Remov...

Page 69: ...6 4 Using pliers remove centering springs 7 8 and 9 5 Remove spring retaining washers 10 and 11 6 Remove shift spool 12 7 Remove orifice poppet 13 INSPECT THE COMPONENTS Inspect new O rings and the se...

Page 70: ...ientamountofhydraulicfluidwillnotmeetthecooling demandsofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger if soequipped Iftheheatexchangerfails orbecomesobstructed itmaynotmeet theco...

Page 71: ...ped Then remove the speed sensor using a 1 2 in hex wrench Units without speed sensor have an O ring plug 15 installed in that location remove it with a 1 4 in internal hex wrench 10 Using a 1 4 in in...

Page 72: ...Remove and discard the O rings 27 17 Remove the rear shaft bearing 28 from the endcap with a bearing puller The bearing may be difficult to remove with a puller Try this as an alternative Pack the bea...

Page 73: ...mmer Drive the screw into the seal surface and use the slide hammer to pull the seal 21 Remove the inner snap ring 35 and the shaft bear ing assembly 22 Remove the snap ring 36 retaining the shaft fro...

Page 74: ...l retaining ring 51 Carefully release the pressure and remove the outer block spring washer 50 block spring 52 and inner block spring washer 53 from the cylinder block Inspection After disassembly was...

Page 75: ...Play Measurement L Frame K Frame SlipperFootThickness mm in 2 71 0 11 4 07 0 16 Piston SlipperEndPlay 0 15 0 006 A Table 3 8 Cylinder Block Measurements Measurement L25 L30 L35 K38 K45 MinimumCylinder...

Page 76: ...ications shown Measure the swashplate thickness from the journals to the running face Replace swash plate if damaged or worn beyond minimum specifica tion Replace swashplate if the difference in thick...

Page 77: ...in the end cap and let it stand for at least five minutes 2 After piston seal has relaxed lubricate and install servo piston into the housing bore Align the piston with the ball socket facing the ins...

Page 78: ...Use assembly grease to keep the bearings seated during assembly Ensure the locating nubs drop into the cavities in the seats If you re reusing the bearings install them in the original location and or...

Page 79: ...gn the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing downward and verify the cylinder kit swashplate journal bearings and servo piston are all secure and...

Page 80: ...al components may prevent the endcap from seating properly Ensure the O rings seat properly when installing the endcap 16 Using an 8 mm internal hex wrench tighten the end cap screws Tighten the screw...

Page 81: ...he drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal 28 SealSupportWasher 29 SnapRing Figure 3 25 Shaft Seal 1 4 in 45 Nm 33 ft lbs 5 16 in 85 Nm 63 ft lbs 5 16in 85 Nm 63...

Page 82: ...pper most case drain port 4 To ensure the pump and motor stay filled with oil install case drain lines into the upper most case drain ports 5 Install a 0 to 500 psi 0 to 35 bar gauge in the charge pre...

Page 83: ...ed away from the frame Assembly 1 When installing the axle assembly follow Removal Steps in reverse 2 If removed shim the wear pad to achieve a maxi mum gap of 1 16 in 1 5mm between the pad and the ax...

Page 84: ...1 from nuts 13 Remove the 2 tapered king pins 12 from the tapered king pin bores on the axle and thrust washer 14 from lower axle Remove spindle from axle Assembly 1 When assembling steer cylinder and...

Page 85: ...spindle 8 removal 2 Disconnect tie rod 2 from spindle by removing screw and pin keeper 4 pin 3 and bearings 2A 3 Support spindle Remove spindle from axle by removing flange bolts 11 from nuts 13 Remo...

Page 86: ...e if damaged Ensure large thrust washer 14 is installed between spindle 8 and bottom of axle Be certain spindle nut 13 is aligned and seated in the machined groove on the axle before tightening NOTE T...

Page 87: ...the shoulder on the lockout cylinder is firmly against the bottom of the mounting plates on the frame before torquing bolts Apply Medium Strength Threadlocking Compound and Threadlocking Compound to...

Page 88: ...nd nuts 7 attaching cylinder to cylinder mount Remove jack cover attach bracket 5 5 Carefully remove cylinder from mount INSTALLATION 1 Follow Removal Steps in reverse NOTE Refer to Figure 4 13 Cylind...

Page 89: ...wiring from the leveling jack tube assembly 4 Remove the eight bolts 3 washers 4 nuts 5 dou bler plate 6 and shim 7 through the frame 5 Carefully lower assembly from the frame INSTALLATION 1 Follow Re...

Page 90: ...l electri cal wires going to platform 4 Detach the center attach link from the platform by removing the bolt 8 locknut 9 pin keeper 10 and pin 11 5 With scissor arm assembly 2 braced remove the slide...

Page 91: ...dis connecting all the wiring inside the control box ASSEMBLY 1 Follow Disassembly Procedures in reverse 2 Ensure electrical wires are properly and securely attached to switches buttons and bulbs NOT...

