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SECTION 5 - HYDRAULICS

5-40

– JLG Lift –

3121259

EDC CONTROL DISASSEMBLY

IT IS NOT NECESSARY TO REMOVE SOLENOIDS (D025) UNLESS YOU ARE
REPLACING THEM.

1.

Use a 4 mm internal hex wrench to remove cap screws
(D050).

IF YOU SUSPECT A COIL MALFUNCTION, REMOVE THE COIL. REMOVE THE
PLASTIC NUT WITH A 26 MM 12 POINT SOCKET. INSTALL A NEW COIL. TORQUE
NUT TO 5 NM [3.7 FT.LBS.].

2.

Remove solenoids (D025). Remove and discard O-rings
(D025A).

DO NOT DISASSEMBLE INTERNAL PARTS OF CONTROL. INTERNAL PARTS ARE
NOT AVAILABLE SEPARATELY. CONTROL IS SOLD AS A COMPLETE UNIT ONLY.

AUXILIARY PAD OR END COVER REMOVAL

REMOVE AUXILIARY PUMP, IF PRESENT.

1.

Position pump so end cover (K100) or auxiliary pad is on
top.

2.

Remove end cover/auxiliary pad screws (K400) using an
8 mm internal hex wrench.

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Summary of Contents for 340AJ

Page 1: ...Service and Maintenance Manual Model 340AJ P N 3121259 June 27 2017...

Page 2: ......

Page 3: ...raulic systems oper ate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Do not...

Page 4: ...INTRODUCTION A 2 JLG Lift 3121259 REVISON LOG Original Issue May 6 2011 Revised January 17 2012 Revised July 9 2013 Revised June 27 2017...

Page 5: ...Machine Inspection 2 1 Preventive Maintenance 2 1 2 2 Service and Guidelines 2 2 General 2 2 Safety and Workmanship 2 2 Cleanliness 2 2 Components Removal and Installation 2 2 Component Disassembly a...

Page 6: ...le Brake Subassembly Disassembly 3 15 Cover Disassembly 3 16 Planet Gear Subassembly 3 18 Spindle Brake Subassembly 3 19 Housing Spindle Subassembly 3 21 Housing Ring Gear Subassembly 3 22 Cover Subas...

Page 7: ...tdown 3 76 3 18 GM Dual Fuel Engine 3 81 Communications with the JLG Control System 3 81 Engine Start 3 81 Oil Pressure 3 81 Engine Speed 3 81 Coolant Temperature 3 81 Fuel Select 3 81 3 19 Fuel Reser...

Page 8: ...e 5 36 Electrical Displacement Control EDC 5 37 Disassembly 5 39 Inspection 5 44 Assembly 5 48 Port Locations and Gauge Installation 5 56 Fastener Size and Torque Chart 5 57 Plug Size and Torque Chart...

Page 9: ...ion Procedure 6 39 Testing Evaluation 6 44 Troubleshooting 6 45 6 7 Resetting The MSSO System 6 46 6 8 System Fault Messages 6 48 SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 1 General 7 1 7 2...

Page 10: ...vi JLG Lift 3121259 TABLE OF CONTENTS SECTION NO TITLE PAGE NO Thispageleftblankintentionally...

Page 11: ...3 13 3 10 Housing Spindle 3 14 3 11 Spindle Brake Subassembly Figure 1 3 15 3 12 Spindle Brake Subassembly Figure 2 3 15 3 13 Spindle Brake Subassembly Figure 3 3 16 3 14 Cover 3 17 3 15 Planet Gear 3...

Page 12: ...hematic 3 74 3 56 Engine Glow Plug Schematic 3 74 3 57 Glow Plug Relay 3 74 3 58 Engine Throttle Actuator Schematic 3 75 3 59 Proportional Fuel Rack Actuator Schematic 3 76 3 60 Engine Starter Schemat...

Page 13: ...Identification 5 33 5 24 Drive Pump Cross Sectional View 5 34 5 25 High Pressure Relief and Charge Check Valve with Bypass Valve in charging mode 5 35 5 26 High Pressure Relief and Charge Check Valve...

Page 14: ...n 7 10 7 14 DT DTP Contact Installation 7 11 7 15 DT DTP Contact Removal 7 11 7 16 HD HDP Contact Installation 7 12 7 17 HD HDP Locking Contacts Into Position 7 12 7 18 HD HDP Contact Removal 7 12 7 1...

Page 15: ...3121259 JLG Lift xi LIST OF FIGURES FIGURE NO TITLE PAGE NO Thispageleftblankintentionally...

Page 16: ...N FMI Cross Reference Chart 3 88 4 1 Troubleshooting 4 25 5 1 Inspection After Assembly 5 3 5 2 Required Tools 5 5 5 3 Special Tools 5 6 5 4 Piston Nut Torque 5 11 5 5 Gland Torque 5 11 5 6 Main Contr...

Page 17: ...8 Machine Configuration Programming Settings 6 36 6 9 Diagnostic Menu Descriptions 6 38 6 10 Accessory Weights 6 40 6 11 SkyGlazier Capacity Reductions 6 42 6 12 Pipe Rack Capacity Reductions 6 42 6...

Page 18: ...xiv JLG Lift 3121259 LIST OF TABLES TABLE NO TITLE PAGE NO Thispageleftblankintentionally...

Page 19: ...gRadius Inside 5 1 52m TurningRadius Outside 13 3 96m MachineHeight stowed 6 7 2m MachineHeight storage 7 1 2 17m MachineLength stowed 18 2 5 52m MachineLength storage 13 1 3 98m UpandOverPlatformHeig...

Page 20: ...obil 424 is desired contact JLG Industries for proper recommenda tions Major Component Weights DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BA...

Page 21: ...MainLift Boomretracted telescopein Mainliftup recordtime Main liftdown recordtime Swing Boomatfullelevation telescoperetracted Swingtheturnta bletotheendstop Swingtheoppositedirection recordtime Swin...

Page 22: ...SECTION 1 SPECIFICATIONS 1 4 JLG Lift 3121259 1 5 5 3 4 5 2 9 7 6 8 5 Figure 1 1 Operator Maintenance and Lubrication Diagram...

Page 23: ...Point s Grease Fitting Capacity A R Lube Lubriplate 930 AAA Interval A R Lube Point s Grease Fitting Capacity A R Lube Mobil SHC 460 Interval A R DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL...

Page 24: ...aulic Tank Return Filter and Breather Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments For breather element twist top to replace 5 Wheel Drive Hub Lube Point s Leve...

Page 25: ...M Lube Point s Fill Cap Spin on Element Capacity 3 1 Quarts 3 L w Filter Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on...

Page 26: ...SECTION 1 SPECIFICATIONS 1 8 JLG Lift 3121259 Figure 1 2 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Page 27: ...SECTION 1 SPECIFICATIONS 3121259 JLG Lift 1 9 Figure 1 3 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e...

Page 28: ...SECTION 1 SPECIFICATIONS 1 10 JLG Lift 3121259 Figure 1 4 Torque Chart Sheet 3 of 5 SAE Fasteners Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue...

Page 29: ...SECTION 1 SPECIFICATIONS 3121259 JLG Lift 1 11 Figure 1 5 Torque Chart Sheet 4 of 5 METRIC Fasteners To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Page 30: ...SECTION 1 SPECIFICATIONS 1 12 JLG Lift 3121259 Figure 1 6 Torque Chart Sheet 5 of 5 METRIC Fasteners Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Page 31: ...ch machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as env...

Page 32: ...in in their containers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cab...

Page 33: ...necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt...

Page 34: ...drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good gra...

Page 35: ...in temper ature Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test Measure drift at cylinder rod with a calibrated dial indicator In an area free...

Page 36: ...ment wound bearing are a dry joint and should not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam...

Page 37: ...1 2 1 2 Bearings 1 2 1 2 WearPads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 1 5 Floor 1 1 2 Rotator 9 5 15 Lanya...

Page 38: ...5 FuelReservoir Cap andBreather 1 5 1 5 Hydraulic ElectricSystem HydraulicPumps 1 2 9 HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 HydraulicHoses Lines andFittings...

Page 39: ...ofthepriorinspection PerformanceCodes 1 Checkforproperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 Ope...

Page 40: ...at 40 C cSt Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Mobilfluid424 55 145 X MobilDTE10Excel32 32...

Page 41: ...ION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE Figure 2 2 Engine Oil Operation Chart GM 1001120075 A NOTICE MACHINE OPERATION USING NON JLG APPROVED ENGINE OIL OR OPERATI...

Page 42: ...SECTION 2 GENERAL 2 12 JLG Lift 3121259 NOTES...

Page 43: ...anges such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extr...

Page 44: ...e drive pump is automatically restricted to approxi mately 0 75 mph 1 2 kph See Drive System in this section for more detail on the drive speeds and see Chassis Tilt Indicator System in this section f...

Page 45: ...20 16 Remove the o ring 19 17 Remove the cardan shaft 18 Assembly 1 Carefully lift from under the gear set to prevent parts from falling out Lay the gearwheel set so the o ring groove is upwards Mark...

Page 46: ...roleum jelly and install them in the balance plate grooves 9 Install the guide pin 27 in the end cover 32 10 Install the balance plate in the end cover 32 11 Grease the spacer 30 with petroleum jelly...

Page 47: ...1 33 34 13 DrainPlug 14 Washer 15 NotUsed 16 MountingFlange 17 O ring 18 CardanShaft 19 O ring 20 GearSet 21 NotUsed 22 ValveDrive 23 PressurePlate 24 GuidePin 25 ChannelPlate 26 StopRing 27 DiscValve...

Page 48: ...LG Lift 3121259 PORT 10 PORT 4 PORT A PORT B DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR PORT CASE PORT 16 PORT 6 PORT B PORT A PORT BRAKE TORQUE HUB TORQUE HUB Figure 3 3...

Page 49: ...E 3121259 JLG Lift 3 7 PORT B DRIVE MOTOR PORT B MOTOR DRIVE PORT A DRIVE MOTOR BRAKE PORT TORQUE HUB PORT CASE MOTOR DRIVE DRIVE MOTOR TORQUE HUB PORT 15 PORT 11 PORT A DRIVE MOTOR Figure 3 4 Left Fr...

Page 50: ...121259 PORT B MOTOR DRIVE TORQUE HUB DRIVE MOTOR PORT A MOTOR DRIVE PORT CASE MOTOR DRIVE PORT BRAKE TORQUE HUB FLOW DIVIDER VALVE PORT 5 PORT 7 PORT 17 PORT B DRIVE MOTOR DRIVE MOTOR PORT 12 PORT A F...

Page 51: ...ft 3 9 TORQUE HUB DRIVE MOTOR PORT BRAKE DRIVE MOTOR CASE PORT PORT A PORT B DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR PORT B DRIVE MOTOR DRIVE MOTOR FLOW DIVIDER VALVE PORT A PORT 7 PORT 5 PORT 18 PORT 13...

Page 52: ...gauge read ing on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o ring...

