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JLG 530LRT, Service And Maintenance Manual

The JLG 530LRT Service And Maintenance Manual is essential for keeping your equipment running smoothly. Download the manual for free from our website to ensure proper maintenance and longevity of your JLG 530LRT. Get detailed instructions and guidelines for servicing your machine efficiently.

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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7-20

3121781

Figure 7-22. Electrical Schematic

MAF03650A

1001236134-A

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12345678

CO1-J6

CO1-J5

PLATFORM CONTROL MODULE

 GROUND MODE

 PLATFORM EMS

 PLATFORM EMS TO GROUND MODULE

 GENERATOR SWITCH POWER

 GENERATOR ON SIGNAL

 +5 ANALOG EXCITATION

 +5 ANALOG EXCITATION

 ANALOG GROUND RETURN

 PLATFORM ALARM

 ALARM RETURN

 GROUND RETURN

 CAN LOW

 CAN HIGH

 CAN SHIELD

CHASSIS TILT INDICATOR

SYSTEM DISTRESSED INDICATOR

LEVELING JACKS STOWED

LEVELING JACKS EXTENDED

PLAT OVERLOAD IND

TRIGGER SWITCH REDUNDANCY

LOW FUEL INDICATOR

LAMP RETURN

ANALYZER POWER

ANALYZER GND (N/C)

ANALYZER RX

ANALYZER TX

BATTERY VOLTAGE

BATTERY VOLTAGE

BATTERY VOLTAGE

BATTERY VOLTAGE

SWITCH POWER

BATTERY VOLTAGE

TRIGGER INPUT 

LEVELING JACKS 

DRIVE 

LIFT 

SPEED LOW 

FUEL/GLOW PLUG 

START 

SWITCH POWER 

HORN 

 DRIVE SIGNAL

 STEER LEFT

 STEER RIGHT

 DRIVE/STEER JOYSTICK RETURN

 GROUND RETURN

 GROUND RETURN

MODULE GROUND 

MODULE POWER 

SPEED HI 

FOOT SWITCH

CO1-J1

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CO1-J8

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X01 

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WHT 1 ANALYZER TX

WHT 1 ANALYZER TX

WHT 2 ANALYZER RX

WHT 2 ANALYZER RX

WHT 3 ANALYZER PWR

WHT 3 ANALYZER PWR

WHT 4 ALARM GND

WHT 4 ALARM GND

WHT 5 ALARM

WHT 5 ALARM

BLU 6 LAMP RETURN

BLU 6 LAMP RETURN

BLU 7 LEVEL JACK UP

BLU 7 LEVEL JACK UP

BLU 8 LEVEL JACK DOWN

BLU 8 LEVEL JACK DOWN

BLU 9 TRIGGER

BLU 9 TRIGGER

BLU 10 STR RT

BLU 10 STR RT

ORG 11 +5V

ORG 11 +5V

ORG 12 STR LT

ORG 12 STR LT

ORG 13 DRV

ORG 13 DRV

ORG 14 GND

ORG 14 GND

ORG 15 AUTO LVL

ORG 15 AUTO LVL

YEL 16 PWR

YEL 16 PWR

YEL 19 EMS IN

YEL 19 EMS IN

X50 

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YEL 18 PLAT EMS OUT

YEL 18 PLAT EMS OUT

YEL 17 SYS IND

YEL 17 SYS IND

YEL 20 LOW FUEL

YEL 20 LOW FUEL

TAN 21 TILT IND

TAN 21 TILT IND

TAN 22 OVLD IND

TAN 22 OVLD IND

TAN/BRN 23 LFT SEL

TAN/BRN 23 LFT SEL

TAN/BRN 24 DRV SEL

TAN/BRN 24 DRV SEL

TAN 25 GEN SW PWR

TAN 25 GEN SW PWR

PNK 26 GEN SW

PNK 26 GEN SW

PNK 27 HORN

PNK 27 HORN

PNK 28 ENG START

PNK 28 ENG START

PNK 29 SPD LOW

PNK 29 SPD LOW

PNK 30 SPD HI

PNK 30 SPD HI

PNK 31 GLOW PLUG/FUEL SEL

PNK 31 GLOW PLUG/FUEL SEL

BLU 6-1 TRIG SW INPUT

BLU 6-1 TRIG SW INPUT

YEL 2-3-3 GND MODE

YEL 2-3-3 GND MODE

ORG 5-1 PLAT EMS

ORG 5-1 PLAT EMS

MS301 

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YEL CANH CANH

GRN CANL CANL

SHIELD SHIELD SHIELD

SHIELD SHIELD SHIELD

BLK 00-112 GND

BLK 00-112 GND

ORG 111 PWR

ORG 111 PWR

BLK 001-1 GND

BLK 001-1 GND

RED 11-3 PWR

RED 11-3 PWR

FOOT SW

SW588 

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RED 125 PWR

RED 125 PWR

WHT 126 FOOT SW

WHT 126 FOOT SW

J4A

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S609 

GRN CANL CANL

S610 

YEL CANH CANH

YEL CANH -3

GRN CANL -3

YEL J2-33 IGN

YEL J2-33 IGN

BLK J2-25 GND

BLK J2-25 GND

HARNESS 

PLAT GND CONN

BOX RECEPT

(SEE SHEET 3-E4)

X50 CONNECTOR

MAIN ARM CABLE 

X50 PLAT GND CONNECTOR TO

X01 BOX RECEPT TO

HARNESS 

X01 CONNECTOR 

(SEE SHEET 5-F1)

(SEE SHEET 9-E6)

(WHEN EQUIPPED)

WORK & FLOODLIGHT OPTIONS

 MS301 CONNECTOR

MS301 CONNECTOR TO HARNESS

on sheet 10-C2

Connector J4B

TO LOAD SENSE

Summary of Contents for 530LRT

Page 1: ...Service and Maintenance Manual Model 530LRT SN E200000676 to Present Including 1200030223 3121781 September 03 2018 Rev A AS NZS...

Page 2: ......

Page 3: ...AREA RESPONSIBILITY OF THE OWNER OPERATOR HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pres sures Every effort should...

Page 4: ...INTRODUCTION b 3121781 REVISION LOG Original Issue A September 03 2018...

Page 5: ...6 Engine SPecifications 1 5 1 7 Platform Height Tilt Limit Settings 1 6 1 8 Torque Charts 1 9 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General 2 1 Preparation Inspectio...

Page 6: ...ylinder Drift Test 2 12 Platform Drift 2 12 Cylinder Drift 2 12 2 7 Pins and Composite Bearing Repair Guidelines 2 12 SECTION 3 CHASSIS PLATFORM SCISSOR ARMS 3 1 Operating Characteristics 3 1 Leveling...