Page 92: ...tConsumption 10mA 12VDC CenteredOutputVoltage 2 50VDC ReverseVoltage 4 0VDC ForwardVoltage 1 0VDC Table 3 10 Joystick Plug Loading Chart Terminal Color Function 1 RED HandleCOM 2 VIOLET TriggerN O 3 S...

Page 93: ...ELEVATED SCISSOR ARMS WITHOUT FIRST PROPERLY BRACING BLOCKING SCISSOR ARM ASSEMBLY NOTE Scissor arms can be removed individually or as an entire assembly ARM REMOVAL 1 Remove platform refer to Figure...

Page 94: ...SCISSOR ARMS 3 46 31215079 Figure 3 37 Scissor Arm Component 330LRT Assembly 1 of 2 D C C C C C C E F G G H B J K MAF04100 A A DETAIL A DETAIL B G o t o D i s c o u n t E q u i p m e n t c o m t o o...

Page 95: ...RMS 31215079 3 47 Figure 3 38 Scissor Arm Component 330LRT Assembly 2 of 2 MAF04111 DETAIL C DETAIL D DETAIL E DETAIL F DETAIL G DETAIL K DETAIL J DETAIL H G o t o D i s c o u n t E q u i p m e n t c...

Page 96: ...SSOR ARMS 3 48 31215079 C MAF04120 C C C C C D C C C C E F F B H J K A G A DETAIL A DETAIL B Figure 3 39 Scissor Arm Component 430LRT Assembly 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t...

Page 97: ...RMS 31215079 3 49 DETAIL C DETAIL D DETAIL E DETAIL F DETAIL G DETAIL K DETAIL J DETAIL H MAF04131 Figure 3 40 Scissor Arm Component 430LRT Assembly 2 of 2 G o t o D i s c o u n t E q u i p m e n t c...

Page 98: ...Engine Compartment Covers 1 Engine Main Compartment Cover 2 Front Engine Door 3 Rear Engine Door 4 Ladder Assembly 5 Door Latch Assembly 6 Door Hinge Assembly 7 Engine Exhaust Tube 8 Generator Shield...

Page 99: ...Side Hydraulic Fuel Compartment Covers 1 Hydraulic Fuel Main Compartment Cover 2 Hydraulic Tank Door 3 Fuel Tank Door 4 Ladder Assembly 5 Door Latch Assembly 6 Door Hinge Assembly 7 Support Ladder G o...

Page 100: ...e the bolts and washers from the front covers or doors remove and lay aside 7 Remove the ladder from the support bracket by removing the bolts washers and nuts 8 Remove the bolts and washers from the...

Page 101: ...y ASSEMBLY 1 Reattach any wires and or plugs 2 Close lid 2 and secure 3 Reattach machine harnesses to the ground control box 6 NOTE If tilt sensor or the ground control station box is removed and repl...

Page 102: ...four nuts and washers 4 from the mounting bolts 3 Remove the module from the mounting plate INSTALLATION 1 Mount new module to the mounting plate using the four bolts nuts and washers 4 2 Reconnect th...

Page 103: ...securing the block to the machine compartment cover INSTALLATION 1 Place battery in the seat Negative battery terminal 2 should be closest to outside of machine 2 Secure battery in place with the hol...

Page 104: ...Before reinstalling apply Low Strength Threadlocking Compound to threads of tank send ing unit bolts If removed before reinstalling into tank insert apply pipe sealant High Strength Threadlocking Com...

Page 105: ...ect cap and label all hoses connected to tank 4 Remove the bolts washers and nuts 3 attaching the hydraulic tank to the machine Remove tank from machine NOTE Hydraulic tank has two lifting lugs on the...

Page 106: ...and ladder 3 bolts nuts and washers to swing the engine tray out for better access as shown below 1 Tray Pivot Pin 2 Tray to Frame Bolt Nut and Washer 3 Ladder To Cabinet Bolt Nut and Washer Figure 3...

Page 107: ...emoval 1 Kubota Engine Shown 2 Engine Lifting Lugs 3 Left Right Side Engine Mounting Brackets 4 Engine Isolator Mount 5 Swinging Engine Tray Figure 3 51 Engine Removal All Engines 5 G o t o D i s c o...

Page 108: ...ing the lifting lugs 2 at the front and rear corners of the engine support engine 1 with lifting device capable of lifting 500 lbs 227 kg refer to engine manual for proper lifting information 5 Remove...

Page 109: ...rate filling equipment 4 Fill LPG tanks outdoors Stay at least 50 ft 15 m from buildings motor vehicles electrical equipment or other ignition sources Stay at least 15 ft 5 m from LPG storage tanks 5...

Page 110: ...cking Compound to the threads of the generator mounting bolts NOTE The generator control box is mounted on the rear wall of the Hydraulic Fuel Tank cabinet just behind the ground control station The p...