Page 53: ...the unit The unit can be carefully pressurized with air to pop the cover subassembly out of the unit 5 Remove O Ring 17 from groove in Cover Subassembly 6 6 Remove the Sun Gear 11 7 Loosen and remove...

Page 54: ...t 3121259 Figure 3 7 Main Disassembly Figure 1 6 Cover 6G RetainingRing 15 IDPlate 17 O ring Figure 3 8 Main Disassembly Figure 2 1E RingGear 4E PlanetShaft 4F PlanetGear 4G RollPin 4H ThrustWasher 9...

Page 55: ...he Loctite that was used to secure the bearing nut on to the Spindle 1 A NOTE The holes in the bearing nut for the set screws were staked for retention of the set screws The holes will need to be clea...

Page 56: ...SECTION 3 CHASSIS TURNTABLE 3 14 JLG Lift 3121259 Figure 3 10 Housing Spindle 1A Spindle 1B LipSeal 1C BallBearing 1D Housing 1F BearingNut 1G Setscrew 1H Stud...

Page 57: ...ach bolt half way out and then finish backing them out Remove Motor Adaptor 1N If necessary remove Retaining Ring 8C knock Ball Bearing 8B out of mounting adaptor coun terbore and check Quad Seal 1K a...

Page 58: ...ternal groove of Coupling 7 using Truarc 0100 or equivalent pliers 9 Remove the Thrust Washer 1M and Spring 1L out of the bore of Coupling 7 10 Knock Ball Bearing 8B out of Spindle 1A counterbore if n...

Page 59: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 17 Figure 3 14 Cover 2 ThrustSpacer 6A Cover 6B DisengageCap 6C Bolt 6D DowelPin 6E O ring 6F PipePlug 6K O ring...

Page 60: ...between the ends of the two rollers which form the space and then slid parallel to the other rollers into place 3 Place Spacer 4D into the bore of the Planet Gear 4F 4 Repeat Step 2 to put in second r...

Page 61: ...into the Spindle 1A aligning with the scallop cuts 3 Place Brake Rotor 8J on top of Brake Stator 8K 4 Repeat steps 2 and 3 until there are a total of nine Brake Stators 8K and eight Brake Rotors 8J i...

Page 62: ...les and then install the smaller twelve Springs 8M into the Springs 8L already installed into the brake piston 15 Press Ball Bearing 8B in the Mounting Adaptor 1N and then install Retaining Ring 8C in...

Page 63: ...to press in studs Don t use excessively high pressures to press in studs or the housing may crack 5 Secure Spindle Brake Subassembly with the flange down and then lower the Housing 1D onto Spindle 1A...

Page 64: ...hole described in Step 2 on Spindle 1A The end of the planet shaft that does NOT have the roll pin hole should be inserted into the spindle FIRST 4 Now insert Planet Shaft 4E through the first set of...

Page 65: ...onto Housing 1D Align the three shipping cap screw holes on Housing 1D and Ring Gear 1E 9 Install three Shipping Cap Screws 19 into Ring Gear 1E and Housing 1G Torque them to15 20 ft lbs 10 With the n...

Page 66: ...Washer 2 that mates with pocket side of the Cover 6A making sure that tangs on washer seats into pockets 5 Install O Ring Pipe Plugs 6F into Cover 6A The plugs should be hand tight The Cover Subassem...

Page 67: ...d shaft into Input Coupling 7 3 Bleed brake Increase hydraulic pressure gradually while trying to rotate the input until brake just starts to release Note this pressure Make sure the pressure falls in...

Page 68: ...OR 2 THRUSTSPACER 4B THRUSTWASHER 4C NEEDLEBEARING 4D THRUSTSPACER 4E PLANETSHAFT 4F PLANETGEAR 4G ROLLPIN 4H THRUSTWASHER 5 RETAININGRING INTERNAL 6A COVER 6B DISENGAGECAP 6C BOLT 6D DOWELPIN 6E O RI...

Page 69: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 27 Figure 3 24 Bearing Pressing Tool...

Page 70: ...SECTION 3 CHASSIS TURNTABLE 3 28 JLG Lift 3121259 Figure 3 25 Seal Pressing Tool Figure 3 26 Drift Pin for Lining Up Thrustwashers with Output Planet Gear...

Page 71: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 29 Figure 3 27 Bearing Nut Wrench...

Page 72: ...is supplied via Drive Pump charge pressure When the control system detects that the Main Boom is below horizontal and swung between the rear tires two control valves are actuated to supply charge pre...

Page 73: ...WEAR PAD DETAIL SECTION B B TORQUE 178 FT LB 241 NM TORQUE 35 FT LB 47 NM TORQUE 40 5 FT LB 55 NM WEAR PAD SHIMS KEEPER AXLE PIVOT PIN BEARING THRUST WASHER LOCKOUT CYLINDER B A A B NOTE MAKE SURE TH...

Page 74: ...e for preventing the machine from reaching an unstable position The 6 angle is used only for the purpose of automatically slowing drive speed when this angle is reached and the boom is in Transport po...

Page 75: ...it Significantlossofspeedunderload 1 Lackofsufficientoilsupply 2 Highinternalmotorleakage 3 Severelywornordamagedinternalsplines 4 Excessiveheat a Checkforfaultyreliefvalveandadjustorreplaceasrequired...

Page 76: ...will need to know to service the motor Thoroughly clean off all outside dirt especially from around fittings and hose connections before disconnect ing and removing the motor Remove rust or corrosion...

Page 77: ...spection 1 Place the motor in a soft jawed vice with coupling shaft 12 pointed down and the vise jaws clamping firmly on the sides of the housing 18 mounting flange or port bosses Remove manifold port...

Page 78: ...Commutator 6 CommutatorRing 7 Manifold 8 RotorSet 8A Rotor 8B StatorHalf 8C StatorVane 8D StatorHalf 9 WearPlate 10 DriveLink 11 ThrustBearing 12 CouplingShaft 13 InnerBushing 14 ThrustWasher 15 Thrus...

Page 79: ...f the commutator 5 is normal Discoloration would indicate excess fluid temperature thermal shock or excess speed and require system investigation for cause and close inspection of end cover commutator...

Page 80: ...12 with the rotor set and wearplate You may have to shift the rotor set on the wearplate to work the drive link out of the rotor and wearplate Inspect the rotor set in its assembled form for nicks sc...

Page 81: ...the rotor lobe to roller vane clear ance at both ends of rotor 11 Remove drive link 10 from coupling shaft 12 if it was not removed with rotor set and wear plate Inspect drive link for cracks and worn...

Page 82: ...is permissible If wear exceeds 0 020 inches 0 51 mm diametrically replace coupling shaft NOTE A slight polish is permissible in the shaft bearing areas Anything more would require coupling shaft repl...

Page 83: ...ring rollers must be firmly retained in the bearing cages but must rotate and orbit freely All rollers and thrust washers must be free of brinelling and corrosion The bushing 19 or 13 to coupling shaf...

Page 84: ...areas SINCE THEY ARE FLAMMABLE BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX I...

Page 85: ...w be pressed into its counter bore in housing 18 flush to 0 03 inch 0 76 mm below the housing wear plate con tact face Use the opposite end of the bearing mandrel that was used to press in the outer b...

Page 86: ...l 8 Be sure that a generous amount of clean corrosion resis tant grease has been applied to the lower outer hous ing bearing bushing 19 Install the coupling shaft 12 into housing 18 seating it against...

Page 87: ...e motor 10 Install drive link 10 the long splined end down into the coupling shaft 12 and engage the drive link splines into mesh with the coupling shaft splines NOTE Use any alignment marks put on th...

Page 88: ...rd the wear plate 9 14 Apply clean grease to a new seal ring 4 and assemble it in the seal ring groove in the rotor set contact side of manifold 7 NOTE The manifold 7 is made up of several plates bond...

Page 89: ...2 and assemble end cover over the alignment studs and onto the commutator set If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing 18 The cor...

Page 90: ...t cannot be readily assembled by hand can be assembled by the following proce dures 1 Place stator onto wear plate 9 with seal ring 4 side down after following assembly procedures 1 through 13 Be sure...

Page 91: ...ry 3 Assemble rotor counterbore down if applicable into stator half and onto wear plate 9 with rotor splines into mesh with drive link 10 splines NOTE Use any marking you applied to rotor set componen...

Page 92: ...upling shaft rotation 4 Use test stand if available to check operation of the motor Installation Refer to Figure 3 31 Swing Motor Removal and Installation 1 Carefully insert the swing motor into the s...

Page 93: ...IS TURNTABLE 3121259 JLG Lift 3 51 3 Install eyebolts as specified in Figure 3 33 Eyebolt for Counterweight in the counterweight 4 Securely strap the booms together to prevent any movement during the...

Page 94: ...equipped remove the LP fuel tank on the side of the frame It may also be desirable to remove the tank retaining brackets to gain additional clearance to work 6 Remove the access covers on either side...

Page 95: ...t 3 53 7 Pull out the engine tray as far as it will go Unbolt the charge filter bracket so it can be moved aside for more working area 41 81 40 135 20 35 M20x2 5Thread Figure 3 33 Eyebolt for Counterw...

Page 96: ...ove the drive orientation and lockout switches so they don t get broken during the removal procedure 11 Swing the engine tray back into position and secure it in place with the retaining bolt 12 Attac...

Page 97: ...nuggly to secure the turn table s position on the swing bearing assembly but do not torque them at this time and keep the lifting device in place to support the weight of the turntable 6 Coat the bear...

Page 98: ...ation 2 At the positions indicated in the figure below try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position 3 Lower the boom to horizontal a...

Page 99: ...S TURNTABLE 3121259 JLG Lift 3 57 90 POSITION POINT OF MINIMAL BACKLASH MARKED WITH AN X AND ALSO BLUE PAINT TO THE FRAME IN THIS POSITION 90 POSITION BEARING BODY TO TURNTABLE AS SHOWN Figure 3 36 Be...

Page 100: ...front of the Pinion 21 4 Remove eight 5 16 12 point cap screws 4 from gear pinion cap 18 Pry cap from housing Cover plate 19 will come off with cap Note where sealant is on Cover and plate so when as...

Page 101: ...ilSeal 10 PipePlug 11 GreaseFitting 12 GreaseFitting 13 GreaseFitting 14 SlewRing 15 Bearing 16 GreaseRing 17 Bearing 18 GearCap 19 CoverPlate 20 WormCap 21 OutputPinion 22 MotorAdapter 23 FaceSeal 24...

Page 102: ...ual to total thickness of shims just set aside Apply sealant LocTite 515 to both sides of each of these shims and tighten screws take care not to twist these screws off Clean extra sealant from surfac...

Page 103: ...RANSPARENT FOR ROUTING CLARITY ROUTE HOSES CABLES THROUGH GUIDE ROD ON BASE BOOM ROUTE HOSES CABLES THROUGH GUIDE ROD ON FLY BOOM LOWER UPRIGHT UPPER UPRIGHT HOSE CABLE PULL LENGTHS UPPER DESCRIPTION...