Page 7: ...embly Removal 3 44 3 9 Side Compartment Covers 3 48 Cover Removal 3 50 Cover installation 3 50 3 10 Ground Control Station 3 50 Control Station Removal 3 50 Ground Control Station Components 3 51 Opti...

Page 8: ...And Torque Specifications 4 9 Assembly Instructions for American Standard Pipe Thread Tapered NPTF Connections 4 10 Assembly Instructions for British Standard Pipe Thread Tapered BSPT Connections 4 11...

Page 9: ...ng the Access Level of the Hand Held Analyzer 5 3 Adjusting Parameters Using the Hand Held Analyzer 5 4 Machine Setup 5 4 Analyzer Menu Flow Charts 5 6 5 2 Diagnostic Troubleshooting codes DTC s and F...

Page 10: ...ctric Grease 6 5 Deutsch HD DT DTM DRC Series 6 6 AMP Seal 6 6 AMP Mate N Lok 6 6 DIN Connectors 6 7 Exclusions 6 7 Brad Harrison Phoenix Contact M12 6 7 Engine Control unit connectors 6 8 Sealed Encl...

Page 11: ...ft Seal 3 20 3 7 Loop Flushing Spool 3 21 3 8 Loop Flushing Spool 3 23 3 9 Plugs Fittings and Speed Sensor 3 23 3 10 End Cap 3 24 3 11 Valve Plate Rear Shaft Bearing 3 24 3 12 Cylinder Kit 3 25 3 13 S...

Page 12: ...7 4 6 MTBL MBTS Thread 4 7 4 7 Bulkhead Thread 4 7 4 8 MFF BSPP Thread 4 8 4 9 ORB MPP Thread 4 8 4 10 Torque Wrench Angle 4 9 4 11 Double Wrench Method 4 50 4 12 FFWR Method 4 51 4 13 Adjustable Stu...

Page 13: ...Sensing System Components 6 5 6 2 LSS Module Load Cell Connector Pinout J5 J6 J7 J8 6 11 6 3 LRT Wiring Diagram 6 12 7 1 Voltage Measurement DC 6 2 7 2 Resistance Measurement 6 2 7 3 Continuity Measur...

Page 14: ...x 3121781 TABLE OF CONTENTS This page left blank intentionally...

Page 15: ...nder Drift 2 12 3 1 Wheel Torque Chart 3 2 3 2 Drive Hub Part Description 3 7 3 3 Excessive Noise and or Vibration 3 22 3 4 System Operating Hot 3 22 3 5 Won t Shift or Slow to Start 3 22 3 6 Displace...

Page 16: ...FL61 FL62 Metric Fasteners 4 49 4 33 Main Valve Port Identification 4 55 4 34 Main Valve Torque Specs 4 55 4 35 Main Valve Porting Specs 4 55 4 36 Leveling Jack Directional Valve Torque Specs 4 58 4...

Page 17: ...imumTireLoad Each 5500lb 2500kg GroundBearingPressure w Standardtires 26 5psi 1 86kg cm2 LevelingJackBearing Pressure 70psi 4 92kg cm2 HydraulicSystemPressure MainRelief SteerRelief 2700psi 186bar 250...

Page 18: ...abilityRequirement 40 Model 530LRT ToeIn Out Max 0 8in 20 32mm SteerAngle InsideTire 42 46degrees SteerAngle OutsideTire 32 34degrees Table 1 6 Tire Specifications Size Ply Rating Foam Fill Tire Assem...

Page 19: ...comparable viscosities Hydraulic Oil Specifications Table 1 10 Mobilfluid 424 1 1 Serial Number Plate 2 Stamped Serial Number Figure 1 1 Serial Number Location Table 1 9 Lubrication Specifications KEY...

Page 20: ...Max2 0 OperatingTemp 17 162 C 0 180 F Storeabove14 C 32 F Viscosity ASTMD445cST40 C 37 ASTMD445cST100 C 8 4 ViscosityIndex ASTMD2270 213 ISOViscosityGrade 46 Density 15 C 0 93 PourPoint C F ASTMD97 33...

Page 21: ...city 1 51Gal 5 7L EngineRPMControl Mechanical LowRPMSet 1200RPM HighRPMSet 3000RPM Alternator 60Amp 12V BeltDrive Battery 112Amp Hour 950ColdCrankingAmps 12VDC FuelConsumption LowRPM HighRPM 0 41gal h...

Page 22: ...unds when above elevation If the machine is operated beyond the specified slope with the platform completely lowered only the warning light is illuminated Table 1 21 Maximum Cutout Height Model High D...

Page 23: ...ECIFICATIONS 3121781 1 7 4150740_B_Hydraulic Figure 1 2 Hydraulic Oil Operating Temperature Specifications 1001204714_A_Dual Fuel Figure 1 3 Engine Oil Operating Temperature Specifications Kubota Dual...

Page 24: ...SECTION 1 SPECIFICATIONS 1 8 3121781 1001120075_C_Diesel Figure 1 4 Engine Oil Operating Temperature Specifications Kubota Diesel Engine...

Page 25: ...SECTION 1 SPECIFICATIONS 3121781 1 9 1 8 TORQUE CHARTS Figure 1 5 Torque Chart Sheet 1 of 5 SAE Fasteners...

Page 26: ...SECTION 1 SPECIFICATIONS 1 10 3121781 Figure 1 6 Torque Chart Sheet 2 of 5 SAE Fasteners...

Page 27: ...SECTION 1 SPECIFICATIONS 3121781 1 11 Figure 1 7 Torque Chart Sheet 3 of 5 SAE Fasteners...

Page 28: ...SECTION 1 SPECIFICATIONS 1 12 3121781 Figure 1 8 Torque Chart Sheet 4 of 5 METRIC Fasteners...

Page 29: ...SECTION 1 SPECIFICATIONS 3121781 1 13 Figure 1 9 Torque Chart Sheet 5 of 5 METRIC Fasteners...

Page 30: ...SECTION 1 SPECIFICATIONS 1 14 3121781 NOTES...

Page 31: ...ental delivery The Frequent Inspection 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 purc...

Page 32: ...broken welds 5 Operates properly 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 legib...

Page 33: ...wer 5 5 PLATFORMASSEMBLY Platform 1 1 GuardRails 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 Pivot...

Page 34: ...ityDecalsInstalled Secure Legible 21 21 AllDecals PlacardsInstalled Secure Legible 21 21 AnnualMachineInspectionDue 21 NoUnauthorizedModificationsorAdditions 21 21 AllRelevantSafetyPublicationsIncorpo...

Page 35: ...lessens as the angle between the supporting 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 remov...

Page 36: ...ication Chart in Section 1 2 4 LUBRICATION AND INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contami nation Contaminants enter the system by various means e g using inadequ...