Page 111: ...ttaching hardware INSTALLATION 1 Follow Removal Steps in reverse NOTE Torque on O2 Sensors is 32 ft lb 44 Nm Diesel ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVIC ING REMOVAL 1 Disable machine...

Page 112: ...PONENTS TO COOL DOWN BEFORE SERVIC ING REMOVAL 1 Disable machine operation If necessary swing engine tray out for better access to components 2 Loosen the clamp 4 and 6 attaching the intake pipe to th...

Page 113: ...te assembly 1 and remove the four large bolts holding the mount ing plate to the engine swivel tray 4 and the lower support bracket 2 5 Re check that all connections hoses etc are discon nected and re...

Page 114: ...ISSOR ARMS 3 66 31215079 Engine Electrical Component Locations 1 Dual Fuel Engine 2 ECM Module Figure 3 56 Duel Fuel Engine Control Module Location 1 G o t o D i s c o u n t E q u i p m e n t c o m t...

Page 115: ...cal Component Locations FC278 FUEL 02 FUSE 10A FC274 POWER FUSE 30A FC271 STAR FUSE 40A RL12 POWER RELAY RL10 START RL11 FUEL SELECT RL13 ETV RELAY ENG END T7 ALT STUD MS153 ALT CONN RELAY RELAY EC3 S...

Page 116: ...Locations T4F RL2 ENG START RELAY RL3 IDLE SPEED RELAY RL4 GLOW PLUG RELAY RL5 PULL RELAY RL6 HOLD RELAY FC257 HOLD RLY FUSE 5A FC258 START FUSE 40A FC259 PULL FUSE 40A FC267 IDLE SPEED FUSE 30A T6 AL...

Page 117: ...to the coupling 4 of the motor Care fully remove the axial pump INSTALLATION 1 Follow Removal Steps in reverse NOTE Apply grease to internal splines of pump coupling 1 and external splines of piston...

Page 118: ...ate Support starter do not hang by electrical wiring Remove the coupler housing 1 4 Remove the five pump coupler bolts to remove the pump coupling from the engine flywheel mounting plate 3 Remove coup...

Page 119: ...the Coupler Hous ing 3 INSTALLATION 1 Install engine speed sensor 1 into the coupler hous ing 3 until the sensor contact the flywheel 2 Back out the engine speed sensor 1 by hand 0 5 to 1 turns Ensur...

Page 120: ...solenoid is energized the actua tor plunger must be fully seated to prevent coil burn out MAF15610 Figure 3 62 Throttle Assembly and Linkages NOTE Illustration shows actuator in de energized state HAR...

Page 121: ...rom the connection location Blown fuse Examine the respective 30 Amp fuse to confirm if it is still good Blown fuse can indicate coil burnout If the fuse has been overloaded burned out replace the res...

Page 122: ...6 2 1 4 3 8 5 1 Clevis Adjustment Connection 2 Eyebolt Adjustment Connection 3 Actuator Plunger 4 Plunger Rod 5 Low Idle Stop 6 High Idle Stop 7 Throttle Lever 8 Throttle Actuator Figure 3 64 Adjustme...

Page 123: ...s freely without binding 3 If binding occurs check the plunger rod It should not come into contact with the eye bolt Also verify the spacer is installed on the correct side of lever arm 4 Use digital...

Page 124: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 125: ...ased the spool auto matically returns to neutral prohibiting any flow through the circuit Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associ...

Page 126: ...ct hydraulic hoses to cylinder port block 6 If used remove lifting device supporting platform or release and stow safety prop activate hydraulic sys tem and run cylinder through one complete cycle to...

Page 127: ...ing this procedure inspect the unit for any damage incurred during shipping and handling Make certain all components are clean prior to filling with hydraulic fluid The methods to pre fill pump is as...

Page 128: ...ANGLE TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Once charge pressure has been established increase speed to normal operating RPM Charge pressure sh...

Page 129: ...nent housing is as clean as possible Store the fill container in such a way as to prevent it from becom ing contaminated Install a 60 bar or 1000 psi pressure gauge in the charge pressure gauge port i...

Page 130: ...valve blocks from the hydraulic tray by removing the attaching bolts INSTALLATION 1 Re attach valve blocks to tray with bolts 2 Re connect all hydraulic lines and electrical harness 1 Main Valve 2 Fl...

Page 131: ...ure 4 2 Main Valve Port Identification PLG6 MAIN HYDRAULIC VALVE TOP LEFT SIDE RIGHT SIDE FRONT BACK 1 4 20 UNC 2BX0 55 DP 2 PLACES NO THREADLOCKING COMPOUND NOTE Refer to Table 4 1 Table 4 2 and Tabl...

Page 132: ...RTValve RightSide Outlet TandemGearPump MS MainRTValve RightSide DiagnosticPort MP1 MainRTValve RightSide DiagnosticPort Table 4 2 Main Valve Torque Specs All Specs Except CE Component Functionality T...