Page 104: ...LOOKING TOWARDS UPPER UPRIGHT AC CABLE WIRE BUNDLE TO UPRIGHT HYDRAULIC MANIFOLD 18 6 CABLE TO MAIN BOOM LIMIT SWITCHES ORIENTATION LOOKING TOWARDS LOWER UPRIGHT SYSTEM TANK TOWER LIFT CYLINDER TANK T...

Page 105: ...USE CABLE TIE IN TURNTABLE AREA EVERY 200 250mm USE CABLE TIES AS REQUIRED DETAILE 50 12 MAINTAIN HOSE CABLE LOOP AT THIS DIMENSION FROM CYLINDER ENDCAP 110 10 DETAIL D JIB LINK CUT AWAY DETAIL F TOW...

Page 106: ...18 GA 5 BLUE 18 GA 6 YELLOW 18 GA 7 BROWN 18 GA 8 PLUG N A 9 RED BLACK 18 GA 10 ORANGE 12 GA 11 BLUE BLACK 18 GA 12 RED 12 GA 13 ORANGE BLACK 18 GA 14 PLUG N A 15 YELLOW BLACK 18 GA 16 BLACK 12 GA 17...

Page 107: ...E HORIZONTAL TO RESET SWITCH SWITCH SW242 OF LOWER BOOM HARNESS DETAIL Q MAIN BOOM LIMIT SWITCHES MAIN BOOM TO BE 1 BELOW HORIZONTAL TO 3 ABOVE HORIZONTAL TO TRIP SWITCH 1 TO 4 BELOW HORIZONTAL TO RES...

Page 108: ...3121259 SEE DETAIL S DETAILS SYSTEM TANK TOWER LIFT CYLINDER TANK TOWER LIFT CYLINDER PRESSURE AC CABLE MAIN LIFT CYLINDER PRESSURE SYSTEM PRESSURE BOOM CABLE LOWER BOOM HARNESS Figure 3 44 Cable Ins...

Page 109: ...IL T DETAIL T UPRIGHT BACK PLATE SHOWN TRANSPARENT CONNECTOR V61 OF UPPER BOOM HARNESS CONNECTOR V59 OF UPPER BOOM HARNESS CONNECTOR V62 OF UPPER BOOM HARNESS CONNECTOR V60 OF UPPER BOOM HARNESS Figur...

Page 110: ...ift 3121259 SEE DETAIL U DETAIL U FLY VALVE COVER SHOWN TRANSPARENT CONNECTOR V57 OF UPPER BOOM HARNESS CONNECTOR V56 OF UPPER BOOM HARNESS CONNECTOR V55 OF UPPER BOOM HARNESS Figure 3 46 Cable Instal...

Page 111: ...Engine Cranking Engine Starting Engine Running ENGINE STOPPED ENGINE RUNNING ENGINE CRANKING ENGINE STARTING RPM greater than 800 for 1 4 second RPM greater than 800 for 1 4 second RPM 0 for 1 2 seco...

Page 112: ...he Engine Shutdown switch must not be activated 10 The Start Switch has been in the deselected position after the Engine State changes to Engine Stopped from Engine Running or Engine Starting 3 14 ENG...

Page 113: ...e Engine State is Engine Running 2 The operator is not shutting down the engine 3 The Control System is configured for a generator 4 The Platform Generator Switch is Enabled and Selected 3 15 ENGINE C...

Page 114: ...is a short hose between the mechanical lift pump and the injection pump 2 Actuate the priming lever on the mechanical lift pump until fuel comes out of the fuel hose 3 Attach the fuel hose and secure...

Page 115: ...e Engine Speed Sensor The engine speed sensor is a variable reluctance sensor used to measure engine speed by monitoring the flywheel teeth while the engine is running Figure 3 51 Engine Oil Pressure...

Page 116: ...cold starting The ground module controls the glow plugs and uses a relay to switch battery current Figure 3 54 Engine Coolant Sensor 5V 270 Ohm J1 15 Input Engine Block Ground Ground Module Engine Oi...

Page 117: ...that limits the opening of the fuel rack to control speeds between the Idle and High Engine positions The two actuators function together to achieve smooth engine speed transitions Refer to Table 3 7...

Page 118: ...includes a one way blocking diode that prevents reverse energy flow into the Ground Module during engine power down This terminal is continuously energized after startup Fuel Pump The Kubota fuel pum...

Page 119: ...77 1 2 3 4 5 6 7 8 9 10 11 12 13 1 FuelTank 2 CoolantRecoveryTank 3 Alternator 4 OilFilter 5 Starter 6 MainPump 7 GearPump 8 Battery 9 AirFilter 10 Muffler 11 StarterRelay 12 FullSpeedRelay 13 GlowPl...

Page 120: ...t 3121259 1 2 3 4 5 6 7 8 9 10 11 1 CoolantRecoveryTank 2 Muffler 3 MainPump 4 GearPump 5 AirFilter 6 FuelFilter WaterSeparator 7 FuelPump 8 FuelLevel SendingUnit 9 FuelTank 10 Radiator 11 PressureCap...

Page 121: ...NNECTION ON MAIN PUMP V83 TO C1 COIL CONNECTION ON MAIN PUMP NEGATIVE GROUND TERMINAL 1 Radiator 2 RadiatorMount 3 EngineOilFilter 4 MidEngineHarness 5 EngineHarness 6 StarterRelay 7 FullSpeedRelay 8...

Page 122: ...10 11 12 13 1 Muffler 2 MainPump 3 GearPump 4 NegativeBatteryTerminal 5 NegativeBatteryPost 6 Battery 7 PositiveBatteryTerminal 8 PositiveBatteryPost 9 FuelSupplyLine 10 FuelReturnLine 11 Radiator 12...

Page 123: ...Engine Start The Ground Module energizes terminal J1 11 to engage the starter The engine ECU considers the engine started when RPMs are greater than 800 and continues in the Run mode unless engine RPM...

Page 124: ...CHASSIS TURNTABLE 3 82 JLG Lift 3121259 1 2 3 4 5 6 7 8 9 10 1 FuelTank 2 CoolantRecoveryTank 3 Radiator 4 OilFilter 5 Starter 6 MainPump 7 GearPump 8 Battery 9 Muffler 10 FuelMixer Figure 3 66 GM Eng...

Page 125: ...TABLE 3121259 JLG Lift 3 83 2 1 3 4 5 6 7 8 9 10 1 CoolantRecoveryTank 2 FuelTank 3 Radiator 4 OilFilter 5 Negative GroundTerminal 6 PositiveTerminal 7 MainPump 8 GearPump 9 Battery 10 Muffler Figure...

Page 126: ...COIL CONNECTION ON MAIN PUMP VENT HOSE FROM CARBON CANISTER TO LP MIXER PURGE POINT 1 2 3 4 5 6 7 8 9 10 11 1 Alternator 2 SupplyFuelHose 3 ReturnFuelHose 4 MainPump 5 FuelPumpHarness 6 Air FuelMixer...

Page 127: ...ick 2 Relays 3 Muffler 4 MainPump 5 GearPump 6 NegativeBatteryCable 7 NegativeBatteryPost 8 Battery 9 PositiveBatteryCable 10 PositiveBatteryPost 11 Air FuelMixer 12 AirFilter 13 FuelPump 14 FuelMixer...

Page 128: ...TO ENGINE EC210 NEGATIVE TERMINAL ON FUEL PUMP EC210 POSITIVE TERMINAL ON FUEL PUMP 1 2 3 4 5 6 7 8 9 10 1 FuelLevelSensor 2 FuelLock offValve 3 Muffler 4 AirMixerValve 5 GearPump 6 FuelPumpHarness 7...

Page 129: ...M CARBON CANISTER 1 1 2 3 4 5 6 7 8 9 10 11 12 11 12 13 1 AirMixerValve 2 Muffler 3 GearPump 4 Battery 5 Alternator 6 FuelLevelSensor 7 FuelTank 8 CarbonCannister 9 CoolantRecoveryTank 10 EngineOilFil...

Page 130: ...O2Open Inactive 520208 10 171 AdaptiveLearnHighGasoline 520200 0 172 AdaptiveLearnLowGasoline 520200 1 182 FuelTempGasolineLowVoltage 174 4 183 FuelTempGasolineHighVoltage 174 3 187 FuelTempLPGLowVolt...

Page 131: ...iveLearnLowLPG 520202 1 1165 LPGCatMonitor 520213 10 1171 LPGPressureHigherThanExpected 520260 0 1172 LPGPressureLowerThanExpected 520260 1 1173 EPRCommLost 520260 31 1174 EPRVoltageSupplyHigh 520260...

Page 132: ...minute After 1 minute the engine will shut off for a sec ond time and the machine will return to the Engine Shut down fault mode The machine will then stay in this mode until the fuel level is returne...

Page 133: ...ft 3 91 3 22 COUNTERWEIGHT If the counterweight has been removed ensure the retaining bolts are torqued to the proper value as shown in Figure 3 73 Counterweight Bolt Torque Torque to 150 ft lbs 204 N...

Page 134: ...SECTION 3 CHASSIS TURNTABLE 3 92 JLG Lift 3121259 NOTES...

Page 135: ...e switches are normally closed and unactuated when in the transport position Above transport angle is recognized when the main boom travels from the stowed position to 2 above horizontal it resets at...

Page 136: ...NOTE The telescope cylinder weighs approximately 53 lbs 24 kg 6 Using a suitable lifting device remove telescope cylin der from the rear of the boom sections 7 Remove hardware securing the front wear...

Page 137: ...oom 1 Using JLG P N 0100011 thread locking compound or equivalent install the bottom wear pads and shims as noted during disassembly on the rear of the fly section Torque the retaining bolts to 40 ft...

Page 138: ...portable power supply to the cylinder to extend or retract the cylinder for alignment Install the retaining pin and secure it in place with the retaining ring 6 Using JLG P N 0100011 thread locking co...

Page 139: ...4 BOOM PLATFORM 3121259 JLG Lift 4 5 1 4 6 8 7 3 9 5 2 1 MasterCylinder 2 UpperLiftCylinder 3 Jib 4 MainBoom 5 LevelCylinder 6 UpperUpright 7 MidBoomLink 8 MidBoom 9 JibCylinder Figure 4 1 Main Boom A...

Page 140: ...SECTION 4 BOOM PLATFORM 4 6 JLG Lift 3121259 3 7 5 2 6 1 4 1 Rotator 2 JibCylinder 3 JibPivot 4 PlatformSupport 5 HoseCarrier 6 LowerJibLink 7 UpperJibLink Figure 4 2 Jib Platform Support...

Page 141: ...uires 3 Debris and foreign matter inside of the boom can cause premature failure of components and should be removed Methods to remove debris should always be done using all applicable safety precauti...