Page 37: ...ies which meet a variety of single purpose grease require ments Should any question arise regarding the use of greases in maintenance stock consult your local sup plier for evaluation Refer to Section...

Page 38: ...in tank Oil should be visible in ADD sight window on 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...

Page 39: ...ing Wear Pads Lube MPG Interval Every month or 50 hours Hydraulic Oil Tank Lube Point Fill Cap Fill Level Lube HO API service classification GL 3 Refer ence Figure 1 2 Hydraulic Oil Operating Temper a...

Page 40: ...Minimum API CF Viscosity See Figure 1 4 Engine Oil Operating Temperature Specifica tions Kubota Diesel Engine Interval Every Year or 200 hours of operation Check oil level daily maintain within marke...

Page 41: ...e Interval Every 6 months or 300 hours of opera tion 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...

Page 42: ...ring opera tion 2 Filament 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 ha...

Page 43: ...active again Lift A proportional flow control valve allows for propor tional control of the lift up function Proportional valves on both the upper and lower cylinders allow for smooth control of the...

Page 44: ...safe condition regard ing stability Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO...

Page 45: ...Hub 3 and Drive Motor 6 from the axle 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 Fol...

Page 46: ...hen checking for air bubbles If you detect a 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 c...

Page 47: ...Assembly A Carrier Housing B Thrust Washer 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 Di...

Page 48: ...3 23 29 28 30 39 20 37 40 41 22 21 21 19 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 6...

Page 49: ...Spacer 6B CoverPlate 6C O Ring 6D DisconnectRod 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...

Page 50: ...out of hub 1G BEWARE OF SHARP EDGES IN COUNTERBORE 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 i...

Page 51: ...e to the carrier when removing the planet 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...

Page 52: ...g the thrust washer place the cluster gear 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...

Page 53: ...lange of the cover cap 3 Insert disconnect 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...

Page 54: ...tighten the bolts 9 Using a torque wrench apply 2 95 to 3 69 ft lb 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 t...

Page 55: ...the counterbore before pressing 4 Turn hub 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...

Page 56: ...b assembly is com plete Main Assembly BEWARE 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 pinc...

Page 57: ...nd of input shaft 7A 7 Place other spacer 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 SUDDEN...

Page 58: ...in the ring gear 4 over one of the shoulder 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...

Page 59: ...the pipe plug holes according to the align ment prior to disassembly 18 Place four flat washers 16 on top of the bolt holes in the cover sub assembly 19 Place shoulder bolts 13 into the four shoulder...

Page 60: ...sert coupling 14 into the end of the spindle 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...

Page 61: ...e applies to torque hubs with integral 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 relea...

Page 62: ...internal stops The large diameter servo pis ton allows smooth acceleration and deceleration with relatively large circuit orificing Shaft Seal Replacement REMOVAL 1 Remove the snap ring 1 retaining t...

Page 63: ...h remove plug 3 3 Remove O rings 4 5 and 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...

Page 64: ...reservoirand oilsupplytothepump Insufficientamountofhydraulicfluidwillnotmeetthecooling demandsofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger if soequipped Iftheheatexchangerfail...

Page 65: ...the speed sen sor lock nut 14 if equipped Then remove the speed sensor using a 1 2 inch hex wrench Units without speed sensor have an O ring plug 15 installed in that location remove it with a 1 4 inc...

Page 66: ...rt number are stamped on its surface 16 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...

Page 67: ...avoid damaging the shaft during seal removal install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull the seal 21 Remov...

Page 68: ...7 hold down pins 48 and retaining ring 49 from the cylinder block NOTE Most repairs do not require block spring removal Perform this procedure only if you suspect problems with the block spring RISK O...

Page 69: ...h scored or excessively rounded slipper edges Measure the slipper foot thickness Replace any piston assemblies with excessively worn slippers Check the slipper axial end play Replace any piston assemb...

Page 70: ...ding the surface condition meets specifications shown Measure the swashplate thickness from the journals to the running face Replace swash plate if damaged or worn beyond minimum specifica tion Replac...

Page 71: ...for the seal to relax after installation To speed up seal relaxation compress the seal by install ing the piston head into the servo cavity in the end cap and let it stand for at least five minutes 2...

Page 72: ...guide before assembly Set the cylinder kit aside on a clean surface until needed 6 Install the journal bearings 13 into the housing seats Use assembly grease to keep the bearings seated during assemb...

Page 73: ...kit 19 onto the shaft Install with the slippers facing the swashplate Rock the shaft to align the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing downward...

Page 74: ...the endcap 25 onto the housing with the endcap screws 26 Check to ensure the endcap will properly seat onto the housing without interference Improper assembly of the internal components may prevent th...

Page 75: ...seal Install seal support washer 28 and snap ring 29 19 Install remaining plugs and fittings to the housing Refer to the drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal...

Page 76: ...id Pour filtered oil directly into the upper 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...

Page 77: ...from the frame ASSEMBLY 1 When installing the axle assembly follow Removal Steps in reverse 2 Shim both the stop block pad and the wear pad to achieve a maximum gap of 1 16 in 1 5 mm between the pad a...

Page 78: ...bly follow Removal Steps in reverse 2 If removed shim the wear pad to achieve a maxi mum gap of 1 16 in 1 5 mm between the pad and the axle machined surface NOTE Apply Loctite 242 to bolts 8 attaching...

Page 79: ...e spindle from axle by removing flange bolts 11 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...

Page 80: ...to frame using four bolts 2 and washers 3 NOTE Make sure the shoulder on the lockout cylinder is firmly against the bottom of the mounting plates on the frame before torquing bolts Apply Loctite 242 a...

Page 81: ...ylinder Remove the four bolts 6 and nuts and washers 7 attaching cylinder to cylinder mount Remove jack cover attach bracket 5 5 Carefully remove cylinder from mount INSTALLATION 1 Follow Removal Step...

Page 82: ...nder and switches Remove hoses and wiring from the leveling jack tube assembly 4 Remove the eight bolts 3 washers 4 nuts 5 and doubler plate 6 through the frame 5 Carefully lower assembly from the fra...

Page 83: ...isconnect and label all 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 br...

Page 84: ...s connector terminal nut and discon necting all the wiring inside the control box ASSEMBLY 1 Follow Disassembly Procedures in reverse 2 Ensure electrical wires are properly and securely attached to sw...

Page 85: ...leAxis YAxisOnly InputVoltage 5V CurrentConsumption 10mA 12VDC CenteredOutputVoltage 2 50VDC ReverseVoltage 4 0VDC ForwardVoltage 1 0VDC Table 3 10 Joystick Plug Loading Chart Terminal Color Function...

Page 86: ...cissor Arms Removal NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT FIRST PROPERLY BRACING BLOCKING SCISSOR ARM ASSEMBLY NOTE Scissor arms can be removed individually or as an entire assembly ARM REMOV...