Page 133: ...Refer to Table 4 4 Table 4 5 and Table 4 6 BLK Figure 4 3 Main Valve Port Identification CE Only MAIN HYDRAULIC VALVE TOP LEFT SIDE RIGHT SIDE FRONT BACK NO THEARDLOCKING COMPOUND FRONT 1 4 20 UNC 2BX...

Page 134: ...ainRTValve RightSide Outlet TandemGearPump MS MainRTValve RightSide DiagnosticPort MP1 MainRTValve RightSide DiagnosticPort Table 4 5 Main Valve Torque Specs CE Only Component Functionality Torque SV2...

Page 135: ...SECTION 4 BASIC HYDRAULIC INFORMATION SCHEMATICS 4 12 31215079 Flow Divider Valve 9 Figure 4 4 Flow Divider Valve G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 136: ...raulic circuits Figure 4 32 on Page 4 42 Figure 4 5 Leveling Jack Directional Valve S1 1 OUTRIGGER CYLINDERS THERMAL RELIEF REST NON ADJUSTABLE OUTRIGGER CYLINDERS EXTEND PRESSURE VALV OUTRIGGER CYLIN...

Page 137: ...ylindersExtendTankValve 28 33ft lb 38 45Nm S3 LevelingJackCylindersExtendPressureValve 22 26ft lb 30 35Nm CoilsS1 3 Coils12VDC 8 Ohms 3 4 5ft lb 4Nm 3 4 A MAF12910 Figure 4 6 Leveling Jack Valves NOTE...

Page 138: ...on page 4 15 For internal hydraulic circuits see Figure 4 32 on page 4 43 Figure 4 7 Leveling Jack Manifold Valve 1 2 1 2 3 PORT 1 PORT 3 PORT 2 MAF06141 Table 4 9 Leveling Jack Manifold Valve Torque...

Page 139: ...ridge Adjust clockwise to increase counter clockwise to decrease f Re install the coil onto the lift up solenoid valve SV1 and torque coil nut to 5 ft lbs 2 Steer Work Port Relief Valve a Install a pr...

Page 140: ...p Diesel Table 4 10 Gear Pump Specs Diesel Rotation ViewingDriveEnd Clockwise Displacement Front Rear 14 4cc rev 175GPM 3 9cc rev 47GPM MaxRatedSpeed withmax fluidviscosityof50mm2 sec 2800rpm RatedPre...

Page 141: ...el Gas LPG MAF04080 2 1 Table 4 11 Gear Pump Dual Fuel Gas LPG Rotation ViewingDriveEnd Clockwise Displacement Front Rear 8 4cc rev 8 9GPM 2 62cc rev 2 77GPM MaxRatedSpeed withmax fluidviscosityof50mm...

Page 142: ...harge Gage Port SAE 6 8 M14 Gage Port SAE 4 9 Port A SAE 16 10 Charge Pump Suction Port SAE 16 11 Port B SAE 16 12 Case Drain Port L1 SAE 12 Figure 4 10 Axial HI 45 Pump Table 4 12 Axial HI 45 Pump Sp...

Page 143: ...l 2 Swashplate Feedback Pin 3 Piston 4 Slipper 5 Shaft Seal 6 Shaft 7 Front Bearing 8 Swashplate Bearing 9 Swashplate 10 Cylinder Block 11 Charge Pump 12 Rear Bearing 13 Valve Plate 14 Servo Piston Fi...

Page 144: ...thoroughly tested on a test stand before installing on a machine These pumps should never be dry started The time it takes for the charge pump to create a vacuum to draw in the fluid send it out throu...

Page 145: ...for at least five minutes to bleed all air and flush system contaminants out of loop NOTE Normal charge pressure fluctuation may occur dur ing forward and reverse operation 13 Check that the reservoir...

Page 146: ...50 5 Using a 5 mm internal hex wrench torque the cap screws D250 to 10 lb ft 13 5 Nm Control Solenoids REMOVAL 1 Disconnect electrical connection and remove the three capscrews D050 using a 4 mm inter...

Page 147: ...in 0 12mm or 0 0028 in 0 72 mm of the inside lip of the carrier see illustration 4 Cover the shaft with a protective sleeve while install ing the seal carrier Hand press the seal carrier into the hous...

Page 148: ...alance plate S200 in the same ori entation as removed 6 Install the thrust washer K500 Coated side goes toward charge pump coupling K200 7 Install a new cover gasket K150 If removed install guide pins...

Page 149: ...aks Charge Pressure Relief Valve Replace the charge pressure relief valve V10 as a com plete unit Do not attempt to repair the internal compo nents of the valve Torque to 38 lb ft 52 Nm REMOVAL 1 Usin...

Page 150: ...ves L300 L400 Discard O rings INSPECTION 1 Inspect the sealing surfaces of the pump for nicks or scratches REASSEMBY 1 Install new O ring Lubricate 0 ring with petroleum jelly 2 Replace pressure limit...

Page 151: ...bracket 1 using the mounting bolts washers 2 2 Uncap and reconnect the hydraulic lines 5 and 6 to the filter NOTE If removed and reinstalled filter bowl torque is 30 ft lb 40 Nm MAF06120 1 2 3 5 4 6 7...