Page 142: ...FILTER PORT HYD TANK HYD TANK HYD TANK RETURN FILTER PORT PORT P1 UPRIGHT VALVE PORT V2 TELE CYL PORT V1 TELE CYL PORT T1 UPRIGHT UPRIGHT VALVE VALVE UPRIGHT VALVE TO TELE LIFT CYL LIFT CYL PORT T2 P...

Page 143: ...RT BARREL END MASTER CYL PORT ROD END MASTER CYL FLY BOOM LEVEL CYL FLY BOOM VALVE JIB LIFT CYL LEVEL CYL PORT P1 HELAC PORT P2 HELAC PORT R1 FLY BOOM VALVE PORT R2 FLY BOOM VALVE PORT P PORT P2 UPRIG...

Page 144: ...lines cause the shaft to rotate When the control valve is closed oil is trapped inside the housing preventing piston movement and locking the shaft firmly in position The shaft is supported radially b...

Page 145: ...t 11 FELT MARKER Highlights timing marks and outlines troubled areas Permanent ink is recommended 12 T HANDLE SCREW EXTRACTOR 13 HEX WRENCH SET Removal and replacement of port plugs and set screws 106...

Page 146: ...e port plugs 106 1 106 2 and drain oil Inspect oil for signs of contamination i e water metal shavings 2 Remove the cap screws 113 that cover the end cap lock pins 109 3 Using a 1 8 3 mm drill bit dri...

Page 147: ...aft 3 PistonSleeve 4 EndCap HARDWARE 103 1 Screw 103 2 Washer 106 1 PortPlug SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 304 1 WiperSeal BEARINGS 302 WearGuide 304 ThrustWasher A...

Page 148: ...ARE 103 1 Screw 103 2 Washer 106 1 PortPlug 106 2 PortPlug 109 LockPin 113 Capscrew SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 304 1 ExclusionSeal BEARINGS 302 WearGuide 304 Thr...

Page 149: ...etween models One set indicates the timing between the piston sleeve 3 and the housing 1 upper photo the second set between the piston and the shaft lower photo To ensure correct rotation and accurate...

Page 150: ...ter gear There should now be timing marks on the housing 1 ring gear the piston 3 and the shaft 2 13 To remove the piston 3 use a rubber mallet and a plas tic mandrel so the piston and housing bore ar...

Page 151: ...on 21 Remove the inside diameter piston seal 200 Inspection PRIOR TO ASSEMBLY OF ACTUATOR THESE STEPS MUST BE CLOSELY FOL LOWED TO ENSURE PROPER OPERATION OF THE ACTUATOR 1 Clean all parts in a solven...

Page 152: ...stall the thrust washer 304 onto shaft 2 and end cap 4 3 Install the exclusion seal 304 1 into the appropriate grooves on the shaft 2 and end cap 4 around the out side edge of the thrust washer 304 4...

Page 153: ...ne end of backup ring in the lower groove and feed the rest in using a circular motion Make sure the wedged ends overlap correctly Insert the other back up ring in upper groove Repeat both of these st...

Page 154: ...to damage the piston seals Do not engage the piston gear teeth yet 12 Looking at the actuator from the end opposite the shaft flange use the existing timing marks to align the gear teeth on the shaft...

Page 155: ...ead the end cap 4 onto the shaft 2 Make sure the wear guide remains in place on the end cap as it is threaded into the housing 1 17 Tighten the end cap 4 using a metal bar In most cases the original h...

Page 156: ...e 8 bolts New bolts should be installed with a new valve Loctite 242 should be applied to the shank of the three bolts at the time of installation 4 Torque the 1 4 inch bolts 110 to 120 inch pounds 12...

Page 157: ...SECTION 4 BOOM PLATFORM 3121259 JLG Lift 4 23 Figure 4 8 Rotator Counterbalance Valve...

Page 158: ...iters is purged 1 Connect a 3 16 inside diameter x 5 16 outside diame ter x 5 foot clear vinyl drain tube to each of the two bleed nipples Secure them with hose clamps Place the vinyl tubes in a clean...

Page 159: ...tiononpage 24ofthismanual e Re buildtheactuator Removeallrustthenpolish Replacementpartsmaybeneeded f Re buildtheactuator Usefluidthatiscompatiblewith sealsandbearings 2 Operationiserraticornotrespons...

Page 160: ...A B D C D A B C D Torqueto35ft lbs 48Nm Loctite 242 Torque250 270ft lbs 340 365Nm Checktorqueevery150hoursofoperation Figure 4 9 Platform Support Torque Values NOTE If any rotator bolts are replaced...

Page 161: ...he following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush with the other hand to dip...

Page 162: ...e bottom of the fitting This should signify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated spong...

Page 163: ...he surface of the cylinder before disassembly 2 Handle every part with care Each part is precision made and hitting parts together or letting them fall could damage the machined surfaces 3 Do not twis...

Page 164: ...ift 3121259 A B C D E 2mm 1mm F G Checktheoilleakagestatusontherodsurfacewithaflowof20cc 40cc OilleakageinanamountasshowninexampleAisunac ceptable ExamplesB Gareacceptable OILRING Figure 5 1 Acceptabl...

Page 165: ...G Lift 5 5 Table 5 2 Required Tools Item No Description Quantity 1 Flat headScrewdriver 1 2 AllenWrenchSet 1Set 3 Vise 1 4 SpannerWrench 1Set 5 Punch 1 6 TorqueWrench 1Set 7 PlasticHammer 1 8 Crescent...

Page 166: ...lace with caulking Using a spanner wrench unscrew the gland from the barrel It is easier to do this with rod pulled out 5cm from the gland If there is no caulking continue with the disassembly process...

Page 167: ...GIVE ATTENTION TO THE FOLLOWING IT IS POSSIBLE FOR THE ROD TO FALL AND BE DAMAGED WHEN REMOVED FROM THE BARREL IF NOT PROPERLY SUP PORTED PLACE SUPPORT UNDER THE BARREL AS SHOWN BELOW 5 Place the Rod...

Page 168: ...rded after removal They can not be reused 10 Remove the gland seal a Remove the rod seal and backup ring b Remove the retaining ring with a flat head screw driver prior to removing the dust wiper and...

Page 169: ...KAGE 1 Pin bushing assembly Coat the opening with oil to aid in assembly and press the bushing into the rod as shown below 2 Gland seal assemblies a Coat the opening with oil to aid in assembly and pr...

Page 170: ...the groove c Using a proper tool press the piston seal onto the piston When installing the piston seal it is stretched while passing over the head d Install the wear ring assembly by spreading it apar...

Page 171: ...er barrel end so that it locks the cylinder head in place and it does not unscrew from the barrel If there is no caulking hole caulking is not necessary 8 Test operation a Install the cylinder on a ma...

Page 172: ...10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 PoppetValve 18 CheckValve 19 Plug 20 O ring 21 Orifice 22 MPRBearing 23 Plug 24 O ring Figure 5 2 Tower Lift Cylinder 1...

Page 173: ...Ring 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 Spacer 18 O ring 19 PoppetValve 20 CheckValve 21 Plug 22 O ring 23 Orifice 24 MPRBearing 25 Plug 26 O ring Figure 5 3 Upper Lift...

Page 174: ...1259 1 Tube 2 Rod 3 Gland 4 DustWiper 5 RetainingRing 6 RodSeal 7 BackupRing 8 DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 MRPBearing 18 Plug Fi...

Page 175: ...g 8 DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 MRPBearing 18 CounterbalanceValve 19 CounterbalanceValve 20 Plug 21 O ring 22 Plug 23 O ring 24...

Page 176: ...istonSeal 14 WearRing 15 O ring 16 PistonRing 17 HexNut 18 MRPBearing 19 MRPBearing 20 PoppetValve 21 CheckValve 22 CounterbalanceValve 23 Plug 24 O ring 25 Orifice 26 Plug 27 O ring Figure 5 6 Jib Cy...

Page 177: ...HYDRAULICS 3121259 JLG Lift 5 17 1 Tube 2 Rod 3 Piston 4 Gland 5 DustWiper 6 RodSeal 7 DryBearing 8 O ring 9 BackupRing 10 O ring 11 WearRing 12 PistonSeal 13 MRPBearing Figure 5 7 Steer Cylinder 100...

Page 178: ...DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 HexNut 17 Spacer 18 O ring 19 CounterbalanceValve 20 CounterbalanceValve 21 LoadShuttleValve 22 Plug 23 Pl...

Page 179: ...g 6 WearRing 7 CounterbalanceValve 8 Bleeder 9 Plug 10 O ring 11 Plug 12 O ring 13 NotUsed 14 NotUsed 15 Plug 16 O ring 17 Plug 18 O ring Figure 5 9 Axle Lockout Cylinder Torque22ft lbs 30Nm Max 10011...

Page 180: ...SECTION 5 HYDRAULICS 5 20 JLG Lift 3121259 1 6 2 4 5 3 1 ReturnFilter 2 Breather 3 FillCap 4 InternalBaffle 5 DrainPlug 6 OilLevelGauge Figure 5 10 Hydraulic Tank...

Page 181: ...BS 24 32 Nm THREADLOCKER P N 0100011 UPRIGHT CONTROL VALVE TORQUE 10 14 FT LBS 14 19 Nm FLY BOOM CONTROL VALVE TORQUE 10 14 FT LBS 14 19 Nm THREADLOCKER P N 0100011 TORQUE 10 14 FT LBS 14 19 Nm THREAD...

Page 182: ...0 14 FT LBS 14 19 Nm THREADLOCKER P N 0100011 MAIN CONTROL VALVE THREADLOCKER P N 0100011 MANUAL PUMP PUMP HANDLE HYDRAULIC TANK VALVE MOUNT PLATE FLOW DIVIDER VALVE TORQUE 18 24 FT LBS 24 32 Nm THREA...

Page 183: ...IN CHARGE PUMP FILTER CHARGE PUMP FILTER OUTLET SIDE PORT A PORT B MAIN PUMP MAIN PUMP GAUGE PORT MA MAIN PUMP MAIN PUMP GAUGE PORT MB PORT X3 MAIN PUMP MAIN PUMP FLOW DIVIDER VALVE PORT 3 PORT 1 PORT...

Page 184: ...MAIN VALVE PORT 20 PORT M4 MAIN VALVE MAIN VALVE MAIN VALVE PORT 1 MAIN VALVE HYDRAULIC TANK RETURN PORT HYD TANK VALVE BOTTOM PORT M4 PORT 1 PORT 2 RETURN PORT HYDRAULIC TANK FLOW DIVIDER VALVE PORT...

Page 185: ...2 PORT M1 OUTLET SIDE PUMP FUNCTION PUMP FUNCTION OUTLET SIDE PORT P1 PORT P2 VALVE MAIN VALVE MAIN VALVE MAIN VALVE MAIN SWING MOTOR PORT B MOTOR SWING PORT A MOTOR SWING OUTLET CHARGE PUMP PORT FILT...

Page 186: ...35 4 2 Solenoid wIntegralRelief Valve 24 26 32 7 35 4 3 SolenoidValve 16 20 24 4 27 1 4 SolenoidValve 16 20 24 4 27 1 5 ReliefValve 19 21 25 8 28 6 6 FlowControlValve 19 21 25 8 28 6 7 FlowControlValv...