Page 87: ...RM SCISSOR ARMS 3121781 3 45 NOTE See Figure 3 37 and Figure 3 38 for letter detail views Route hoses wiring through wire rod on arm behind safety prop Figure 3 36 Scissor Arm Hose and Wiring Routing...

Page 88: ...ty rod keeper plate it must rotate freely Detail A C D F G and H Apply Loctite 242 to threads Figure 3 37 Scissor Arm Component Assembly 1 of 2 MAF03780 DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E DE...

Page 89: ...OTE Coat all pins Detail B J K L M and V with moly paste lubricant example Loctite 51049 before assembly Figure 3 38 Scissor Arm Component Assembly 2 of 2 DETAIL P DETAIL J DETAIL U DETAIL K DETAIL L...

Page 90: ...MPARTMENT COVERS Figure 3 39 Left Side 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...

Page 91: ...49 Figure 3 40 Right 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 Assembl...

Page 92: ...e 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 front top and back of the large...

Page 93: ...ve and replace components if necessary ASSEMBLY 1 Reattach any wires and or plugs 2 Close lid 2 and secure 3 Reattach machine harnesses to the ground control box 5 NOTE If Chassis tilt sensor or the g...

Page 94: ...n the module 2 Remove the 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 an...

Page 95: ...ove the bolts washers and nuts 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...

Page 96: ...OTE If removed reuse or replace sending unit gasket as necessary Before reinstalling apply Loctite 222 to threads of tank sending unit bolts If removed before reinstalling into tank insert apply pipe...

Page 97: ...id in appro priate receptacle 3 Disconnect 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 Hyd...

Page 98: ...e of the engine remove the tray 2 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 Cab...

Page 99: ...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 During transfer of LPG...

Page 100: ...with the bolts NOTE Apply Loctite 242 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 grou...

Page 101: ...ust manifold by removing the four bolts nuts washers and gasket at the exhaust manifold INSTALLATION 1 Follow Removal Steps in reverse NOTE Torque on O2 Sensors is 32 3 6 ft lb 44 4 9 Nm DIESEL ALLOW...

Page 102: ...LLOW ENGINE AND COMPONENTS 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 th...

Page 103: ...ate 4 Support the radiator mounting plate 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 connect...

Page 104: ...l Fuel Engine Control Module Location 1 Figure 3 54 Duel Fuel Engine Compartment Electrical Component Locations FC273 ALT FUSE FC271 STRT FUSE FC274 PWR RELAY FUSE RL13 ETV RELAY RL12 PWR RELAY RL10 S...

Page 105: ...ions T4F and CE MAF04490 RL1 IGN RELAY RL3 2 SPD RELAY RL4 GLOW PLUGS RL2 START RELAY RL5 PULL RELAY FC258 STRT FUSE FC267 2 SPD FUSE FC259 PULL RL FUSE FC257 HOLD RL FUSE FC260 ALT EXCITE FUSE RL6 HO...

Page 106: ...g 2 4 Remove the two bolts and washers attaching the axial pump 3 to the coupling 4 of the motor Care fully remove the axial pump INSTALLATION 1 Follow Removal Steps in reverse NOTE Apply grease to in...

Page 107: ...engine block plate 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 plat...

Page 108: ...E SERVIC ING REMOVAL 1 Disable machine operation Disconnect battery posi tive terminal Swing engine tray 5 out for access to both sides of engine 5 1 Kubota Engine 2 Engine Lifting Lugs 3 Left Right S...

Page 109: ...ar 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 the four large bolts nuts and washers sec...

Page 110: ...SECTION 3 CHASSIS PLATFORM SCISSOR ARMS 3 68 3121781 NOTES...

Page 111: ...ithin the hydraulic system to protect associated systems and components against excessive pressure Excessive pres sure can be developed when a cylinder reaches its limit of travel and the flow of pres...

Page 112: ...draulic sys tem and run cylinder through one complete cycle to check for leaks 4 4 OSCILLATING AXLE LOCKOUT CYLINDER TEST IF EQUIPPED LOCKOUT CYLINDER SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME...

Page 113: ...ion 4 5 DRIVE PUMP PRE FILL PROCEDURE The drive pump should be pre filled with recommended hydraulic fluid prior to machine start up Before starting this procedure inspect the unit for any damage incu...

Page 114: ...fluid prior to start up Fill housing by pouring filtered oil into upper case drain port Install a 0 to 500 psi 0 to 35 bar pressure gauge in the charge pressure gauge port to monitor charge pressure...

Page 115: ...has been purged and the fitting can be retightened to its specified torque If the tank needs to be pressurized in order to start the flow of oil a vacuum reading should be taken at the inlet of the p...

Page 116: ...d earlier Start the engine checking to be certain the pump remains in neutral With the engine at normal operating RPM slowly check for forward and reverse machine operation Charge pressure may slightl...

Page 117: ...ions JIC 37 flare per SAE J514 SAE 45 flare per SAE J512 ORFS o ring face seal per SAE J1453 MBTL metric flareless bite type fitting pressure rating L medium per ISO 8434 DIN 2353 MBTS metric flareles...

Page 118: ...connector will no longer thread onto the mating part when tightened by hand or fin gers Finger Tight is relative to user strength and will have some variance The average torque applied by this method...

Page 119: ...r care should be taken not to introduce sealant into the system d Avoid applying sealant to the area of the threads where the sealant will be forced into the system This is generally the first two thr...

Page 120: ...of turns per Table 4 1 NPTF Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 4 1 NPTF Pipe Thread are applicable for the following material conf...

Page 121: ...ting the number of turns per Table 4 2 BSPT Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 4 2 BSPT Pipe Thread are applicable for the followi...

Page 122: ...THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE 3 Torque assembly to value listed in Table 4 3 37 Flare JIC Thread Steel or Table 4 4 37 Flare JIC Thread Aluminum Brass...

Page 123: ...60 0 50 12 70 14 15 15 19 20 21 1to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 22 23 24 30 31 33 1to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 42 44 46 57 60 63 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22 20 60 63...

Page 124: ...20 0 46 11 60 0 50 12 70 9 10 10 12 13 14 1to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 14 15 16 19 20 21 1to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 27 29 30 37 39 41 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22...

Page 125: ...ON OR SEALANT IS REQUIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE Torque fitting to value listed in Table 4 5 45 Flare SAE Steel and Table 4 6 45 Flare SAE Alumin...

Page 126: ...1 06 27 00 84 88 92 114 119 125 Aand Bthreaddimensionsforreferenceonly SeeFFWRandTFFTMethodsforFFWRprocedurerequirements Table 4 6 45 Flare SAE Aluminum Brass TYPE FITTING IDENTIFICATION Torque MATER...