Page 152: ...ylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture NOTE Steps 6 and 7 apply only to the steer cylinder 5 Using a spanner wrench loosen the spanner nut ret...

Page 153: ...on o rings seal rings and backup rings 16 Remove piston spacer if applicable from the rod 17 Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Di...

Page 154: ...ittings and holding valve Replace as necessary 16 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 17 If applicable inspect piston rings for cra...

Page 155: ...on one side This side faces the solid seal See magnified insert in See Figure 4 23 The split of seals and backup rings must be positioned so as not to be in alignment with each other 1 Using suitable...

Page 156: ...dequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 12 Continue pushing the rod into the barrel...

Page 157: ...ue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder 22 If applicable secure the cylinder head retainer using a suitable chain wrench 23 After the...

Page 158: ...4 35 4 13 CYLINDER ASSEMBLIES STEER CYLINDER 1 Barrel 2 Rod 3 Head Torque to 434 ft lb 588 Nm 4 Wiper 5 Rod Seal 6 Backup Ring 7 Dry Bearing 8 O Ring 9 O Ring 10 Piston Seal 1 G o t o D i s c o u n t...

Page 159: ...ve block Do not put cylinder into service without cartridge valves installed LIFT CYLINDER 1 Nut 2 Piston 3 Seal 4 O Ring 5 Wear Ring 6 Barrel 7 Rod 8 Head 9 O Ring 10 Backup Ring 11 Seal 12 Wiper Rin...

Page 160: ...0 12lb ft 13 6 16 3Nm 5 35lb ft 47 5Nm 6 5lb ft 6 8Nm 7 30lb ft 40 7Nm 8 25lb ft 33 9Nm 9 40lb ft 54 2Nm 10 40lb ft 54 2Nm 11 40lb ft 54 2Nm 12 60lb ft 81 3Nm Figure 4 27 Lift Cylinder Valve Cartridge...

Page 161: ...3 Bleeder Valve 4 CounterBalance Valve 5 Barrel 6 Wear Ring 7 Seal 8 Wiper NOTE Torque item 4 to 22 lb ft 30 Nm NOTE Torque item 2 to 22 24 lb ft 30 32 5 Nm THE CYLINDER ROD CAN SLIDE OUT OF THE CYLIN...

Page 162: ...ium Strength Threadlocking Compound to Capscrews 11 torque to 30 lb ft 40 7 Nm 1 Head 2 Barrel 3 Rod 4 Jack Plate 5 Lock Ring 6 Wear Ring 7 Washer Ring 8 Retaining Ring 9 O Ring 10 Screw 11 Capscrew 1...

Page 163: ...tem Description Torque 1 SolenoidDirectionalValve 39 8lb ft 54Nm 2 StraightFitting 32 1lb ft 43 5Nm 3 StraightFitting 39 8lb ft 54Nm Figure 4 29 Leveling Jack Torques HYDRAULIC SCHEMATIC G o t o D i s...

Page 164: ...alve enough to get a fast stream of oil NOTE A fast stream of oil will exhaust the air out of the hoses and cylinder better than a slow stream of oil 8 Every 3 4 seconds close the bleeder valve so tha...

Page 165: ...FT FRONT AXLE DRIVE MOTORS LEFT RIGHT A B A B A A B B 2 SPEED 2 SPEED A FD2 FD3 FD1 CHARGE FILTER B5 1000 43 PSI BYPASS M4 M5 F E RV1 RV1 CV1 CV1 CY1 CY1 P V P V 4500 PSI 4500 PSI FROM PORT 11 TRACTIO...

Page 166: ...DRAIN JUNCTION MANIFOLD L1 20 PSI 2500 PSI EXT 2 RET 1 SV2 SV4 EXT 4 SV1 SV3 PB4 PB3 PA2 PA4 PA3 PA1 PB1 LP T RIGHT REAR JACK RIGHT FRONT JACK LEFT FRONT JACK LEFT REAR JACK LEVELING JACK SYSTEM OPTIO...

Page 167: ...VE MOTORS LEFT RIGHT A B A B A A B B 2 SPEED 2 SPEED A FD2 FD3 FD1 CHARGE FILTER B5 1000 43 PSI BYPASS M4 M5 F E RV1 RV1 CV1 CV1 CY1 CY1 P V P V 4500 PSI 4500 PSI FROM PORT 11 TRACTION MANIFOLD RAM LO...

Page 168: ...RAIN JUNCTION MANIFOLD L1 20 PSI EXT 2 RET 1 SV2 SV4 EXT 4 SV1 SV3 PB4 PB3 PA2 PA4 PA3 PA1 PB1 LP T RIGHT REAR JACK RIGHT FRONT JACK LEFT FRONT JACK LEFT REAR JACK LEVELING JACK SYSTEM OPTION 3 FROM P...