Page 187: ...CS 3121259 JLG Lift 5 27 V75 LIFT UP V79 TOWER LIFT UP V72 FLOW CONTROL V73 SWING RIGHT V74 SWING LEFT V80 STEER LEFT V81 STEER RIGHT V70 HIGH FLOW DUMP V240 LOW FLOW DUMP Figure 5 17 Main Control Val...

Page 188: ...Flow Divider Specifications Item Torque Ohms ft lbs Nm 1 SolenoidValve 4 5 5 4 6 8 2 SolenoidValve 4 5 5 4 6 8 3 SolenoidValve 4 5 5 4 6 8 4 Pilot DirectionalValve 46 54 62 6 73 4 5 FlowDividerValve 7...

Page 189: ...7 PORT B MOTOR DRIVE PORT 12 PORT A MOTOR DRIVE PORT B MOTOR DRIVE PORT A MOTOR DRIVE PORT 7 PORT 5 PORT 18 PORT 13 PORT 3 PORT 1 PORT 23 PORT 14 PORT 2 VALVE MAIN PORT 20 PORT 2 PORT 1 VALVE MAIN POR...

Page 190: ...5 PORT 11 PORT 9 PORT 8 PORT 21 PORT 22 PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE SECONDARY OSCILLATING AXLE VALVE SEC...

Page 191: ...SECTION 5 HYDRAULICS 3121259 JLG Lift 5 31 V213 BYPASS V212 BRAKE V97 OSC AXLE 2 SECONDARY V96 OSC AXLE 1 PRIMARY V213 BYPASS V212 BRAKE Figure 5 21 Flow Divider Valve Identification Sheet 3 of 3...

Page 192: ...ELAC PORT R2 PORT R1 To PORT P1 HELAC PORT J1 PORT J2 To PORT V1 JIB LIFT CYL To PORT V2 JIB LIFT CYL Figure 5 22 Fly Boom Control Valve Identification NOTE Solenoid Valves are torqued 19 21 ft lbs 25...

Page 193: ...V2 LIFT CYL PORT P1 VALVE UPRIGHT PORT V2 TELE CYL PORT V1 TELE CYL PORT T1 VALVE UPRIGHT PORT V2 VALVE UPRIGHT PORT V2 TELE CYL PORT V1 VALVE UPRIGHT PORT V1 TELE CYL Figure 5 23 Upright Control Valv...

Page 194: ...C and the other half to port B or D Front and rear sections have independent porting in the center section As each piston cycles in and out of its bore fluid is drawn from one port and displaced to th...

Page 195: ...ive heat generating pressure control valve for the pur pose of limiting excessive system pressures The charge check function replenishes the low pressure side of the working loop with charge oil Each...

Page 196: ...s level is nominally set with the pump running at 1800 min 1 rpm For external charge flow the CPRV is set with a flow of 30 l min 8 US gal min In forward or reverse charge pressure will be slightly lo...

Page 197: ...e servo piston moves the swashplate A swashplate feedback link opposing control links and a linear spring provide swashplate position force feedback to the solenoid The control system reaches equilib...

Page 198: ...the pump to neutral position The EDC is a displacement flow control Pump swashplate position is proportional to the input command and therefore vehicle or load speed excluding influence of efficiency...

Page 199: ...s DO NOT DAMAGE THE HOUSING BORE SHAFT OR BEARING WHEN REMOVING THE SHAFT AND SHAFT SEAL 2 Remove the snap ring J200 using snap ring pliers 3 Use an adequate press to remove the bearing from the shaft...

Page 200: ...WITH A 26 MM 12 POINT SOCKET INSTALL A NEW COIL TORQUE NUT TO 5 NM 3 7 FT LBS 2 Remove solenoids D025 Remove and discard O rings D025A DO NOT DISASSEMBLE INTERNAL PARTS OF CONTROL INTERNAL PARTS ARE...

Page 201: ...SSURE LIMITER REMOVAL 1 Using a 14 mm wrench remove pressure limiter car tridges L300 and L400 NOTE Pressure limiter L300 L400 is available as complete unit only Seal L022 is available separately 2 Re...

Page 202: ...lean area pro tecting them from contamination 5 Remove and discard gasket G150 6 If necessary remove bushing G550 using a suitable puller 7 Remove locating pins B010 NOTE If necessary use a hook to re...

Page 203: ...VO PISTON TO DAMAGE INTERNAL MACHINED SUR FACES OF PUMP SERVO PISTON REMOVAL Tilt swashplate up to disengage servo arm from piston Remove the servo piston assembly E100 SWASHPLATE AND SWASHPLATE BEARI...

Page 204: ...spring washer block spring and inner block spring washer C40 from the cylinder block RISK OF PERSONAL INJURY COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 350 TO 400 N 80 TO 90 LBF USE A PRESS SUFFICIE...

Page 205: ...of damage or heavy wear Inspect the shaft surface where it meets the shaft seal Replace the shaft if a groove exists at the sealing land surface where it meets the shaft seal Clean the sealing area w...

Page 206: ...unning face and the bottom surface Perform a magnetic particle inspection to detect cracks Replace if any cracks exist ENDCAP Inspect the endcap Inspect all machined surfaces for scratches or pits Car...

Page 207: ...Inspect slider block for wear or damage Replace if necessary Inspect springs for warping or cracking Replace entire assem bly if springs are damaged Inspect servo piston for wear cracks or damage Rep...

Page 208: ...above surface or 0 72 mm 0 028 in below surface of seal carrier 4 Install the shaft assembly into the front housing Cover the shaft with an installation sleeve to protect it during installation of th...

Page 209: ...icate and install slider block EOT 5 SERVO PISTON INSTALLATION Install servo piston assembly E100 Ensure swashplate pin fits properly in servo slider block EOT5 SERVO CYLINDER INSTALLATION 1 Lubricate...

Page 210: ...TING TO INSTALL THE SPIRAL RETAINING RING RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED 3 Turn the block over and install the hold down pins C25 and ball guide C15 into the cylinde...

Page 211: ...p Lubricate and press the bushings G550 into the end cap to depth shown below NOTE Ensure that bushing is properly installed Improper installa tion resulting in improper depth or misalignment will res...

Page 212: ...81 Ib ft 7 Use torque sequence shown below CHARGE PUMP INSTALLATION NOTE Charge pump components are available as a complete kit only Kit includes S300 S250 SI 00 SI 50 and S200 1 Install new seal S30...

Page 213: ...LATION 1 Install new O ring V024 2 Using a 22 mm wrench install the charge pressure relief valve VI0 3 Torque to 52 Nm 38 Ib ft PRESSURE LIMITER INSTALLATION 1 Lubricate and install O rings L022 2 Usi...

Page 214: ...3mm hex wrench EDC CONTROL ASSEMBLY 1 Install new O rings D025A into solenoids D025 and attach solenoids with capscrews D050 using 4 mm internal hex wrench Torque to 8 Nm 6 ft lbs 2 Replace screen D08...

Page 215: ...ed reinstall using a 3 mm internal hex wrench Torque to 2 5 Nm 1 8 ft lbs 2 Install dowel pins D300 3 Install new gasket D150 4 Position control on pump housing Remove plug on top of control to visual...

Page 216: ...e gauges frequently to ensure accuracy Use snubbers to protect gauges Table 5 7 Port information Port identifier Port size Wrench size Pressure obtained Gauge size bar psi L1 L2 11 16 12UNF28 9 16inte...

Page 217: ...18mm 77Nm 58ft lbs K400 Rearcover auxpadmountingbolt 8mminternalhex 92Nm 68ft lbs L010 Pressurelimiteradjustscrew 8mm NA L300 L400 Pressurelimitercartridge 14mm 30Nm 22ft lbs L024 Pressurelimiterlocki...

Page 218: ...SECTION 5 HYDRAULICS 5 58 JLG Lift 3121259 Figure 5 32 Fasteners and Plugs Sheet 1 of 2...

Page 219: ...SECTION 5 HYDRAULICS 3121259 JLG Lift 5 59 Figure 5 33 Fasteners and Plugs Sheet 2 of 2...

Page 220: ...ill inlet line from reservoir to pump Ensure construc tion plug in control is closed after filling 6 Disconnect the pump from all control input signals 7 Close construction plug removed in step 4 AFTE...

Page 221: ...ANDERS TO PROTECT AGAINST UNIN TENDED MOVEMENT SECURE THE MACHINE OR DISABLE DISCONNECT THE MECHANISM WHILE SERVICING CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID THE MAN UFACTURER S WARRANTY...

Page 222: ...andhighpressurerelief valvesandadjustorreplaceasnecessary Systempressure Frequentorlongtermoperationoversystemreliefsetting createsheatinsystem Measuresystempressure Ifpressureistoohigh reduce loads T...

Page 223: ...nreservoir Lowoillevelcausessluggishresponse Fillreservoir Highpressurereliefvalves pressurelimitersettings Incorrectpressuresettingsaffectssystemreactiontime Adjustorreplacehighpressurereliefvalves L...

Page 224: ...st for leaks CHARGE PRESSURE RELIEF VALVE ADJUSTMENT NOTE Ensure charge pressure is properly set before checking pressure limiter 1 Install a 50 bar 1000 psi pressure gauge in charge pres sure gauge p...

Page 225: ...serial plate gives the factory setting of the PL Pressure Limiter The PL setting is referenced to charge pressure Subtract charge pressure from system pressure gauge readings to compute the effective...

Page 226: ...orque 7 Shut down the prime mover Remove gauges and replace plugs Table 5 15 Pressure Limiter Settings Pressure limiter setting HPRV setting 150 200 180 230 200 250 230 280 250 300 280 330 300 350 330...

Page 227: ...djusting screw to achieve the desired maxi mum displacement Set the adjusting screw against the servo piston by feel before counting turns Refer to the table below for change per turn Clockwise rotati...

Page 228: ...Use a 4mm internal hex wrench to hold the neutral adjusting screw D015 stationary while loosening the locknut D060 with a 13mm wrench 3 Observe pressure gauges If necessary turn adjusting screw D015 t...

Page 229: ...find wrench sizes and plug torques in the Plug size and torque chart SERVO ADJUSTMENT SIDE M4 1 Run prime mover at 1800 rpm 2 If using a PWM signal to set mechanical neutral start with the electronic...

Page 230: ...7 Before replacing the pump replace all filters and drain the hydraulic system Flush the system lines and fill the reservoir with the correct filtered hydraulic fluid 8 Fill the pump with clean filte...

Page 231: ...Nm 4 lb ft 7 Install coil using a 12 point 26 mm socket Torque coil nut to 5 Nm 3 7 ft lbs 8 Reconnect electrical connections and test the pump for proper operation Shaft Seal Roller Bearing and Shaf...

Page 232: ...ring diameter is less than 38 84 mm 1 53 in when installed on the shaft 7 Install the shaft bearing assembly into the pump 8 Lubricate and install a new O ring J260 onto seal car rier J275 Press a new...