Page 127: ...ation of the connection ALUMINUM BRASS FITTINGS OR ALUMINUM BRASS MATING COMPONENTS indicate either the following material configu rations STEEL fittings with ALUMINUM or BRASS mating compo nents ALUM...

Page 128: ...11 16 16 0 63 15 90 0 69 17 50 20 21 22 27 28 30 1 4to1 2 1 2to3 4 8 13 16 16 0 75 19 10 0 81 20 60 26 28 29 35 38 39 1 4to1 2 1 2to3 4 10 1 14 0 94 23 80 1 00 25 40 39 41 43 53 56 58 1 4to1 2 1 2to3...

Page 129: ...e If necessary replace fitting or tube 2 Lubricate thread and cone of fitting body or hardened pre assembly tool as well as the progressive ring and nut threads 3 Slip nut and progressive ring over tu...

Page 130: ...1 75 22 M30x2 27 90 30 00 7 50 22 20 1 5to1 75 28 M36x2 33 90 36 00 7 50 28 20 1 5to1 75 35 M45x2 42 90 45 00 10 50 35 30 1 5to1 75 42 M52x2 49 90 52 00 11 00 42 30 1 5to1 75 TYPE Tube O D Thread M Si...

Page 131: ...ter splits burrs or other foreign material If necessary replace fitting or adapter 2 Remove the locknut from the bulkhead assembly 3 Insert the bulkhead side of the fitting into the panel or bulkhead...

Page 132: ...149 183 193 202 14 15 16 12 170 179 187 230 243 254 16 17 16 12 200 210 220 271 285 298 20 111 16 12 245 258 270 332 350 366 24 2 12 270 284 297 366 385 403 TYPE Dash Size Thread Size Torque ft lb N...

Page 133: ...7 50 53 15 M22x1 5 44 47 50 60 64 68 18 M26x1 5 70 75 80 95 102 108 22 M30x2 115 120 125 156 163 169 28 M36x2 150 157 164 203 213 222 35 M45x2 155 162 169 210 220 229 42 M52x2 220 230 240 298 312 325...

Page 134: ...justable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 4 12 through Table 4 17 while using the Double Wrench Method a The table headings identify the strai...

Page 135: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HEX TYPE PLUGS STUD ENDS with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread S...

Page 136: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION STUD ENDS with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A Torque UNF...

Page 137: ...7 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread Size...

Page 138: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A T...

Page 139: ...47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min Nom Max ALUM...

Page 140: ...30 20 15 8 12 1 63 41 30 24 17 8 12 1 87 47 60 32 21 2 12 2 50 63 50 TYPE FITTING IDENTIFICATION ZERO LEAK GOLD HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min Nom M...

Page 141: ...refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 4 18 Table 4 19 Table 4 20 Table 4 21 Table 4 22 or Table 4 23 while using the Double Wr...

Page 142: ...69 72 103 108 113 140 146 153 M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209 M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374 M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550 M48x2...

Page 143: ...2 137 66 70 73 90 95 99 M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198 M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341 M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495 M48x2...

Page 144: ...0 73 90 95 99 M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149 M33x2 28 266 280 293 360 380 397 166 175 183 225 237 248 M42x2 35 398 418 438 540 567 594 266 280 293 360...

Page 145: ...72 125 132 138 170 179 187 M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297 M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450 M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594 M48x2 38...

Page 146: ...2x1 5 18 100 105 110 135 142 149 100 105 110 135 142 149 M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198 M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342 M42x2 35 332 349 365 450 473...

Page 147: ...115 121 92 97 101 125 132 137 59 62 65 80 84 88 M22x1 5 18 89 94 98 120 127 133 100 105 110 135 142 149 M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 M33x2 28 266 280 293 360 380 397 M42x2...

Page 148: ...the fitting by hand until contact 5 For Adjustable fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 4 24 while using the Double...

Page 149: ...93 237 249 262 M33x2 25 120 126 132 160 171 179 230 242 253 310 328 343 M38x2 135 142 149 183 193 202 235 247 259 319 335 351 M42x2 30 155 163 171 210 221 232 245 258 270 330 350 366 M48x2 38 190 200...

Page 150: ...refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 4 25 Table 4 26 Table 4 27 Table 4 28 Table 4 29 or Table 4 30 while using the Double Wre...

Page 151: ...9 133 140 146 180 190 198 G1A 28 111 117 122 150 159 165 243 255 267 330 346 362 G1 1 4A 35 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 42 214 225 235 290 305 319 465 489 512 630 663 694 M...

Page 152: ...0 146 180 190 198 133 140 146 180 190 198 G1A 28 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 35 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 42 398 418 438 540 567 594 398 418 4...

Page 153: ...243 254 103 108 113 140 146 153 G1A 28 236 248 260 320 336 353 148 156 163 200 212 221 G1 1 4A 35 398 418 438 540 567 594 295 313 5 332 400 425 450 G1 1 2A 42 516 542 568 700 735 770 332 349 365 450...

Page 154: ...209 219 270 283 297 G1A 25 111 117 122 150 159 165 251 264 276 340 358 374 G1 1 4A 30 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 38 214 225 235 290 305 319 516 542 568 700 735 770 MATERIA...

Page 155: ...0 133 140 146 180 190 198 133 140 146 180 190 198 G1A 25 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 30 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 38 398 418 438 540 567 594 3...

Page 156: ...0 95 99 89 94 98 120 127 133 G3 4A 20 92 97 101 125 132 137 170 179 187 230 243 254 G1A 25 236 248 260 320 336 353 G1 1 4A 30 398 418 438 540 567 594 G1 1 2A 38 516 542 568 700 735 770 MATERIAL BSPP T...

Page 157: ...scratches dirt foreign matter or burrs 2 Install o ring as per O ring Installation Replacement 3 Pre lubricate the o ring with Hydraulic Oil 4 Position flange and clamp halves 5 Place lock washers on...

Page 158: ...16 111 116 122 150 158 165 40 2 50 64 3 50 88 90 1 2 13 77 81 85 105 110 116 111 116 122 150 158 165 48 3 00 76 4 19 106 43 5 8 11 155 163 170 210 221 231 218 228 239 295 310 325 56 3 50 89 4 75 120 6...

Page 159: ...71 75 92 97 101 40 2 50 64 3 50 88 90 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 48 3 00 76 4 19 106 43 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 56 3 50 89 4 75 120 65 M16x2 155 163 170 210...

Page 160: ...ench If two wrenches are not used inadvertent component rotation may occur which absorbs torque and causes improper joint load and leads to leaks For hose connections the layline printed on the hose i...

Page 161: ...nnection has been properly tightened mark a straight line across the connecting parts not covering the dots to indicate the connection has been properly tightened Adjustable Stud End Assembly For Adju...