Page 169: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 170: ...le has a four pin connector at each end It cannot be connected backwards 2 Power up the control system by turning the lower key to the platform position and pulling out both emergency stop buttons m e...

Page 171: ...ER is pressed again the display moves to the fol lowing display LOGGED HELP 1 STARTUP 2 1 Or last recorded fault At this point the analyzer will display the current fault if any are present You may sc...

Page 172: ...DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the password Use the UP or DOWN arrow ke...

Page 173: ...ple FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION GROUND ALARM 1 DESCENT The effect of the machine digit value is displayed along with its value The a...

Page 174: ...and Flash Codes Description IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTI LIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COM PO...

Page 175: ...F VALVES LIFT DN OFF VALVES PROP LFT LJ XXX VALVES PROP LIFT XXX VALVES PROP LJ XXX UPPER LIFT DOWN COMMAND XXXXMA UPPER LIFT DOWN FBK XXXXMA LOWER LIFT DOWN COMMAND XXXXMA LOWER LIFT DOWN FBK XXXXMA...

Page 176: ...X XS LIFT UPR DN MIN XXXXMA LIFT UPR DN MAX XXXXMA LIFT LWR DN ACCL X XS LIFT LWR DN DECL X XS LIFT LWR DN MIN XXXXMA LIFT LWR DN MAX XXXXMA PERSONALITIES LOAD LOAD OVERLD XXXX KG LOAD ACC Y XXXX KG...

Page 177: ...YES ENTER NO ESC 1 JOYSTICK CAL FORWARD ENTER 1 JOYSTICK CAL CENTER ENTER 1 JOYSTICK CAL REVERSE ENTER 1 JOYSTICK CAL COMPLETE 1 JOYSTICK CAL FAILED 1 MENU SERVICE 1 SERVICE MODE ECM OVERRIDE 1 ECM OV...

Page 178: ...ached end of stroke Check if the cylinder is at end of stroke normal operation Check the wiring to the Rear Right Leveling Jack end of stroke switch 0045 0 0 EngineShutdownCommanded CheckEngineSensors...

Page 179: ...wiring to the Rear Left Leveling Jack pressure transducer 246 2 4 RearRightLevelingJackPressureTransducerFailure Rear Right Leveling Jack pressure transducer reading is outside of the allowed range C...

Page 180: ...lOpen Machine Setup Leveling Jacks is set to 1 YES The Lift Level Drive Mode Digital Inputs are LOW simultaneously for 1000ms 22102 2 2 TriggerFaulty Disagreement between the trigger input at the plat...

Page 181: ...he wiring to the Front Left Leveling Jack 3519 3 5 FrontLeftLevelingJackOpenCircuit The Front Left Leveling Jack is open circuit Check the wiring to the Front Left Leveling Jack 3520 3 5 FrontRightLev...

Page 182: ...HIMhasdetectedaOContheDriveForwardValveoutputandcom municated it to the LRT Ground Module via CAN Only detectable when a function is active 33321 3 3 DriveReverseValve ShorttoBattery The HIM has detec...

Page 183: ...ttery charge and cables 442 4 4 BatteryTooHigh SystemShutDown Battery voltage is over 16 Volts Check the battery charge and cables 4310 4 3 NoAlternatorOutput The Alternator input is high after 15 sec...

Page 184: ...CANbus messages not received for 250mS 6671 CanbusFailure HydraulicsImprovementModule The LRT Ground Module has not received HIM messages for 250ms 813 8 1 ChassisTiltSensorNotCalibrated The chassis...

Page 185: ...t Active 8115 8 1 AxleTiltSensorOutOfRange The Axle Tilt Sensor Raw X or Raw Y axis reads 530 LRT 25 deg or 25 deg 330 430 LRT 30 deg or 30 deg 8118 8 1 AxleTiltSensorStagnant If DTC s 6650 8113 8115...

Page 186: ...kedOut HimModuleSoftwareVersionImproper DTC 6671 does not exist AND The LRT Ground Module software major version number does not match the major version number of the HIM module software 99187 9 9 LSS...

Page 187: ...ove procedures in reverse order when installing the chassis tilt sensor assembly Torque screws 7 to 106 in lbs 12 Nm NOTE After installing be sure to calibrate the chassis tilt sensor refer Section 5...

Page 188: ...n Sensor on scissor arm link at chassis 2 Arm Stack Tilt Sensor on bracket under cross member 3 Oscillating Axle Tilt Sensor mounted to front oscillating axle if equipped Figure 5 6 Chassis Sensor Loc...

Page 189: ...led one or both of the channels X axis and Y axis c Tilt sensor has moisture intrusion that has shifted its output d Water and or corrosion in the box has cor rupted electrical connections or caused a...

Page 190: ...E 2 Input the pass code 22954 and select Enter 3 The Analyzer will display ALLOW FUNCTIONS Select Enter for YES 4 Analyzer will display FUNCTS ALLOWED 5 Select Escape to leave menu Elevation Service T...