Page 233: ...ugh full range of con trols to ensure proper operation Check for leaks Charge Pressure Relief Valve Replace the charge pressure relief valve V010 as a complete unit Do not attempt to repair the intern...

Page 234: ...ding with disassembly it may be necessary to prepare some subassemblies separately The details for preparing each subassembly are given in the following section Also some general recommendations are g...

Page 235: ...DO NOT scribe inter nal surfaces PROCEDURE 1 Clamp the unit Clamp the unit in a vice from the flange side Make sure the vice jaws are clean and have smooth sur faces to prevent damage to the pump Clam...

Page 236: ...SECTION 5 HYDRAULICS 5 76 JLG Lift 3121259 Figure 5 39 Gear Pump Cutaway...

Page 237: ...ts side and carefully remove the bearing block and gear set To accomplish this hold the pump body and push with your fingers on the rear bear ing block Mark the relative positions of the gear mesh dri...

Page 238: ...ng internal snap ring pliers remove the snap ring 10 Remove the shaft seal Check the shaft seal quality and remove if necessary To remove pry the bottom of the shaft seal and force it out while rotati...

Page 239: ...p ring pliers Ensure the snap ring fits securely in its groove This is necessary to retain the shaft seal 4 Install pressure seals Prepare the pressure seals by lightly lubricating them with grease In...

Page 240: ...ion 8 Prepare the bearing blocks Clean the two bearing blocks Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges If necessary remove burrs with very fine emery paper T...

Page 241: ...ny excess lubrication and grease from the mat ing surfaces of the pump body Ensure that these sur faces are dry and free of contamination before moving on to the next step 12 Install the dowel pins In...

Page 242: ...gainst the direction of the flow if the unit is a unidi rectional motor If the unit is a bidirectional motor the arrow does not appear on the cover Ensure that all the pressure seals stay in place dur...

Page 243: ...re tighten the capscrews Then using a torque wrench tighten them to the proper torque Torque 44 54 Nm 32 40 ft lbs 18 Install socket head capscrews Using a 4 mm internal hex wrench install the socket...

Page 244: ...ervoir 2 Checkinletlineforleaks 3 Checkpressureatpumpinlet Recommendedinletpressure 0 8to3 0barabsolute 0 6 Minimumatcoldstart Description Excessiveairwillcausecavitationsound Excessiveairwillcausecav...

Page 245: ...adjustable and is located on the T port face of the valve block The steer relief valve is located right next to the swing relief valve To check install a pressure gauge at port M2 Activate steer right...

Page 246: ...SECTION 5 HYDRAULICS 5 86 JLG Lift 3121259 Figure 5 40 Oil Sampling Port...

Page 247: ...sed motor con trol unit installed on the boom lift The JLG Control System provides simplicity in viewing and adjusting the various personality settings for smooth control of acceleration deceleration...

Page 248: ...des real time status information about the control system as a diagnostic aid 3 SYSTEM TEST This menu is used to activate and then interact with the Control System s self test functionality Starting t...

Page 249: ...le the cable cannot be connected backwards 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emer gency stop buttons on Using the Analyzer With...

Page 250: ...s a power up When a top level menu is selected a new set of menu items may be offered for example SYSTEM DATALOG VERSIONS ENGINE OPER CONTROLS Pressing ENTER with any of the above displayed menus will...

Page 251: ...eat the above steps if the correct access level is not dis played or you can not adjust the personality settings Adjusting Parameters Using the Hand Held Analyzer Once you have gained Service Access a...

Page 252: ...ecommended setting NOTE Refer to Table 6 6 Machine Model Adjustment for the rec ommended factory settings NOTE Password 33271 will give you Service Access which will permit you to change all machine p...

Page 253: ...ILTED ELEV ELEVATION ENG ENGINE EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWFS HARDWAR...

Page 254: ...R SN SERIALNUMBER SPD SPEED STOW STOWED STOWD STOWED SW SWITCHorSOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ TORQUE TRN TRANSPORT T T TURNTABLE T TOWER TURNTBL TURNTABLE TWR TOWER U UPPERorUP V VOLT...

Page 255: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 9 PLATFORM MODULE GROUND MODULE Figure 6 2 Control Module Location...

Page 256: ...SECTION 6 JLG CONTROL SYSTEM 6 10 JLG Lift 3121259 Figure 6 3 Ground Module Sheet 1 of 4...

Page 257: ...AL OUTPUT 6 FUEL GROUND GROUND INPUT 7 PLATFORM LEVEL DOWN SOLENOID DIGITAL OUTPUT 8 RIGHT FRONT STEER SOLENOID DIGITAL OUTPUT 9 TOWER LIFT DOWN SOLENOID DIGITAL OUTPUT 10 UNUSED PLATFORM ROTATE LEFT...

Page 258: ...UND INPUT 20 OSCILLATING AXLE COIL 2 ANALOG INPUT 21 UNUSED TOWER TELESCOPE PROXIMITY DIGITAL INPUT 22 UNUSED DIGITAL INPUT 23 UNUSED DIGITAL INPUT 24 CAN1 LOW SERIAL I O 25 UNUSED GROUND GROUND INPUT...

Page 259: ...L OUTPUT 14 PLATFORM OVERLOADED INDICATOR DIGITAL OUTPUT 15 UNUSED BOOM MALFUNCTION INDICATOR DIGITAL OUTPUT 16 AUXILIARY POWER FUNCTION ENABLE DIGITAL INPUT 17 PLATFORM LEVEL UP DIGITAL INPUT 18 PLAT...

Page 260: ...T TOUCH LIMIT SWITCH POWER BATTERY VOLTAGE 8 FOOTSWITCH SIGNAL DIGITAL INPUT 9 GENERATOR ON SIGNAL DIGITAL INPUT 10 7 REFERENCE VOLTAGE 7 REFERENCE VOLTAGE 11 LOAD CELL INPUT 1 ANALOG INPUT 12 LOAD CE...

Page 261: ...REFERENCE VOLTAGE 35 SPEED PUMP POTENTIOMETER DIGITAL INPUT CONNECTOR PIN ASSIGNMENT FUNCTION J2 GRAY 1 UNALLOCATED DIGITAL INPUT 2 UNALLOCATED DIGITAL INPUT 3 BATTERY VOLTAGE HS DIGITAL INPUT 4 DRIVE...

Page 262: ...owerLift Up J4 10 Down J4 21 Lift Up J4 23 Down J4 33 Telescope In J4 7 Out J4 30 JibLift Up J4 19 Down J4 8 PlatformLevel Up J4 17 Down J4 5 PlatformRotate Left J4 6 Right J4 18 Table 6 3 Platform Co...

Page 263: ...c cessfulCANBuscommunication Successfulcommunication VerifyhealthyCANBusandpresenceofPlatformMod ule Successfulcommunication Ifapplicable confirmpresenceofLSSsystem Successfulcommunication CANBus2 Ifa...

Page 264: ...rgizeandverifycurrentpath TelescopeInValve NoSTB OC NoSTG energizeTeleInandOutsimultaneously TelescopeOutValve NoSTB OC NoSTG energizeTeleInandOutsimultaneously LevelUpValve NoSTB OC NoSTG energizeLev...

Page 265: ...e NoSTB OC NoSTG energizeJibUp JibDownValve NoSTB OC DonotcheckSTG RotateLeftValve NoSTB OC NoSTG energizeRotateLeftandRightsimultaneously RotateRightValve NoSTB OC NoSTG energizeRotateLeftandRightsim...

Page 266: ...CTION 6 JLG CONTROL SYSTEM 6 20 JLG Lift 3121259 1 A O Figure 6 9 Analyzer Top Level Menu See Figure 6 15 See Figure 6 16 See Figure 6 13 See Figure 6 12 See Figure 6 14 See Figure 6 11 See Figure 6 1...

Page 267: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 21 Figure 6 10 Analyzer Diagnostics Menu Sheet 1 of 4...

Page 268: ...SECTION 6 JLG CONTROL SYSTEM 6 22 JLG Lift 3121259 Figure 6 11 Analyzer Diagnostics Menu Sheet 2 of 4...

Page 269: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 23 Figure 6 12 Analyzer Diagnostics Menu Sheet 3 of 4...

Page 270: ...SECTION 6 JLG CONTROL SYSTEM 6 24 JLG Lift 3121259 Figure 6 13 Analyzer Diagnostics Menu Sheet 4 of 4...

Page 271: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 25 Figure 6 14 Analyzer Personalities Menu Sheet 1 of 2...

Page 272: ...SECTION 6 JLG CONTROL SYSTEM 6 26 JLG Lift 3121259 Figure 6 15 Analyzer Personalities Menu Sheet 2 of 2...

Page 273: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 27 Figure 6 16 Analyzer Machine Setup Menu...

Page 274: ...SECTION 6 JLG CONTROL SYSTEM 6 28 JLG Lift 3121259 Figure 6 17 Analyzer Calibrations Menu...

Page 275: ...tedMax 250 850mA 790mA Mid EngineElevatedMax 250 975mA 900mA MaxTorqueCreep 250 750mA 725mA Mid EngineCreep 250 890mA 850mA STEER Accel 0 0 5 0sec 0 8sec Decel 0 0 5 0sec 0 1sec MinRight 10 100 35 Max...

Page 276: ...T Accel 0 0 5 0sec 1 2sec Decel 0 0 5 0sec 0 5sec MinUp 250 1400mA 400mA MaxUp 250 1400mA 1075mA CreepUp 250 1400mA 575mA MinDown 10 70 32 MaxDown 10 70 53 CreepDown 10 70 48 PLATFORMLEVEL Accel 0 0 5...

Page 277: ...n 250 1400mA 750mA Telescope 250 1400mA 1250mA JibUp 250 1400mA 1075mA JibDown 10 70 53 PlatformLevel 250 1400mA 1250mA PlatformRotate 250 1400mA 1250mA NOTE Personality settings can be adjusted anywh...

Page 278: ...wheelteeth 1 Thismenuitemisnotvisible GLOWPLUG 5 1 2 3 NOGLOWPLUGS Noglowplugsinstalled AIRINTAKE Glowplugsinstalledintheairintakeonthemanifold IN CYLINDER Glowplugsinstalledineachcylinder 3 Thismenui...

Page 279: ...nswilllimittiltoptionsandalterdefaultsetting Note Anyoftheselectionsabovewilllightthetiltlampwhenatiltedconditionoccursandwillsoundtheplatformalarmwhenthemachineisalsoaboveelevation JIB 10 1 2 NO Noji...

Page 280: ...CUTE T Drive steercutoutaboveelevationandtilted 1 Onlyvisibleundercertainmarketselections Certainmarketselectionswilllimitfunctioncutoutoptionsoralterdefaultsetting GROUNDALARM 19 1 2 3 4 NONE Nogroun...