Page 162: ...f any are found replace o ring 2 Ensure proper o ring to be installed Many o rings look the same but are of different material different hard ness or are slightly different diameters or widths 3 Use a...

Page 163: ...to valves 2 Remove the 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 har...

Page 164: ...ulic Valve Figure 4 15 Main Valve Port Identification See Table 4 34 on page 4 55 MAF04050B 3 15 13 2 15 1 15 15 5 16 4 16 8 10 7 14 12 17 11 11 20 18 6 11 B1 2S1 T1 L2 T4 P1 L1 S1 S2 G 2S2 T2 B2 T3 P...

Page 165: ...UnionTee T2 MainRTValve LeftSide ReturntoTank P2 MainRTValve RightSide LP LevelingJackValve PS MainRTValve RightSide Outlet TandumGearPump MS MainRTValve RightSide DiagnosticPort MP1 MainRTValve Righ...

Page 166: ...BASIC HYDRAULIC INFORMATION SCHEMATICS 4 56 3121781 Flow Divider Valve 3 CV1 CV5 MAF04310B 13 9 7 CV3 CV4 6 CV5 CV6 10 8 5 OR1 FD2 FD3 CV8 12 4 1 FD1 CV7 OR3 2 OR2 11 1001234828 B Figure 4 16 Flow Div...

Page 167: ...For internal hydraulic circuits see Figure 4 44 on page 4 85 Figure 4 17 Leveling Jack Directional Valve 1001217108 C MAF04350C OUTRIGGER CYLINDERS RETRACT VALVE OUTRIGGER CYLINDER EXTEND PRESSURE VAL...

Page 168: ...S2 LevelingJackCylindersExtendTankValve 28 33ft lb 38 45Nm S3 LevelingJackCylindersExtendPressureValve 22 26ft lb 30 35Nm CoilsS1 S3 LevelingJackCylindersCoils12VDC 8 0OHMS 3 4 5ft lb 4Nm Table 4 37...

Page 169: ...lenoid valve and is the top relief cartridge 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 lb s 2 Ste...

Page 170: ...DriveEnd Clockwise Displacement Front Rear 14 4cc rev 13 3GPM 3 9cc rev 3 6GPM MaxRatedSpeed withmax fluidviscosityof50mm2 sec 3500rpm RatedPressure 3045psi 210bar MinimumSpeedatRatedPressure 1000rev...

Page 171: ...dry which can cause gear wear which affects the volumetric efficiency of the pump To prime the pump 1 Fill the hydraulic tank to the full mark 2 Using a 2 in wrench loosen the suction hose fitting at...

Page 172: ...ration Port to inlet on filter 6 MB Gage Port SAE 6 7 M3 Charge 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 F...

Page 173: ...3 14 MAF06330 1 Electric Displacement Control 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 Re...

Page 174: ...lled on the machine Ensure pump has been 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 vacu...

Page 175: ...ue to cycle between forward and reverse 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 rever...

Page 176: ...the control module and six cap screws D250 5 Using a 5 mm internal hex wrench torque the cap screws D250 to 10 ft lb 13 5 Nm Control Solenoids REMOVAL 1 Disconnect electrical connection and remove the...

Page 177: ...he seal until it is flush within 0 005 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 Ha...

Page 178: ...pump coupling K200 5 Install pressure balance 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 ga...

Page 179: ...to ensure proper operation Check for leaks 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...

Page 180: ...2 CHARGE PUMP FILTER REMOVAL 1 Disconnect and cap the hydraulic lines 5 and 6 on the filter assembly 3 2 Remove the mounting bolts washers 2 on top to remove the filter assembly from the bracket INSTA...

Page 181: ...ding valve and fittings from the cylinder 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...

Page 182: ...ylinder rod 15 Remove and discard the piston 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...

Page 183: ...ent 15 If applicable inspect port block fittings 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 I...

Page 184: ...rings for the solid seal have a radius on one side This side faces the solid seal See magnified insert in See Figure 4 33 The split of seals and backup rings must be positioned so as not to be in alig...

Page 185: ...d while adequately 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 19 Continue pushing the rod into t...

Page 186: ...er Ensure that the piston loading o ring and seal ring are not damaged or dislodged 28 Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder 2...

Page 187: ...MATION SCHEMATICS 3121781 4 77 4 14 CYLINDER ASSEMBLIES Figure 4 37 Steer Cylinder 1 Steer Cylinder 1 Barrel 2 Rod 3 Head Torque to 434 ft lb 588 Nm 4 Wiper 5 Road Seal 6 Back up Ring 7 Dry Bearing 8...

Page 188: ...Rod 3 Head Torque to 332 ft lb 450 Nm 4 Piston Torque to 1003 ft lb 1360 Nm 5 Screw Torque to 7 ft lb 10 Nm 6 Bearing 101 Wear Ring 102 O Ring 103 Back up Ring 104 Rod Seal 105 O Ring 106 Wiper Ring 1...

Page 189: ...orque to 332 ft lb 450 Nm 4 Piston Torque to 575 ft lb 780 Nm 5 Screw Torque to 4 ft lb 5 Nm 6 Bearing 7 LSS Transducers If Equipped 101 Wear Ring 102 O Ring 103 Back up Ring 104 Rod Seal 105 O Ring 1...

Page 190: ...1 1 2 1 4 5 UPPER CYLINDER LOWER CYLINDER 3 2 1 6 7 1 2 3 2 3 Item Torque 1 33 37ft lb 45 50Nm 2 3 4 5ft lb 4 6Nm 3 18 5 22ft lb 25 30Nm 4 5 7ft lb 7 10Nm 5 75 85ft lb 102 115Nm 6 4 5ft lb 5 4 6 8Nm...

Page 191: ...Rod 3 Wiper Seal 4 Wear Ring 5 Rod Seal 6 Wear Ring 7 CounterBalance Valve 8 Bleeder Valve 9 Pilot Port 10 Valve Port NOTE Torque item 7 to 22 ft lb 30 Nm Figure 4 41 Oscillating Axle Cylinder THE CY...

Page 192: ...he Jack Pad 16 Apply Loctite 242 to Capscrews 11 and torque to 30 ft lb 40 7 Nm 1 11 10 9 8 7 13 12 6 5 4 2 14 15 3 4 MAF04290 Figure 4 41 Leveling Jack Cylinder 1 Head 2 Barrel 3 Rod 4 Jack Plate 5 R...

Page 193: ...MATION SCHEMATICS 3121781 4 83 1 2 X E M1 1 2 3 MAF04300 Item Description Torque 1 SolenoidDirectionalValve 18 4to22 1ft lb 25 30Nm 2 StraightFitting 16 2ft lb 22Nm 3 StraightFitting 40ft lb 54 2Nm Fi...