Page 191: ...ter 5 The Analyzer will display L J RETRACTED Select Enter 6 The Analyzer will display DRIVE ALLOWED Select Escape to leave menu Allow Leveling Jack Retract This mode allows a service technician to re...

Page 192: ...fferent Defaults by market CE 2 1 GROUNDALARM 8 0 1 2 NOTINSTALLED VehiclealarmwillfunctionforOverload ifLOADenabled DESCENT VehiclealarmwillfunctionforOverload ifLOADenabled andduringLiftDown motion...

Page 193: ...0 1 CSA 0 2 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X 0 1 2 0 1 0 X 0 1 0 1 CE 0 3 0 1 2 0 1 2 3 0 1 0 1 2 0 X 2 0 1 2 0 1 0 1 0 1 0 1 AUSTRALIA 0 4 0 1 2 0 1 2 3 0 1 0 1 2 0 1 X X X 2 0 1 0 X 0 1 0 1 KOREA 0 5...

Page 194: ...ht ANSIEXPORT 5 toFullHeight 3 toFullHeight CSA 3 toFullHeight 3 toFullHeight CE 5 toFullHeight 3 toFullHeight AUSTRALIA 5 toFullHeight 3 toFullHeight KOREA 5 toFullHeight 3 toFullHeight 430LRT ANSIUS...

Page 195: ...0 1000mA 860 850 ElevRevMax 700 1000mA 860 850 LIFT Accel 0 1 5 0 sec 2 0 2 0 Decel 0 1 3 0 sec 1 0 1 0 UpAccel 0 1 5 0 sec NA NA UpDecel 0 1 3 0 sec NA NA MinUp 0 35 19 19 MaxUp 0 75 55 55 MinDown 0...

Page 196: ...nsfromthegroundcontrolmaybeprevented dependingonmachine BATTERYTOOHIGH 4 4 IncomingSupplyVoltage 34 0Vdc Thecontrolsystem sbatteryvoltageistoohigh Thismaybeduetoover chargingorimproper chargeroperatio...

Page 197: ...enu adjust performance of the LSS All adjustments must be made in Access Level 1 33271 Table 6 2 Diagnostic Menu Descriptions DIAGNOSTICS MENU DISPLAYED ON ANALYZER 1ST LINE PARAMETER DISPLAYED ON ANA...

Page 198: ...rm weight To access the Calibration Load Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu Press the ENTER key to select the menu Press the LEFT and RIGHT arrow keys...

Page 199: ...CALIBRATE COMPLETE If the empty platform weight is less than minimum cali bration value the calibration attempt will be unsuccess ful and the Analyzer will show the following CALIBRATE MIN CAL If the...

Page 200: ...ch a way that all support force for the platform is applied through them for mea surement The four Shear Pin Load Cells plug directly into the LSS Module The Wire Harness connects the LSS Module to th...

Page 201: ...ails to meet these guidelines 1 Plug the JLG Analyzer into the Host Control System 2 Park the vehicle on a level surface The platform should be fully stowed and level within 5 both directions 3 Observ...

Page 202: ...on for safety Place 120 of the machines rated load in the center of the platform and ensure that the overload visual and audible warnings are active Reduce the platform load to 100 rated load and ensu...

Page 203: ...ter a particular connection is removed If so carefully inspect the wiring between the module and that sensor 3 There is a short circuit on the pre regulated supply for the JLG Analyzer present on J2 1...

Page 204: ...is through the sensor bodies nothing else touches except wires Re assemble according to print if necessary 4 Damage to the platform or arm structure has occurred or one of the components is out of tol...

Page 205: ...Controlsarepreventedinthesamemanner aswhenoverloaded TheLSSModuleisun powered un calibrated orisexperiencingaMeasurementPerformancedifficulty Alternately the HostControlSystemisnotreceivingthepropers...

Page 206: ...erPin 1 approx 12V 2 TX RS 232forJLGAnalyzer AnalyzerPin3 3 TRP1 120OhmCANbusTerminator 4 CANH 1 CANbusInterfaceHigh 5 CANS 1 CANbusShieldTermination NotsameasGND 6 CANH 2 ConnectstoCANH 1 7 CANL 2 Co...

Page 207: ...J4 12 GLWG J4 13 AUXP J4 14 HRMT J4 15 B J2 1 B J2 2 FWS J2 3 RVS J2 4 LTS J2 5 RTS J2 6 DPS J2 7 BRS J2 8 LOSAX J2 11 2SPD J2 9 UPS J2 10 ROSAX J2 12 GEN J2 13 GND J2 14 GND J2 15 OPT VALVE J2 16 GE...

Page 208: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 209: ...To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way...

Page 210: ...ouching leads together Resistance should read a short circuit very low resis tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing If meter...

Page 211: ...leads by touching leads together Meter should produce an audible alarm indicating continuity Current Measurement Set up the meter for the expected current range Be sure to connect the meter leads to...

Page 212: ...d Check connections and measurement setup Redo measurement If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure co...