Page 281: ...telematics optionsisdisabled YES ClearSky telematics optionisenabled 1 CRIBBINGOPTION 24 1 2 NO CribbingOptionisdisabled 1 YES CribbingOptionisenabled 1 4150364 A Table 6 7 Machine Configuration Prog...

Page 282: ...2 2 2 GenSetCutout 1 1 1 1 1 1 2 2 2 2 2 2 Head Taillights 1 1 1 1 1 1 2 2 2 2 2 2 CableBreakSwitch 1 1 1 1 1 1 LoadSystem 1 1 1 1 1 1 X 2 X X X 2 X 3 X 3 3 3 X 4 X 4 X 4 X 5 X X X X FunctionCutout 1...

Page 283: ...ovement is permitted by a Removing the excess platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized p...

Page 284: ...e 6 9 Diagnostic Menu Descriptions Diagnostics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLATFORMLOAD STAT...

Page 285: ...approximately level for calibra tion Level the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the...

Page 286: ...6 10 Accessory Weights Use the up and down analyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LOAD SENSING accessory xxxlb...

Page 287: ...ess than 575 lbs 261 kg If the platform weight is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system w...

Page 288: ...acity Reductions and Table 6 12 Pipe Rack Capacity Reduc tions Table 6 11 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 1...

Page 289: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 43 14 Press ENTER If calibration is successful the screen will read...

Page 290: ...Overload Visual Warning at the Ground Controls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional whe...

Page 291: ...rsastheywillleaveconductiveresidue Moistureshouldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnecto...

Page 292: ...rm console NOTE If performing the procedure from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen...

Page 293: ...ROL SYSTEM 3121259 JLG Lift 6 47 12 Press Enter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the...

Page 294: ...n Ground Mode display will read GROUND MODE OK Pressing ENTER again will cause the Analyzer to display the current Help description followed by its Diagnostic Trouble Code DTC Help Messages larger tha...

Page 295: ...223 FUNCTIONSWITCHESLOCKED SELECTEDBEFOREENABLE 2224 FOOTSWITCHSELECTEDBEFORESTART 2247 FUNCTIONPROBLEM PLATFORMROTATELEFTPERMANENTLYSELECTED 2248 FUNCTIONPROBLEM PLATFORMROTATERIGHTPERMANENTLYSELECTE...

Page 296: ...BOOMPREVENTED DRIVESELECTED 2516 DRIVEPREVENTED ABOVEELEVATION 2517 DRIVEPREVENTED TILTED ABOVEELEVATION 2518 DRIVEPREVENTED BOOMSELECTED 2520 FUNCTIONSLOCKEDOUT CONSTANTDATAVERSIONIMPROPER 331 BRAKE...

Page 297: ...ROUND 33101 JIBLIFTUPVALVE OPENCIRCUIT 33102 JIBLIFTUPVALVE SHORTTOBATTERY 33103 JIBLIFTDOWNVALVE SHORTTOGROUND 33104 JIBLIFTDOWNVALVE OPENCIRCUIT 33105 JIBLIFTDOWNVALVE SHORTTOBATTERY 33106 TOWERLIFT...

Page 298: ...CURRENTFEEDBACKREADINGLOST 33419 FLOWCONTROLVALVE CURRENTFEEDBACKREADINGLOST 33420 TRACTIONLOCKVALVE SHORTTOBATTERY 33421 TRACTIONLOCKVALVE OPENCIRCUIT 33422 TRACTIONLOCKVALVE SHORTTOGROUND 33423 OSCI...

Page 299: ...GLOST 441 BATTERYVOLTAGETOOLOW SYSTEMSHUTDOWN 442 BATTERYVOLTAGETOOHIGH SYSTEMSHUTDOWN 443 LSSBATTERYVOLTAGETOOHIGH 444 LSSBATTERYVOLTAGETOOLOW 445 BATTERYVOLTAGELOW 662 CANBUSFAILURE PLATFORMMODULE 6...

Page 300: ...FUNCTIONSLOCKEDOUT PLATFORMMODULESOFTWAREVERSIONIMPROPER 9911 FUNCTIONSLOCKEDOUT LSSMODULESOFTWAREVERSIONIMPROPER 9915 CHASSISTILTSENSORNOTGAINCALIBRATED 9919 GROUNDSENSORREFVOLTAGEOUTOFRANGE 9920 PLA...

Page 301: ...sisisconsideredTilted CreepModeisactive LowerMachineandplaceon firm levelsurface RUNNINGATCREEP PLAT FORMSTOWED 00301 PlatformisinStowedPosition LiftDownandLevelDown functionspeedmaximumsare limitedto...

Page 302: ...CKED JOYSTICK MOVEDBEFOREFOOTSWITCH 2212 TheControlSystemdetectsoneofthefollowingconditions ThemachineisinPlatformModeandthedrivejoystickisnotinthe neutralpositionimmediatelyfollowingStartUp Themachin...

Page 303: ...dSwinginPlatform Mode Iffaultoccursbyengagingthe footswitchafterthecontrol thenmachineisnotpermitted toentertheMachineEnabled state ReturnLift Swingcontrolsto neutralwhilenotinthe Enabledstate ReturnL...

Page 304: ...gesunderappropriate menuinDIAGNOSTICS OPER CONTROLSonAnalyzer Replacetheswitchiffaulty FUNCTIONPROBLEM TELE SCOPEINPERMANENTLY SELECTED 2251 ThemachineisinPlatformmodeandthetelescopeswitchissending ac...

Page 305: ...IAGNOSTICS BOOM 234 TheGroundModuledetectsoneofthefollowingconditions ThemachineisinGroundModeandbothdirectioninputsofthe followingboomcontrolsareenergizedatthesametime Engine Start Aux Telescope Plat...

Page 306: ...Replacethe switchifdefective FUNCTIONPROBLEM JIBLIFT UPPERMANENTLYSELECTED 2370 ThemachineisinGroundmodeandtheJibLiftswitchisselectedand tryingtoactivatetheJibLiftUpfunctionatstartup JibLiftUpandDown...

Page 307: ...PROBLEM TOWERLIFTDOWNPERMA NENTLYSELECTED 23106 ThemachineisinGroundmodeandtheTowerLiftswitchisselected andtryingtoactivatetheTowerLiftDownfunctionatstartup TowerLiftUpandDownprohib ited Withthemachin...

Page 308: ...ORMLEVELDOWNPERMA NENTLYSELECTED 23112 ThemachineisinGroundmodeandthePlatformLevelswitchis selectedandtryingtoactivatethePlatformLevelDownfunctionat startup PlatformLevelUpandDown prohibited Withthema...

Page 309: ...machinechangesfromBelowEleva tiontoAboveElevation Allboomfunctionsaredis abled StopoperatinganyDriveor Steerfunctions Activatethe Boomfunction DRIVEPREVENTED ABOVE ELEVATION 2516 Themachineissetuptocu...

Page 310: ...ut GroundModuleLiftUpand Downoutputsaredisabled Inspectwiringforphysical damageandcheckforwire continuity Cyclepowertoclear thefault LIFTDOWNVALVE OPEN CIRCUIT 336 TheGroundModuledetectsanopencircuita...

Page 311: ...ECU groundmodulewillonlyevaluatefor opencircuitconditionsuntilfirstStartisattemptedforeachpower cycleduetopossibilityofECUopeninggroundsolenoidreturnpath todisableStartandcausingerroneousdiagnostics N...

Page 312: ...werto clearthefault GENSET WELDER SHORTTO BATTERY 3375 TheGroundModuledetectsashorttobatteryattheGenSet Welder output TheGroundModuleGenerator relayoutputisdisabled butthe GroundModuleconsidersthe Gen...

Page 313: ...dforcontinuity throughthiscircuit Inspect wiringforphysicaldamage Cyclepowertoclearthefault PLATFORMLEVELUPVALVE SHORTTOBATTERY 3384 TheGroundModuledetectsashorttobatteryatthePlatformLevel UpValveoutp...

Page 314: ...lveoutput TheGroundModulesuspends TowerLiftUp Downcom mandsandrevertstoOpen LoopCurrentcontrolforTower Lift TowerLiftspeedislimited toCreepafterbothTowerLift Up Downcontrolshavebeen returnedtoneutrala...

Page 315: ...andcheckforwire continuity Checkforcoildam ageorshortingconditionin connector Cyclepowertoclear thefault THROTTLEACTUATOR OPEN CIRCUIT 33131 TheGroundModuledetectsanopencircuitattheThrottleActuator ou...

Page 316: ...existsontheGroundMod uleoutputpinfordiagnostic purposes Inspectwiringfor physicaldamage Cyclepower toclearthefault TELESCOPEINVALVE SHORT TOGROUND 33190 TheGroundModuledetectsashorttogroundattheTelesc...

Page 317: ...rcontinuity throughthiscircuit Withthe solenoiddisconnected an opencircuitvoltageofnearly 8 0VexistsontheGroundMod uleoutputpinfordiagnostic purposes Inspectwiringfor physicaldamage Cyclepower toclear...

Page 318: ...rphysical damageandcheckforwire continuity Cyclepowertoclear thefault DRIVEFORWARDVALVE SHORTTOGROUND 33319 TheGroundModuledetectsashorttogroundattheDriveForward Valveoutput GroundModuleDriveForward a...

Page 319: ...VES SHORTTO BATTERY 33412 TheGroundModuledetectsashorttobatteryateithertheSwing RightorSwingLeftvalve GroundModuleSwingLeftand Rightoutputsaredisabledand openthegroundcurrentreturn pathisopencircuited...

Page 320: ...anded currentisbeingdivertedfrom thegroundreturnpath Inspect wiringforphysicaldamageand checkforwirecontinuityanda lowresistancereturnpath Cyclepowertoclearthefault SWING CURRENTFEEDBACK READINGLOST 3...

Page 321: ...iftUp andDownoutputsaredisabled andopenthegroundcurrent returnpath Inspectwiringforphysical damageandcheckforwire continuity Cyclepowertoclear thefault PLATFORMROTATELEFT VALVE OPENCIRCUIT 349 ThePlat...

Page 322: ...hysicaldamage Cyclepowertoclearthefault JIBLIFTUPVALVE SHORTTO GROUND 3417 ThePlatformModuledetectsashorttogroundattheJibLiftUpValve outputandreportsittotheGroundModule JibLiftUpoutputisdisabled JibLi...

Page 323: ...servestate changeonAnalyzerunder DIAGNOSTICS ENGINE ENGINEOILPRESS COOLANTTEMPERATURE SHORTTOGROUND 435 MACHINESETUP ENGINE KUBOTAD1105 GroundModulecoolanttemperatureinput J1 14 detectsavoltage lessth...

Page 324: ...msandEngineoilpressureisnotLOW GroundModuletolimitall functionspeedstocreep but runatHighEnginespeeduntil theoilpressuredropstoalow value GroundModuletodis ableGeneratorrelayoutput untilgeneratoropera...

Page 325: ...han9volts DisableallGroundModule valveoutputsexceptthose usedduringEmergency Descent TowerLiftDown Lift Down JibUp Down If MACHINESETUP H T LIGHTS YESor ENGINE KUBOTAD1105turnofflights anddisableglowp...