Page 194: ...he aerated oil 7 Open the bleeder valve 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 sec...

Page 195: ...SV2 SV4 EXT 4 2500 PSI SV1 SV3 PB4 PB3 PA2 PA4 PA3 PA1 PB2 PB1 LP T RIGHT REAR JACK RIGHT FRONT JACK LEFT FRONT JACK LEFT REAR JACK LEVELING JACK SYSTEM REAR AXLE DRIVE MOTORS RIGHT LEFT FRONT AXLE D...

Page 196: ...c Schematic SHEET 2 1001232921 B MAF03730B A B C D E F G H 1 2 3 4 5 5 4 3 2 1 R2P2W L2P2W L2P3W R2P3W P AR AL OPTION AXLE LOCKOUT VALVE RV1 RV1 CV1 CV1 RAM LOCKOUT CYLINDERS CY1 CY1 T P V P V FROM PO...

Page 197: ...l station connector 2 X32 as shown Connect the remaining end of the cable to the ana lyzer m enu PRESS ENTER HELP AnalyzerDisplay EscapeKey Toreturnhomeoraccess previousmenu EnterKey StoresandselectsT...

Page 198: ...analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read In platform mode HELP EVERYTHING OK In ground mode GROUND MODE OK If ENT...

Page 199: ...ESS LEVEL menu For example MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key positi...

Page 200: ...g the up and down arrows check the access level to ensure you are at access level 1 Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example...

Page 201: ...the face of the platform control box as shown NOTE Flash codes are also displayed on the handheld ana lyzer For descriptions see Table 5 1 DTC and Flash Code Descriptions IT IS A GOOD PRACTICE TO AVO...

Page 202: ...OFF VALVES 2 SPD OFF VALVES LIFT UP OFF 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 COMM...

Page 203: ...X LIFT UPR DN ACCL X XS LIFT UPR DN DECL 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...

Page 204: ...1 CALIBRATIONS JOYSTICK 1 JOYSTICK CAL 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 SERVI...

Page 205: ...ingJackAtEndOfStroke Rear Right Leveling Jack cylinder has reached 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 stro...

Page 206: ...ed range Check the wiring to the Rear Left Leveling Jack pressure transducer 246 2 4 RearRightLevelingJackPressureTransducerFailure Rear Right Leveling Jack pressure transducer reading is outside of t...

Page 207: ...FunctionProblem LiftandLevelActiveTogether Machine Setup Leveling Jacks is set to 1 YES Lift and Level Digital Inputs on the Platform Control Module are HIGH simultaneously for 1000ms 22100 2 2 Funct...

Page 208: ...ionsLockedOut ECMLost MACHINE SETUP ENGINE KUBOTAD FECMandCANbuscommuni cation is lost for 250mS 23107 2 3 FunctionProblem LiftUpPermanentlySelected Ground lift up switch is closed during a power up 2...

Page 209: ...etract valve 3534 3 5 LevelingJackRetractValveOpenCircuit The Leveling Jack retract valve is open circuit Check the wiring to the Leveling Jack retract valve 33132 3 3 ThrottleActuator ShorttoBattery...

Page 210: ...ToGround The fuel sensor value is under the minimum allowed value Check the fuel sensor input J2 34 resistive 4382 4 3 FuelSensor OpenCircuity The control system measures Fuel Sensor A2D value 768 cou...

Page 211: ...than or equal to 250ms AND Low Temperature Cutout is configured 671 6 7 AccessoryFault CAN faults reported by the Accessory Module 6635 6 6 CanbusFailure ChassisTiltSensor Thecontrol system failedtor...

Page 212: ...eading lower then 0 PSI Check Sensor wiring 873 8 7 MachineSafetySystemOverrideOccurred The Platform was moved while overloaded using the MSSO button Can be reset only with an Analyzer via the CALIBRA...

Page 213: ...reset to defaults Replace controller 9910 9 9 FunctionsLockedOut PlatformModuleSoftware VersionImproper DTC 662 does not exist AND The LRT Ground Module software major version number does not match t...

Page 214: ...and washers 6 NOTE Follow the above procedures in reverse order when installing the chassis tilt sensor assembly After installing be sure to calibrate the chassis tilt sensor refer to Section 5 4 Loca...

Page 215: ...5 JLG CONTROL SYSTEM 3121781 5 19 5 4 LOCATION OF ADDITIONAL SENSORS 1 Oscillating Axle Tilt Sensor 2 Arm Stack Tilt Sensor 3 Rotary Angle Elevation Sensor Figure 5 8 Chassis Sensor Locations 1 2 3 M...

Page 216: ...that the tilt sensor will not cali brate are a The surface the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level b The tilt sensor has fai...

Page 217: ...rive Auto Level or Generator function is needed This service mode will bypass the ECM CAN loss DTCs and allow the machine to function as normal 1 Using the Analyzer navigate to SERVICE MODE ECM OVERRI...

Page 218: ...this service mode the ser vice technician must verify the platform is stowed and the leveling jacks are retracted before drive function will be enabled Drive speed will only be allowed at elevated sp...

Page 219: ...redisabledwhenoverloaded NOTE Different Defaults by market CE 2 1 GROUNDALARM 8 0 1 2 NOTINSTALLED VehiclealarmwillfunctionforOverload ifLOADenabled DESCENT VehiclealarmwillfunctionforOverload ifLOADe...

Page 220: ...preventedwhen ElevatedandTiltedFronttoBack beyondthefollowinglimits LiftUpandDrivepreventedwhen ElevatedandTiltedSidetoSide beyondthefollowinglimits Drivepreventedwhen Elevatedbeyondthefol lowingheigh...

Page 221: ...A 1300 LowDrvRev 900 1100mA 950 ElevFwdMax 700 1000mA 860 ElevRevMax 700 1000mA 860 LIFT UpAccel 0 1 5 0 sec 1 5 UpDecel 0 1 1 5 sec 0 5 MinUp 0 35 17 MaxUp 0 75 55 UprDnAccel 0 1 5 0 sec 0 5 UprDnDec...

Page 222: ...6 3121781 TEMPCUTOUT CutoutSet 30 0 C 27 1001241349_A NOTE These settings may be changed in order to achieve optimal performance Table 5 5 Machine Model Personality Adjustment Adjustment Adjustment Ra...

Page 223: ...platformcontrolareprevented andfunc tionsfromthegroundcontrolmaybeprevented dependingonmachine BATTERYTOOHIGH 4 4 IncomingSupplyVoltage 34 0Vdc Thecontrolsystem sbatteryvoltageistoohigh Thismaybedueto...

Page 224: ...g parameter in the PERSONALITIES LOAD menu 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 ANALY...

Page 225: ...on Menu is used to zero the Empty Platform 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...