Page 213: ...s or dust contamination The following connector systems are specifically addressed because of their widespread use at JLG However this guid ance may be applied to similar devices AMP Mate N Lok This c...

Page 214: ...used as an exception in other applications Enclosures Application of dielectric grease is not required in properly sealed enclosures To meet criteria the enclosure must be rated to at least IP56 dust...

Page 215: ...it straight into the appropri ate circuit cavity as far as it will go See Figure 7 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 lbs to be sure the retention fing...

Page 216: ...Release the locking latches by squeezing them inward See Figure 7 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 9 Connector Assem...

Page 217: ...each direction gently pull the wire until the contact is removed NOTE The wedge lock should never be removed from the housing for insertion or removal of the contacts Wedge Lock The wedge lock has sl...

Page 218: ...harp point This practice should be discouraged when dealing with the AMP SEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow moisture to invade...

Page 219: ...edgelock will snap into place Rectangular wedges are not oriented They may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly 1 Remove wedgelock us...

Page 220: ...l environmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 2 Slide tool along into the insert cavit...

Page 221: ...r indicate position Mechanical limit switches are just like manu ally operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch...

Page 222: ...d This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switc...

Page 223: ...ONAL LIFT CABLE ARM STACK HOLD VALVE CABLE ARM STACK PLATFORM CONTROL 430LRT HARNESS GROUND CONTROL BOX TILT SENSOR HARNESS CHASSIS HARNESS ENGINE DIESEL HARNESS ENGINE DUAL FUEL HARNESS LEVELING JACK...

Page 224: ...49 6 ANALYZER RX RED 2 7 2 ANALYZER PWR RED 2 7 2 ANALYZER PWR BLK 49 2 ALARM GND BLK 49 2 ALARM GND YEL 49 1 ALARM YEL 49 1 ALARM BLU 49 3 LEVEL JACK UP BLU 49 3 LEVEL JACK UP BLK 00 1 LAMP RETURN BL...

Page 225: ...TAN 23 TAN 23 PNK 29 PNK 29 PNK 30 PNK 30 PNK 31 PNK 31 PNK 28 PNK 28 PNK 27 PNK 27 YEL 16 YEL 16 To work ood light option Platform Control Module To platform control box Platform I O Harness To Arm S...

Page 226: ...M N P R S T U V W X RED BLK CABLE RED CABLE ORG CABLE BLK CABLE ORG CABLE BLU CABLE BLK WHT CABLE YEL SAE1939 GRN SAE1939 YEL BLK CABLE YEL CABLE ORG BLK CABLE BLU BLK CABLE BRN CABLE Cable Cable Cabl...

Page 227: ...und Control Box SW13 3 1 YEL RED 124 NOT USED YEL RED 124 NOT USED XB11 1 2 3 4 5 6 7 8 XB11B 1 2 3 4 5 6 7 8 SW14 1 1 SW14 2 2 SW14 3 3 RELAY 1 2 3 4 5 HORN AH3 1 1 AH3 2 1 D1 WHT 71 3 HORN 16 AWG WH...

Page 228: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 X13B To connector X13A on sheet 4 D7 or 4 B7 2 T2 1 ROTARY SENSOR SN1 A B C PLAT OPT POWER 10A 1 2 BLK 00 24 ANLG GND WHT 76 1 ROT ANG WHT...

Page 229: ...26 3 LP VAL WHT 26 3 LP VAL S46 WHT 25 2 ENG STRT WHT 25 2 ENG STRT S42 YEL 44 2 IGN PWR YEL 44 2 IGN PWR BLK 54 2 SN GND WHT 30 PRE O2 SN BLK 2 PRE O2 HTR BLK 2 PRE O2 HTR BLK 54 1 SN GND BLK 54 1 SN...

Page 230: ...8 1 2 3 4 5 6 RED RED BLK BLK WHT WHT RED RED BLK BLK WHT WHT RED RED BLK BLK WHT WHT RED RED WHT WHT BLK BLK WHT 55 25 WHT 55 24 WHT 55 23 WHT 55 22 S248 WHT 55 24 2 WHT 55 24 1 WHT 55 21 WHT 55 21 W...

Page 231: ...GHT SIG YEL ORG 122 1 LIGHT SIG BLK 00 113 1 LIGHT GND BLK 00 113 1 LIGHT GND RED 120 1 PWR RED 120 1 PWR RED 120 2 PWR RED 120 2 PWR WHT 121 1 LIGHT PWR WHT 121 1 LIGHT PWR WHT 121 2 LIGHT PWR WHT 12...

Page 232: ...HI GRN CAN LO GRN CAN LO Load Sense Harness Oil Hyd Cooler Harness HYD OIL RLY 30 85 87A 87 86 T55 To Aux Power Block 1 T55 To Aux Ground Block 1 X555 1 X556 To Fan 1 2 HYD OIL FUSE 25A 1 2 RED 55 1 H...

Page 233: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 234: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

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