Page 326: ...hisrequiredto resumeoperation Withpoweroff disconnectthe boomcableatthebottomof thePlatformbox Withamulti meter verifythattheresistance betweentheCAN1HandCAN1L pinsoftheboomcableis approximately120ohm...

Page 327: ...ClearSkyTCU CHASSISTILTSENSORNOT CALIBRATED 813 Thetiltsensorhasnotbeencalibrated TheGroundModulereportsa faultedchassistiltangleof90 degrees CalibratetheTiltsensortoclear thefault CHASSISTILTSENSOROU...

Page 328: ...slatchedwithinagivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE2 STAG NANT 8223 Thecontrolsystemhasdeterminedthatthestraingauge2readingin theloadsensorisstagnant notchanging Iftheplatformisnot...

Page 329: ...ult onceannunciatedislatchedwithinagivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE2 INITIAL IZATIONERROR 8229 Theshearbeamisreportinganinitializationissuewiththestrain gauge2sensor Iftheplatf...

Page 330: ...agivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE1 NOT INSTALLED 8234 Theshearbeamisreportinganotinstalledissuewiththestraingauge 1sensor Iftheplatformisnotoverloadedthemachinewillbeplacedinto...

Page 331: ...onsformachine response Notallofthetriggerconditions aremet DRIVE BOOMPREVENTED PLATFORMOVERLOADED 827 ThePlatformisOverloadedand MachineSetup LOADSYSTEM CUTOUTPLATFORM Platform Modeisactive andconditi...

Page 332: ...etoOver loaded Cyclepowertoclearthefault LSSINTERNALERROR PIN EXCITATION 993 TheGroundModuledetectsanLSSreportofimproperexcitation voltage TheGroundModulesetsthe PlatformLoadStatetoOver loaded Cyclepo...

Page 333: ...ODE1 9923 TheGroundModuledetectsfaultyhardware Noresponserequired Cyclepowertoclearthefault if faultsremains replaceboard FUNCTIONSLOCKEDOUT MACHINENOTCONFIGURED 9924 Themachineispoweredupandnomodelha...

Page 334: ...ONIMPROPER 9979 GroundModuledetectsadisagreementwithinternalchecksonthe versionofsoftware Allmachineandenginefunc tionsaredisabled i e com mandengineshutdownanddo notpermitstart Cyclepowertoclearthefa...

Page 335: ...onotreportFault ReportFault ReportFault DonotreportFault Donotreportfault Activatecreepmodeallfunctions DonotpermitMachineEnable no creeplight Overloadshallhavenoeffecton functionspeeds Overloadshallh...

Page 336: ...SECTION 6 JLG CONTROL SYSTEM 6 90 JLG Lift 3121259 NOTES...

Page 337: ...ng the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec...

Page 338: ...to ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continui...

Page 339: ...ure to apply Silicone Dielectric Com pound to the electrical connectors This procedure applies to all plug connections not enclosed in a box Silicone grease should not be applied to connectors with ex...

Page 340: ...hin layer of dielectric grease on the face of the connector 4 Assemble the connector system immediately to prevent moisture ingress or dust contamination 5 Pierce one of the unused wire seals prior to...

Page 341: ...N Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not benefit from dielectric grease or may be permane...

Page 342: ...omponents with the M12 con nector system AMP JUNIOR TIMER This type of connector uses back seals for moisture integrity However the low force contacts cannot displace dielectric grease and create elec...

Page 343: ...pplication for this connector is on David Clark Intercom connections in Aerial Work Platforms 7 4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open or as shipped position See Figur...

Page 344: ...dge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 10 4 Slide the wedge lock into the housing until it is flush with the housing See Figur...

Page 345: ...forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PIE...

Page 346: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 10 JLG Lift 3121259 Figure 7 13 Connector Installation...

Page 347: ...ard exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Serie...

Page 348: ...ire cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be remov...

Page 349: ...OX SHEET 3 PLATFORM AND BOOM COMPONENTS SHEET 4 CHASSIS TURNTABLE AND UGM SHEET 5 GROUND USER INTERFACE SHEET 6 ENGINE KUBOTA AND GENERATOR SHEET 7 ENGINE GM VENDOR SCHEMATIC SHEET 8 MIDENGINE HARNESS...

Page 350: ...H IGN WHT 2 17 8 SWITCH IGN WHT 13 1 MAIN TELE IN WHT 13 1 MAIN TELE IN WHT 14 1 MAIN TELE OUT WHT 14 1 MAIN TELE OUT WHT 2 17 9 SWITCH IGN WHT 2 17 9 SWITCH IGN WHT 53 1 AUX POWER WHT 53 1 AUX POWER...

Page 351: ...RLOAD WHT 56 1 TILTED WHT 56 1 TILTED WHT 48 1 GLOW PLUGS WHT 48 1 GLOW PLUGS WHT 39 3 1 4 FUEL LVL WHT 39 4 1 2 FUEL LVL WHT 39 5 3 4 FUEL LVL WHT 0 22 FUEL GND WHT 39 6 FULL FUEL LVL GENERIC EMERGEN...

Page 352: ...T3 1 T4 TO SHEET 2 X2 INSIDE PLATFORM BOX 1 T5 1 T6 1 BLU BLK BLU BLK ORN BLK YEL BLK BRN BLK BLK RED BLK RED X2 1 2 3 4 5 6 7 8 9 10 11 12 GENERIC FOOT SWITCH SW43 1 2 3 SHLD TP CAN CABLE SHLD TP CA...

Page 353: ...ED BLK 18AWG ORN BLK 18AWG SHLD SHLD BLK 12AWG X5 12 16 1 2 3 5 4 6 7 8 11 14 17 19 18 10 15 9 13 X7 TO SHEET 4 BOOM CABLE X7 12 16 1 2 3 5 4 6 7 8 11 14 17 19 18 10 15 9 13 T2 1 T3 1 T4 1 T5 1 T6 1 B...

Page 354: ...3 TWR LIFT UP STEER LEFT GENERIC V80 1 2 STEER RIGHT GENERIC V81 1 2 DRIVE REVERSE GENERIC V82 1 2 DRIVE FORWARD GENERIC V83 1 2 WHT 9 2 STEER LFT WHT 9 2 STEER LFT WHT 10 2 STEER RT WHT 10 2 STEER R...

Page 355: ...STROBE GENERIC LB104 1 2 WHT 0 13 1 TWR VLV RTN RED 1 9 B RED 1 9 1 B S143 WHT 0 18 VLV GND WHT 0 18 VLV GND WHT 2 16 1 IGN WHT 2 16 IGN S145 WHT 73 2 OSC AXLE 2 WHT 73 2 OSC AXLE 2 S146 WHT 73 1 OSC...

Page 356: ...LFT WHT 53 2 AUX ENABLE WHT 53 2 AUX ENABLE WHT 2 14 SWITCH IGN WHT 2 14 SWITCH IGN WHT 45 2 START WHT 45 2 START WHT 2 14 1 SWITCH IGN WHT 2 14 1 SWITCH IGN WHT 2 14 2 SWITCH IGN WHT 2 14 2 SWITCH I...

Page 357: ...17 2 LAMP GND WHT 0 17 2 LAMP GND WHT 0 17 3 LAMP GND WHT 0 17 3 LAMP GND WHT 0 17 4 LAMP GND WHT 0 17 4 LAMP GND WHT 0 17 5 LAMP GND WHT 0 17 5 LAMP GND WHT 0 17 6 LAMP GND WHT 0 17 6 LAMP GND WHT 0...

Page 358: ...PLUGS 12AWG WHT 84 2 GLOW PLUGS 12AWG RED 1 10 1 B 12AWG RED 1 10 2 B 12AWG RED 1 10 5 B 12AWG RED 1 10 6 B 12AWG RED 1 10 6 B 12AWG RED 1 10 3 B 12AWG RED 1 10 4 B 12AWG WHT 83 1 OIL PRESSURE WHT 83...

Page 359: ...OR HARNESS X42 TO VOLTAGE REGULATOR 1 2 3 4 5 X28 TO GENERATOR TO GENERATOR CASE TO ENGINE BLOCK 1 2 3 X35 TO SHEET 8 X35 A B T30 TO E STOP 2A2 1 T31 TO SHEET 4 GND BUS POS 5 1 S236 WHT 0 33 GND WHT 5...

Page 360: ...75 TERMINAL 1 4 SPADE FEMALE PED_12160825 CONNECTOR PED_12177150 TERM GOLD PED_12160826 LOCK PED_12089678 SEAL PED_12162834 CONNECTOR PED_12124075 TERMINAL PED_12162193 CONNECTOR PED_12124075 TERMINAL...

Page 361: ...SEAL PED_15305171 CAVITY PLUG PED_15358639 CLIP PED_15326840 CONNECTOR PED_15326269 TERMINAL PED_12191153 SEAL PED_15305171 CAVITY PLUG PED_15358639 CLIP PED_15317363 LOCK CAP CONNECTOR 2 WITH MATING...

Page 362: ...THROTTLE ACT WHT 80 1 THROTTLE ACT WHT 0 43 THROTTLE RTN WHT 0 43 THROTTLE RTN CO66 J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 X175 TO SHEET 4...

Page 363: ...G H J K L M N P R S NC RED TP CAN CABLE BLK TP CAN CABLE SHLD WHT 85 1 FULL THROTTLE X40 A B C D E F G H WHT 2 21 IGN 16AWG Sheet_4 3 H WHT 82 2 SPEED VCC T362 TO ESTOP 1B2 1 T363 TO KEYSWITCH POS 1...

Page 364: ...K RED 1 12 B 12AWG WHT 0 45 1 GND WHT 0 45 1 GND LEFT FRONT GENERIC LB390 1 2 LEFT REAR GENERIC LB391 1 2 RIGHT FRONT GENERIC LB392 1 2 RIGHT REAR GENERIC LB393 1 2 CHASSIS LIGHT OPTION J8 1 2 J8_1 1...

Page 365: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121259 JLG Lift 7 29 This page left blank intentionally...

Page 366: ...2 0 50mm ROD 1 3 32mm STROKE 38 5 978mm OSCILLATING AXLE CYLINDERS BARREL 2 75 69 85mm STROKE 2 75 69 85mm STEER CYLINDER BARREL 2 5 65mm ROD 1 75 45mm STROKE 5 5 139mm JIB ROTATE FLY BOOM VALVE T P J...

Page 367: ...c REDUCTION 170 7 1 CHARGE FILTER MICRON LEVEL 5 BYPASS VALVE 43 PSI 3 BAR DRIVE PUMP 2 75 cu in 45 cc 4060 PSI 280 BAR Max 377 PSI 26 BAR Charge 0 73 cu in 12cc Charge Pump Displacement P1 Main relie...

Page 368: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 JLG Lift 3121259 NOTES...

Page 369: ......

Page 370: ...de Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5...

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