Page 226: ...ration value If successful the Analyzer will show the following CALIBRATE COMPLETE Calibration values are as follows Minimum Calibration 485 lb 220 kg Maximum Calibration 2205 lb 1000 kg If the empty...

Page 227: ...the platform and the arm structure in such 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 Wi...

Page 228: ...his manual if the Load Sensing System fails 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...

Page 229: ...the platform in the fully stowed position 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 p...

Page 230: ...rve if the module begins to function after 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 supp...

Page 231: ...t between the platform and the support 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...

Page 232: ...arnings soundevenwhentheplatformisempty Controlsarepreventedinthesamemanner aswhenoverloaded TheLSSModuleisun powered un calibrated orisexperiencingaMeasurementPerformancedifficulty Alternately the Ho...

Page 233: ...re RegulatedSupplyforJLGAnalyzer AnalyzerPin 1 approx 12V 2 TX RS 232forJLGAnalyzer AnalyzerPin3 3 TRP1 120OhmCANbusTerminator 4 CANH 1 CANbusInterfaceHigh 5 CANS 1 CANbusShieldTermination NotsameasGN...

Page 234: ...8 FDEG J4 9 FDRG J4 10 RDEG J4 11 RDRG 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...

Page 235: ...e source Backprobing 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 circui...

Page 236: ...ct range See multimeter s operation manual Use firm contact with meter leads First test meter and leads by touching leads together Resistance should read a short circuit very low resis tance Circuit p...

Page 237: ...fore testing continuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm i...

Page 238: ...e under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not completely isolated disconnect battery te...

Page 239: ...must be applied at the joint where the male and female connec tors come together Any other joints around strain reliefs etc where water could enter the connector should also be sealed NOTE This condi...

Page 240: ...le terminals If trapped air prevents the connector from latching pierce one of the unused wire seals After assembly install a seal plug JLG 4460905 in that location to prevent moisture ingress Note th...

Page 241: ...Phoenix Contact M12 The connector uses gold contact material to resist corrosion and an o ring seal for moisture integrity If dielectric grease is mistakenly applied to this connector system the low f...

Page 242: ...et and all wiring must pass through cable entrances MIL C 5015 SPEC Connector s Crown Connector Inc s recommendation is to not use dielec tric grease for this series connector For similar model series...

Page 243: ...conductivity sili cone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by u...

Page 244: ...Pull back on the contact wire with a force of 1 or 2 lbs to be sure the retention fingers are holding the contact See Figure 7 11 Connector Assembly 2 of 4 3 After all required contacts have been inse...

Page 245: ...and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed Figure 7 14 Connector Disassembly NOTE The wedge lock should never be removed from the housing...

Page 246: ...ires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the in...

Page 247: ...oward exterior locking mechanism The wedgelock 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 Se...

Page 248: ...e cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed...

Page 249: ...Limit switches are used to control movement or indicate position Mechanical limit switches are just like manu ally operated switches except that the moving object operates the switch These switches c...

Page 250: ...ve side of the power source and the load 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...

Page 251: ...LER HARNESS OPTION SHEET 4 PLATFORM CONTROL HARNESS PLATFORM I O MODULE SHEET 5 PLATFORM CONTROL BOX HARNESS PLATFORM BOX SHEET 6 DIESEL ENGINE HARNESS ENGINE KUBOTA DIESEL CABLE BATTERY KIT WIRE 10 G...

Page 252: ...18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 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 J5 1 2 3 4 5 6 J3 1 2 3 4 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 253: ...8 REAR RIGHT PRESSURE TRANSDUCER SN13 A B C REAR LEFT TRANSDUCER PRESSURE SN12 A B C FRONT RIGHT TRANSDUCER PRESSURE SN11 A B C FRONT LEFT TRANSDUCER PRESSURE SN10 A B C RED RED_1 RED RED_1 WHT WHITE_...

Page 254: ...WHT 4 ALARM GND WHT 4 ALARM GND WHT 5 ALARM WHT 5 ALARM BLU 6 LAMP RETURN BLU 6 LAMP RETURN BLU 7 LEVEL JACK UP BLU 7 LEVEL JACK UP BLU 8 LEVEL JACK DOWN BLU 8 LEVEL JACK DOWN BLU 9 TRIGGER BLU 9 TRIG...

Page 255: ...ETURN X08 1 2 3 4 5 6 BLK 00 1 LAMP RETURN BLK 00 1 LAMP RETURN BRN 55 1 SYS IND BRN 55 1 SYS IND BLK 00 2 1 GND BLK 00 2 1 GND BRN 55 2 FUEL LOW BRN 55 2 FUEL LOW BLK 00 2 2 GND BLK 00 2 2 GND YEL 55...

Page 256: ...LVL SN BRN 47 9 FUEL LVL SN BLK 00 1 8 FUEL SN GND S20 BLK 00 17 2 IGN RL GND T1 1 1 BLK 00 17 1 GND BLK 00 17 GND S17 WHT 1 3 ENG STRT RL WHT 1 3 1 ENG STRT RL START FUSE 40A A B S16 RED 1 10 2 PWR...

Page 257: ...YEL 9 1 STR LT VAL YEL 9 1 STR LT VAL BLK 00 3 4 GND BLK 00 3 4 GND YEL 10 1 STR RT VAL YEL 10 1 STR RT VAL BLK 00 3 6 GND BLK 00 3 6 GND WHT 50 1 DUMP VAL WHT 50 1 DUMP VAL BLK 00 3 8 GND BLK 00 3 8...

Page 258: ...26 1 PWR WHT 45 4 STRT SIG WHT 45 4 STRT SIG S44 YEL 44 1 IGN PWR ALTERNATOR IGN LAMP B KUBOTA MS153 1 2 3 T7 1 YEL 44 2 IGN PWR ALT FUSE 5A A B YEL 44 4 IGN PWR YEL 44 4 IGN PWR YEL 44 3 IGN PWR BLU...

Page 259: ...1 LIGHT SIG YEL ORG 122 1 LIGHT SIG POWER BUS MS170 1 2 3 4 5 6 GROUND BUS MS180 1 2 3 4 5 6 LIGHT 10A A B T2 1 T2 1 RED 120 1 PWR RED 120 1 PWR RED 120 2 PWR RED 120 2 PWR WHT 121 1 LIGHT PWR WHT 12...

Page 260: ...9 10 11 12 J2 LSS MODULE 1 2 3 4 5 6 7 8 9 10 11 12 J1 LSS MODULE 1 2 3 4 5 6 7 8 9 10 11 12 X550 Analyzer Port Connector 1 2 3 4 RED CABLE RED CABLE WHT CABLE WHT CABLE BLK CABLE BLK CABLE SHIELD SHL...

Page 261: ......

Page 262: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 VisitourwebsiteforJLGWorldwideLocations www jlg com 3121781...

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